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Sterling GG-30, Installation Instructions Manual

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40

IDENTIFICATION OF PARTS 

RESIDENTIAL TUBULAR 30-120 MBH UNIT SIZES

Figure 28 - Internal Furnace Components

Figure 26 - Propeller Parts

Figure 27 - Component Parts

Figure 29 - Power Ventor Assembly

D4810

NOTE: No rubber grommets are supplied with the 30 and 45 unit 
sizes.

Gas Valve

D4430

Fan Guard

Fan Blade

Hardware

Hardware

Motor

D6963

D03339

Pressure Switch

D03339

Summary of Contents for GG-30

Page 1: ...NT OF INSTALLATION RECORD THE UNIT MODEL AND SERIAL No s IN THE SPACE PROVIDED RETAIN FOR FUTURE REFERENCE INSTALLATION INSTRUCTIONS AND PARTS LIST TUBULAR GAS FIRED DIRECT SPARK PROPELLER UNIT HEATERS FOR RESIDENTIAL INSTALLATIONS 04 08 Please utilize this toll free number to contact your local representative 800 490 2290 FOR YOUR SAFETY WHAT TO DO IF YOU SMELL GAS Do not try to light any applian...

Page 2: ...7 Standard Combustion 18 25 Separated Combustion 26 30 OPERATION Explanation of Controls and Operation 31 Main Burner Orifice Schedule 32 Adjustments 32 High Altitude Operation 32 33 MAINTENANCE Servicing Cleaning 33 TROUBLESHOOTING GUIDE 34 38 IDENTIFICATION OF PARTS 39 40 WARRANTY 41 MODEL NUMBER 42 INSPECTION SHEET 43 See Identification of Parts throughout this manual DESCRIPTION The Residentia...

Page 3: ...as 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 ...

Page 4: ...3 203 219 219 219 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 ...

Page 5: ...5 Figure 2 Dimensional Drawing Tubular 30 thru 120 Propeller Unit Heater DIMENSIONS XXX STANDARD UNITS DIMENSIONS IN PARENTHESIS XXX MILLIMETERS ...

Page 6: ... 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...

Page 7: ...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 ...

Page 8: ...able 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 75 Cu ft hr Using Table 2 a 3 4 inch pipe is needed NOTE Se...

Page 9: ...ational 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 ga...

Page 10: ...ructions 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 contr...

Page 11: ...11 ELECTRICAL CONNECTIONS continued Figure 11A Honeywell Control Board Figure 10A UT Control Board ...

Page 12: ...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 connecttheGterminalofthethermostat to the G terminal of the unit heater ...

Page 13: ...ntrol and UT Control Board ELECTRICAL CONNECTIONS continued 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 connecttheGterminalofthethermostat to the G terminal of the unit heater ...

Page 14: ...as 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 connecttheGterminalofthethermostat to the G terminal of the unit heater ...

Page 15: ...ol and Honeywell Control Board ELECTRICAL CONNECTIONS continued 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 connecttheGterminalofthethermostat to the G terminal of the unit heater ...

Page 16: ...n clothes dryers and any exhaust fans such as range hoods and bathroom exhausts so they shall operate at maximum speed Do not operate a summer exhaust fan Close fireplace damper 4 Follow the lighting instructions Place the appliance being inspected in operation Adjust thermostat so that the appliance will operate continuously 5 After it has been determined that each appliance connected to the vent...

Page 17: ...tions 1 Installationmustconformwithlocalbuildingcodes orin the absence of local codes with current 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 2 Any reference to U S standards or codes in these instructions are to be ignored and the applicable Canadian standards or codes applied Min...

Page 18: ...732 or equivalent silicone sealant with a tempera ture rating of 500 deg F or 3M 425 aluminum foil tape or equivalent The vent system must be installed to prevent collection of condensate Pitch horizontal pipes downward 1 4 inch per foot 21mm per meter toward the outlet for condensate drainage Install a tee with a condensate drain at the low point of the pipe see Figure 13 As an alternate a 3 8 in...

Page 19: ...ows Vent Length Vertical Rise Distance Size in Ft In from Wall 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 24 24 105 5 2 7 24 24 120 5 1 5 24 24 5 2 7 24 24 One elbow is required to make the vertical extension See Figure 13 Figure 13 Category I Horizontal Venting Requirements D6838C ...

Page 20: ...20 Figure 14 Vent Support D 06839A ...

Page 21: ... cap must be supplied by the customer for each power vented unit The vent pipe diameter must be 4 inches 102mm 6 Through the wall venting for these appliances shall not terminate over public walkways or over an area where the condensate or vapor could create a nuisance hazard or could be detrimental to the operation of regulators relief valves or other equipment see Figures 15A 16 and 18 7 The ven...

Page 22: ...t pipe should extend at least 2 feet 0 61m above the highest point on the roof Consideration should be made for anticipated snow depth Install an Amerivent Americap or Metalbestos vent cap over the vent opening Slope horizontal runs upward from the gas unit heater at least 1 4 inch per foot 21mm m minimum Horizontal portions of the venting system shall be supported at minimum intervals of 4 feet 1...

Page 23: ...re 15A Category III Horizontal Venting Requirements Using Single Wall Vent Pipe Figure 15B Category III Horizontal Venting Requirements Using Type B Double Wall Vent Pipe Figure 15C Type B Draft Hood Connector ...

Page 24: ...24 Figure 16 Figure 17 VENTING continued ...

Page 25: ...25 VENTING continued Figure 18 Figure 19 ...

Page 26: ...on metallic pipe for venting To do so may result in serious damage to the unit and or severe personal injury or death 5 Long runs of single wall combustion air piping passing through an unheated space may require insulating if condensation becomes noticeable 6 The combustion air system must be installed to prevent collection of condensate Pitch horizontal pipes downward 1 4 inch per foot toward th...

Page 27: ...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 then be used to seal each joint High temperature silicone sealant may be used instead of the tape Silicone sealant must be used to seal the joint between the Type B vent pipe and the single wall pipe 9 For horizontal vent systems longer than 5 feet 1 5m the s...

Page 28: ...28 Figure 22 Vertical Intake Vent Installation Figure 21 Concentric Vent Installation ...

Page 29: ...9 Figure 23 Horizontal Intake Vent Installation Figure 24 Horizontal Intake Vent Installation VENTING continued Vent Terminal 1 8M Min Adjacent Building D 3330 6 0 Min 0 9M Min 3 0 Min Building Overhang ...

Page 30: ... location on outside wall for vent terminal In most applications the terminal should be on level with the flue outlet of the unit less a 1 4 inch per foot pitch for condensate drainage toward the outside of the building See Figure 23 The location of the vent terminal must be in accordance with the National Fuel Gas Code ANSI Z223 1 in the U S or the Natural Gas Installation Code CAN CGA B149 1 or ...

Page 31: ... limit switch interrupts the flow of electric current to the control board the unit will begin a post purge period When the post purge period ends the power venter motor is de energized 7 The fan operation is delayed 30 seconds once the thermostat is closed and continues operation for 30 seconds after the thermostat opens The start up fan delay must not exceed 30 seconds from a cold start 8 The wa...

Page 32: ...ressure of 10 0 inches W C 2 5 kPa must be maintained for proper operation of the unit heater 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 3 The adjusted manifold pressure should not vary more than 10 fro...

Page 33: ...Cu ft Altitude Feet Table 8 Manifold Pressure In W C Heating Value BTU Cu ft 10 0 10 0 10 0 10 0 10 0 9 9 9 7 9 6 9 5 2 278 2 237 2 196 2 156 2 116 2 077 2 039 2 000 1 964 3 5 3 5 3 5 3 4 3 4 3 4 3 3 3 3 3 2 2 000 2 500 3 000 3 500 4 000 4 500 5 000 5 500 6 000 948 931 914 897 881 865 849 833 818 Manifold Pressure In W C PROPANE LP GAS NATURAL GAS Heating Value BTU Cu ft Altitude Feet Notes 1 Cons...

Page 34: ...ecure ignitor bracket 11 Check for 24V at gas valve terminals during trial for ignition period If present with no manifold pressure Replace valve 12 Refer to symptom Q 1 Refer to Installation Venting 2 Check gas supply pressures to unit Refer to Installation 3 Refer to Installation 1 Burner orifice incorrect 2 Low manifold Pressure 1 Irregular orifice causing whistle or resonance 2 Excessive gas i...

Page 35: ...k voltage and amps at the fan motor Check gas input to ensure unit is not over fired Check heat exchanger to ensure unit is not dirty 5 Check orifice size replace if undersized 1 Refer to Operation Check orifice size If too big replace 2 Check thermostat for operation to ensure circuit open and closes 3 Check wiring per diagram check operation at the gas valve look for a short in thermostat circui...

Page 36: ...is the switch open during start up 4 Check for 24v on line side of the high limit Constant voltage should be recorded if not control board is suspect Check flash code 1 Check all wring in the power vent circuit to ensure good connection including Neutral 2 Check for 115v between motor leads and check amp draw of motor Replace if needed 3 Check for continuous 115v on terminal CBM Blower and neutral...

Page 37: ...sformer grounded to chassis 2 Loose spark ignitor 1 Gas supply off or gas supply pressure too low 2 Flame sense rod contaminated or loose wire 3 Gas valve switch is off or wires are not connected 4 Broken or cracked porcelain on flame probe or spark ignitor 1 Obstructions or restrictions in appliance air intake or flue outlet are preventing proper combustion airflow 2 Moisture or debris in tubing ...

Page 38: ...itch Replace bad pressure switch 1 Check sensor wire and make sure it is connected properly 1 Check for short If no short replace fuse and start unit 2 If no short is found check gas valve for possible over amp condition Replace gas valve 1 Check transformer for proper voltage Replace transformer if not correct 1 Switch off power and check flame rod wiring 1 Turn unit off and back on If fault code...

Page 39: ...er Assembly 20 Flue Collar Assembly 21 Vinyl Tubing Pressure Switch 22 Power Venter Mounting Plate 23 Louver 24 Louver Spring 25 Control Board 26 Access Panel 27 Top Jacket Panel w Insulation 28 Bottom Jacket Panel w Insulation 29 Front Jacket Panel 30 Rear Jacket Panel 31 Bracket Manifold 32 Tube Support Bracket 33 Green Ground Screw 34 Hanger Bracket 35 Manifold Clamp 36 Pipe Nipple 37 Left Side...

Page 40: ...Internal Furnace Components Figure 26 Propeller Parts Figure 27 Component Parts Figure 29 Power Ventor Assembly D4810 NOTE No rubber grommets are supplied with the 30 and 45 unit sizes Gas Valve D4430 Fan Guard Fan Blade Hardware Hardware Motor D6963 D03339 Pressure Switch D03339 ...

Page 41: ... 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 in turn notify the distributor or manufacturer b shipment to t...

Page 42: ...P5 24V SPST Relay Specify Purpose VC 4 4 Vent Cap VC 5 5 Vent Cap Capacity 075 120 Category I Horizontal Vent Only X7 4 Concentric Vent Kit Capacities 030 075 X7 5 Concentric Vent Kit Capacities 090 120 Low Profile Tubular Gas Fired Unit Heater Model Number Description Digit G X X X 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Item Prefix UT CA FT FM GT AL GC SV MT DL AS Internal use Only 1 2 Unit Type UT ...

Page 43: ...all field installed controls been installed Do you understand all the controls on this equipment If not contact your wholesaler or rep DO NOT START this equipment unless you fully understand the controls GAS EQUIPMENT START UP GENERAL With power and gas off Make certain all packing has been removed Tighten all electrical terminals and connections Check all fans blowers for free movement Check all ...

Page 44: ...www sterlinghvac com HVAC PRODUCTS 260 NORTH ELM ST WESTFIELD MA 01085 TEL 413 564 5540 FAX 413 562 5311 ...

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