Sterling QVSD User Manual

INSTALLATION INSTRUCTIONS AND SERVICE MANUAL

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.

SCDFM-5

J30-05393

Unit No.

Serial No.

FOR Y OUR SAFETY

The use and storage of gasoline or other ﬂ ammable v apors and liquids in open containers in the vicinity of this appliance is hazardous.

FOR Y OUR SAFETY

If you smell gas:

1. Open windows.

2. Don’t touch electrical switches.

3. Extinguish any open ﬂ ame.

4. Immediately call your gas supplier.

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

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 may cause cancer, birth defects, or other reproductive harm.

03/13

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 received to determine if any damage has occurred to the unit during shipment. After the unit has been uncrated, check for any visible damage to the unit. If any damage is found, the consignee should sign the bill of lading indicating such damage and immediately file claim for damage with the transportation company.

260 NORTH ELM ST., WESTFIELD, MA 01085

TEL: (413) 568-9571 FAX: (413) 562-8437

www.mestek.com

TABLE OF CONTENTS

GENERAL SAFETY INFORMATION SEPARATED COMBUSTION DUCT FURNACE ...................................1,2,3

SPECIFICA TIONS ........................................................................................................................................4

PERFORMANCE DATA ................................................................................................................................5

CLEARANCES .............................................................................................................................................6

INSTALLATION

Location ...........................................................................................................................................6

Ductwork, Air Flow ........................................................................................................................6,7

Suspension ...................................................................................................................................7,8

Electrical Connections, Wiring Diagrams .......................................................................8,9,10,11,12

Combustion Air Inlet System Piping .........................................................................................12,13

Exhaust Venting ...................................................................................................................13,14,15

Gas Piping .....................................................................................................................................16

Pipe Installation ...................................................................................................................17,18,19

OPERATION

Explanation of Controls .................................................................................................................21

Primary Air Shutter Adjustments ...................................................................................................21

Shut Down .....................................................................................................................................21

MAINTENANCE .........................................................................................................................................22

COMPONENT PARTS ...........................................................................................................................20,23

TROUBLESHOOTING CHART ........................................................................................................................24-28

WARRANTY ...........................................................................................................................................................29

UNIT NUMBER DESCRIPTION .............................................................................................................................30

START UP/INSPECTION SHEET ..........................................................................................................................32

GENERAL SAFETY INFORMATION

The duct furnace design is certiﬁ ed by ETL for use with natural and LP (propane) gases. ANSI and NFPA 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 certiﬁ ed. 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 exceeding 2,000 feet (610m) above sea level, derate the input by 4% for each 1,000 feet (305m) rise above sea level. Special oriﬁ ces 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 f eet (610m) are to be ignored. At altitudes of 2,000 to 4,500 feet (610 to 1372m), the units must be oriﬁ ced for 90% of normal altitude rating, and be so marked in accordance with ETL certiﬁ cation.

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 av oided, 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.

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 ﬁ tter 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 No. 88B.

If installed in Canada, the installation must conform with local building codes, or in the absence of local building codes, with CSA-B149.1 “Installation Codes for Natural Gas Burning Appliances and Equipment” or CSA-B149.2 “Installation Codes for Propane Gas Burning Appliances and Equipment. ” These duct furnaces have been designed and certiﬁ ed to comply with CSA 2.6. Also see sections on installation in AIRCRAFT HANGARS and PUBLIC GARAGES.

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

Never service any component without ﬁ rst disconnecting all electrical and gas supplies to the unit, or severe per sonal injury or death may occur!

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 qualiﬁ ed 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 qualiﬁ ed 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.

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.

Do not depend upon a thermostat or other switch as sole means of disconnecting power when installing or servicing duct furnace. Always disconnect power at main cir cuit 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 qualiﬁ ed electrician.

Do not insert ﬁ ngers or foreign objects into furnace or its air moving device. Do not b lock 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 ﬂ ammable, e xplosiv e, 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.

The open end of piping systems being purged shall not discharge into areas where there are sources of ignition or into conﬁ ned 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 speciﬁ ed, the following conversions may be used for calculating SI unit measurements: 1 foot = 0.305 m 1 inch = 25.4 mm 1 gallon = 3.785 L 1 pound = 0.453kg 1 psig = 6.894 kPa 1 cubic foot = 0.028m

1000 BTU/cu. ft. = 37.5 MJ/m 1000 BTU per hour = 0.293 kW 1 inch water column = 0.249 kPa liter/second = CFM x 0.472 meter/second = FPM ÷ 196.8

SPECIFICATIONS

Table 1

A B C D (Dia)*† Gas Inlet Weight Unit inches inches inches inches inches lb. 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) (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)

†NOTE: “D” diameter equals the air inlet opening and the ﬂ ue discharge opening.

Figure 1 - Separated Combustion Duct Furnace

DIMENSIONS XXX STANDARD UNITS DIMENSIONS IN PARENTHESIS (XXX) MILLIMETERS

PERFORMANCE DATA

Table 2

Input Output MAX MIN MIN Temp. Rise PD MAX Temp Rise PD Unit MBH MBH MBH CFM °F in. of WC CFM °F in. of WC Size (kW) (kW) (kW) (cu. m/s) (°C) (kPa) (cu. m/s) (°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 20 1.81 (43.9) (22.0) (35.1) (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)

NOTE:

Ratings are shown for elevations up to 2,000 feet (610M) above sea level. Above 2,000 feet (610M), input must be 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 90% of the normal altitude rating, and be so marked in accordance with the ETL certiﬁ cation.

TEMPERATURE RISE AND PRESSURE DROP-GRAPH #1

°C°F

CLEARANCES

Under no circumstances should combustible material be located within the clearances speciﬁ ed in T ab le 3. Failure to pr ovide proper clearance could result in personal injury or equipment damage from ﬁ re .

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.

INSTALLATION

NOTICE: Furnace sizing should be based on heat loss calculations where the furnace output equals or exceeds heat loss.

Do not install duct furnaces in a corrosive or flammable atmosphere! Premature failure of, or severe damage to the unit will result!

Duct furnaces must not be installed in locations where air for combustion would contain chlorinated, halogenated, or acidic vapors. If located in such an envir onment, 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 ﬂ oor in shops, ofﬁ ces, 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 speciﬁ ed in the latest edition of NFP A 88B, Repair Garages.

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 ﬂ ames. This will g reatly 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.

In parking structures, duct furnaces must be installed so that the burner ﬂ ames are located a minimum of 18 inches (457mm) above the ﬂ oor 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 CSA 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 ﬂ ue 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 ﬂ ow of air across the surfaces of the heat exchanger , is essential to satisfactory unit performance and life of the equipment.

All duct ﬂ anges/seams must be sealed to prevent air leaks. Sealant/tape must be suitable for temper atures of 250°F (121°C) minimum.

Any attempt to straighten the 90° duct connection ﬂ anges on the duct furnace will affect the operation of the furnace and void the warranty.

INSTALLATION (Continued)

If uniform air distribution is not obtained, install additional bafﬂ es and/or turning vanes in the ductwork.

Access panels large enough to observe smoke and reﬂ ected 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 & 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 speciﬁ ed on the appliance rating plate.

Figure 2 - Recommended Design for Field Installation of Ductwork for Straight-through Arrangement

BYPASS: When a gas duct furnace is installed to operate

in conjunction with a summer air conditioning system, the cfm air delivery of the system blower should be adjusted to meet the design air volume requirements for cooling. If this cfm delivery is greater than that required for heating, resulting in a low air temperature rise, install a damper bypass around the gas duct furnace to bypass a portion of the air.

SUSPENSION: Refer to Figure 4 f or typical suspension arrangements.

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. Refer to Figure 4 for typical suspension arrangements. DO NO T mount duct furnaces in series (one in front of another).

NOTICE: When mounting duct furnaces side by side, units must have opposite side gas connections (determined by Digit #6 - Furnace Type in the unit number). Minimum safety clearances must also be maintained; see Table 3. When service/accessibility clearances are greater than minimum safety clearances, service/accessibility clearances take precedence. See “Accessibility” section under “Installation”.

Figure 3 - Recommended Ductwork Design for Elbowed Arrangement

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!

INSTALLATION (Continued)

3/8-16 Treaded Suspension Rod & Jam Nut By Installer

3/8-16 Speed Grip Nut Retainer

Outside Jacket Panel (Duct)

D4285

Section “S-S”

Detail Showing Recommended

Method Of Suspension

(Typical)

“S” “S”

D4284

Figure 4 - Typical Four Point Duct Suspending Arrangement

ELECTRICAL CONNECTIONS

HAZARDOUS VOL TAGE!

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/ 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 the terminals to check for power. Use a voltmeter.

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

MAKE CERTAIN THAT THE STRUCTURE TO WHICH THE FURNACE 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 ELECTRICAL CONDUIT FOR SUPPORT. FAILURE TO HEED THESE WARNINGS MAY INJURY OR DEATH.

RESULT IN PROPERTY DAMAGE,

PERSONAL

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 s witch 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 of the National Electrical Code, ANSI/NFPA No. 70, or CSA Standard C22.1 Sample wiring diagrams are shown in Figures 6, and 7.

Table 4 - Full Load Current In Amperes

Ampere Values Apply to All Unit Capacities

Amps at 115 Volts 1.9 Amps at 208 Volts 1.1 Amps at 230 Volts 1.0 Amps at 460 Volts 0.5 Amps at 575 Volts 0.4

INSTALLATION (Continued)

THERMOSTAT WIRING AND LOCATION NOTICE: The thermostat must be mounted on a

vertical, vibration-free surface, free fr om air currents, and in accordance with the furnished instructions.

Mount the thermostat approximately 5 feet (1.5m) above the ﬂ oor, in an area where it will be exposed to a free circulation of average temperature air. Alwa ys 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 ra ys , 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

THERMOST A T HEA T ANTICIPAT OR 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 f or a guide . If further information is needed, consult your thermostat manufacturer’ s instructions.

Recommended heat anticipator setting ranges:

25 feet (7.6m) T'stat wiring 50 feet 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.

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