Mestek 44488010, Installation And Operation Instructions Manual

Page 1: ...n adjustment alteration service or maintenance can cause property damage injury or death Read the installation operation and maintenance instructions thoroughly before installing or servicing this equipment IF YOU SMELL GAS FOR YOUR SAFETY DO NOT try to light any appliance DO NOT touch any electrical switch DO NOT use any telephone in your building IMMEDIATELY call your gas supplier from a neighbo...

Page 2: ...ons 32 14 0 Instructions for Pressure Test Gauge Connection 34 15 0 Electrical thermostat Connections 36 15 1 Single Stage N5 L5 Internal and Thermostat Connections 37 15 2 Two Stage N7 L7 Internal and Thermostat Connections 39 16 0 Venting 42 17 0 Air for Combustion 47 17 1 Direct Outside Air for Combustion 47 18 0 Lighting and Shutdown Instructions 49 19 0 Sequence of Operation single stage n1 l...

Page 3: ... Installation and Operation Instructions Where unvented heaters are used gravity or mechanical means shall be provided to supply and exhaust at least 4 CFM per 1 000 Btu hr input of installed heaters Never use the heater as a support for a ladder or other access equipment Do not hang anything from the heater Supply all installation materials necessary that are not included with the heater Check th...

Page 4: ...or Unvented mode The term Unvented actually means Indirect Vented While the products of combustion are expelled into the building national codes require ventilation in the building to dilute these products of combustion This ventilation may be provided by gravity or mechanical means This heater is not an explosion proof heater Where the possibility of exposure to volatile and low flash point mater...

Page 5: ... burner box WARNING Certain materials or objects when stored under the heater will be subjected to radiant heat and could be seriously damaged Observe the Minimum Clearances to Combustibles listed in the manual and on the heater at all times NOTE 1 The clearances specified above must be maintained to combustibles and other materials that may be damaged by temperatures 90ºF above ambient temperatur...

Page 6: ...tage Input N2 Natural Two Stage Gas Valve Modulating Input High Low Fire L2 Propane Two Stage Gas Valve Modulating Input High Low Fire Type Gas Gas Pipe Connection Tube Diameter Flue Connection1 Fresh Air Connection1 Electrical Supply Current Rating Natural or Propane MPT Male 4 4 Round 4 Round 120 Volt 60Hz 1 Phase 1 74 Amp 1 See Section 16 0 for vent sizes when multiple heaters are connected int...

Page 7: ...NE RMS U175L1U0 44490140 PROPANE RMS U175L2U0 44490640 PROPANE RMS U200L1U0 44490160 PROPANE RMS U200L2U0 44490660 PROPANE SINGLE STAGE CONTROLS STERLING TWO STAGE CONTROLS STERLING MODEL NO PART NO GAS TYPE MODEL NO PART NO GAS TYPE RSS U040N1U0 44488010 NATURAL RSS U040N2U0 44488510 NATURAL RSS U050N1U0 44488030 NATURAL RSS U050N2U0 44488530 NATURAL RSS U075N1U0 44488050 NATURAL RSS U075N2U0 444...

Page 8: ...492600 PROPANE RBS U150L1U0 44492120 PROPANE RBS U150L2U0 44492620 PROPANE RBS U175L1U0 44492140 PROPANE RBS U175L2U0 44492640 PROPANE RBS U200L1U0 44492160 PROPANE RBS U200L2U0 44492660 PROPANE B R B S M S 040 200 Body Package Descriptions Package Part Number is indicated on the outside of each corresponding carton Systems 10Ft System 20Ft System 30Ft System 40Ft System 50Ft System R B S M S Body...

Page 9: ... pkg 44137090 50 Ft pkg 44138080 Part Each Body Package Includes Qty Qty Qty Qty Qty 42912180 10 Ft Tube with 12 Hole Flange Aluminized 1 1 1 42912169 10 Ft Tube with 6 Hole Flange Alumi Therm 1 1 41932100 10 Ft Tube less Flanges Aluminized 1 2 3 4 43319100 Reflector 9 11 1 2 3 4 5 30462980 Tube Coupling 1 2 3 4 43318000 Tube Hanger Support Bracket 13 1 2 3 4 5 43980010 Wire Hanger 1 2 3 4 5 Body ...

Page 10: ...8 13 02189020 HWHSM Screw 10 16 x TEKS 8 14 14 24 U Bend Package 43208020 43208020 43208020 43208020 42913020 U Bend 1 1 1 1 43318500 31 Tube Support Hanger Bracket 1 1 1 1 30462980 Tube Coupling 1 1 1 1 02189020 HWHSM Screw 10 16 x TEKS 2 2 2 2 Systems 60Ft System 70Ft System R B S M U Body Packages Alumi Therm Hot Rolled 40 Ft Pkg 44137100 20 Ft Pkg 44135010 40 Ft Pkg 44137120 30 Ft Pkg 44136040...

Page 11: ...27110 Hex Nut 5 16 18 5 8 8 13 02189020 HWHSM Screw 10 16 x TEKS 8 14 14 24 U Bend Package 43208020 43208020 43208020 43208020 42913020 U Bend 1 1 1 1 43318500 31 Tube Support Hanger Bracket 1 1 1 1 30462980 Tube Coupling 1 1 1 1 02189020 HWHSM Screw 10 16 x TEKS 2 2 2 2 60Ft System 70Ft System R B S M U Body Packages Alumi Therm Aluminized 40 Ft Pkg 44137090 20 Ft Pkg 44135030 40 Ft Pkg 44137110 ...

Page 12: ...ies Only Contains Elbow 43175000 QTY 1 10 16 x Self Drilling Screws 02189020 QTY 2 Tube Coupling 30462980 QTY 1 C Corner Reflector Accessory Package Part 43342000 Option for S Straight Series Only Contains Corner Reflector Assembly 43345000 QTY 1 Speed Clips 02266010 QTY 4 D U Bend Package Part 43208020 Option for U Series Only Contains U Bend 42913020 QTY 1 10 16 x Self Drilling Screws 02189020 Q...

Page 13: ...Self Drilling Screws 02189020 QTY 4 Installation Form 43489000 QTY 1 F 31 Hanger Tube Support Part 43318500 Option for Angle Mounting of U Series Only G Exhaust Hood Package Part 42924000 Contains Exhaust Hood Assembly 42925550 QTY 1 8 18 x Self Drilling Screws 02189030 QTY 2 H Kit 2 Stage Relay Board Part 44195000 Contains Relay Board 30709058 QTY 1 Enclosure 30709059 QTY 1 Cord Connector 3063504...

Page 14: ...5 25 Ft 35 Ft R B S M S 200 50 Ft 70 Ft R B S M U 200 25 Ft 35 Ft NOTES 1 In all configurations the control unit must be connected directly to either a the 12 radial hole flange of the 10 ft aluminized steel starting body section for 10 ft 20 ft and 30 ft systems or b the 6 hole flange of the 10 ft alumi therm steel starting body section for 40 ft 50 ft 60 ft and 70 ft systems 2 Joining of two 90º...

Page 15: ...Form 43343350 14 Dec 2017 7 1 TYPICAL ASSEMBLY LAYOUT STRAIGHT SERIES SHOWN ...

Page 16: ...Form 43343350 Dec 2017 15 8 0 DIMENSIONS STRAIGHT SERIES Typical Dimensions Up to 60 Ft Shown ...

Page 17: ...Form 43343350 16 Dec 2017 8 1 DIMENSIONS U SERIES Typical Dimensions Up to 50 Ft Shown ...

Page 18: ...Form 43343350 Dec 2017 17 8 2 HEATER ASSEMBLY JOINING OF TUBE SECTIONS ...

Page 19: ...Form 43343350 18 Dec 2017 ...

Page 20: ...ion See Figures b and c 5 Heaters subject to vibration must be provided with vibration isolating hangers 6 Heaters must not be supported by gas or electric supply lines and must be suspended from a permanent structure with adequate load capacity Mestek Inc recommends that the body sections be suspended using chains with turnbuckles This will allow slight adjustments after assembly and heater expan...

Page 21: ...anger Support Bracket 43318000 U bolt 42873000 and 2 pieces of Hex Nut 02127110 for each 10 ft length of emitter tube 10 0 ASSEMBLY OF TUBE SECTIONS During field assembly of the heater body sections the recommended procedure is as follows 1 Before hanging heater sections first determine the actual layout of the system see Sections 7 0 8 0 for details Consideration must also be taken for flue pipe ...

Page 22: ... wire hanger and the tube support bracket Insert the tube into the wire hanger and then raise the tube support bracket end up to the suspension chain use S hooks to attach the wire hanger and tube support bracket to the chain 10 1 ASSEMBLY OF EXTENSION SECTION ...

Page 23: ...coupling tightening instructions MUST be followed properly to ensure the integrity of the tube connections Two 10 self drilling screws MUST be installed at every coupling as shown in the instructions below Failure to do so may result in serious injury or property damage 1 Place the compression coupling over the end of the tube 2 Use the small hole at the centerline of the coupling to check that th...

Page 24: ...ference pins as illustrated above 9 Once all the heater body sections are attached make sure that the heater system is level If it is not slight adjustments can be made using the turnbuckles See Section 9 0 Important NEVER reuse a coupling Always install a new coupling only and torque as per instructions above and the diagrams below 10 2 NSERTING TURBULATORS 1 Assemble the turbulators together by ...

Page 25: ... 2 The tube at the coupling joints must be covered Slide the reflectors together and provide an overlap of two 2 inches for the first reflector overlap after the control unit All remaining reflector overlaps will be approximately one 1 inch This will allow for the natural expansion and contraction of the heater when in operation Note The heaters can expand and contract up to 1 3 4 3 Secure the ref...

Page 26: ...osite leg is 13 as shown 3 Join the tube ends of the body sections and the elbow together and secure with tube couplings as described in Section 10 1 11 1 ADDING OPTIONAL CORNER REFLECTOR STRAIGHT SERIES ONLY 1 Place the corner reflector over the reflectors of both body sections 2 Secure by sliding speed clips on the reflector edges One speed clip is required for each side of reflector 3 The corne...

Page 27: ...wn 2 Slide the speed clips on the reflector edges towards the end of the body section reflectors Two speed clips are required for each side of the U Bend Reflector Make sure that the speed clips fit tightly over both the U Bend Reflector and the reflector on each body section Use two self drilling screws to permanently secure both sides to the reflectors 3 Place the End Reflector flush with the U ...

Page 28: ...ox and gasket to end of tube flange and secure with 1 4 20 locknuts 2 Assemble the optional end reflector flush with the end of the main body reflector Secure by sliding speed clips onto the reflector edges Evenly space the speed clips on the sides one each side and top two required of the reflectors to provide a snug fit Leave a 3 space between the end reflector and the burner box assembly 3 The ...

Page 29: ...m 43343350 28 Dec 2017 The burner box weights 38 lbs Use caution when handling it Failure to install the burner box in an upright position and lights facing the floor will void the manufacturer s warranty ...

Page 30: ...ew TISS wire assembly PN 44176510 spring and spring retainer clamp not included must also be installed Instructions 1 Make sure that the gap between the burner box and end of reflector is 3 and the reflector is securely attached to the reflector support bracket Make adjustments if necessary Step 1 Failure to maintain 3 gap as shown will result in pre mature TISS wire failure 2 Un roll the TISS wir...

Page 31: ...sembly to end of reflector at overlap joint Slide spring retainer clamp over end of reflector as shown Step 3 4 After attachment of the TISS check to make sure that there is sufficient tension on the wire Follow the diagram below to increase or decrease the tension as necessary Step 4 ...

Page 32: ...TISS wire holder clamp must first be re positioned as shown using the bottom hole pattern of the clamp Follow procedures described earlier for all other adjustments Step 5 Failure to re position the wire clamp at the bottom hole pattern will shorten the life expectancy of the TISS wire assembly ...

Page 33: ...it a CSA or U L approved flexible connector supplied with this heater is required for connections between the rigid piping and the heater A union should be installed before the burner box inlet An approved shut off valve should be installed within 6 feet of the union 8 The gas pipe flexible hose and connections must be self supporting The gas pipe work must not bear any of the weight of the heater...

Page 34: ...nstallation in US only The gas connector is 36 long and 1 2 nominal ID and must be installed as shown above in one plane and without sharp bends kinks or twists CANADA ONLY A Type I hose connector should be used that is certified as being in compliance with the Standard for Elastomeric Composite Hose and Hose Couplings for Conducting Propane and Natural Gas CAN CGA 8 1 and is of length of 36 6 in ...

Page 35: ...ll electrical power to the system to connect manometer hoses 2 Turn the pressure test screw 3 32 Hex in the center of the boss not more than one turn counterclockwise Attach a 5 16 hose and manometer over the tapered outlet pressure boss on the valve see Figures 1 and 2 below If regulator needs to be adjusted see instructions below TO ADJUST REGULATOR single stage gas valves 1 Turn on power and en...

Page 36: ...3 Energize main gas valve solenoid as well as the HI terminal 4 Remove regulator cover screw from the high outlet pressure regulator see Figure 2 below and turn screw clockwise to increase pressure or counterclockwise to decrease pressure Replace regulator cover screw and tighten securely DO NOT EXCEED THE PRESSURES SHOWN IN THE GAS PRESSURE TABLE 5 After testing pressure and adjusting the regulat...

Page 37: ...witch 4 The power supply to the unit should be protected with a fused disconnect switch or circuit breaker A service switch as required by local codes shall be located in the vicinity of the heater check local codes for allowable distances and should be identified as Heater Service Switch All electrical wiring must be located in accordance with the required Clearances to Combustibles from the heat...

Page 38: ...CONTROLS INTERNAL CONNECTION WIRING DIAGRAM SINGLE STAGE CONTROLS SCHEMATIC WIRING DIAGRAM IGNITION MODULE TERMINAL DESIGNATIONS 24VAC R 24 VAC Supply to Module TH W Thermostat Input PS W Pressure Switch Input GND System Ground V1 Valve Power V2 Valve Ground L1 120 240 VAC Input Hot IND Blower Output ...

Page 39: ...3343350 38 Dec 2017 SINGLE STAGE CONTROLS THERMOSTAT WIRING DIAGRAMS SINGLE STAGE CONTROLS A LINE VOLTAGE 120V THERMOSTAT CONNECTIONS SINGLE HEATER B LINE VOLTAGE 120V THERMOSTAT CONNECTIONS MULTIPLE HEATERS ...

Page 40: ... 24V THERMOSTAT CONNECTIONS SINGLE HEATERS D LOW VOLTAGE 24V THERMOSTAT CONNECTIONS MULTIPLE HEATERS utilizing a fan center relay 15 2 TWO STAGE N7 L7 INTERNAL AND THERMOSTAT CONNECTIONS TWO STAGE CONTROLS INTERNAL CONNECTION WIRING DIAGRAM ...

Page 41: ...NITION MODULE TERMINAL DESIGNATIONS 24VAC R 24 VAC Supply to Module TH W Thermostat Input PS W Pressure Switch Input GND System Ground V1 Valve Power V2 Valve Ground L1 120 240 VAC Input Hot IND Blower Output TWO STAGE CONTROLS THERMOSTAT WIRING DIAGRAMS TWO STAGE CONTROLS ...

Page 42: ...Form 43343350 Dec 2017 41 A LOW VOLTAGE 24V THERMOSTAT CONNECTIONS SINGLE HEATERS B LOW VOLTAGE 24V THERMOSTAT CONNECTIONS MULTIPLE HEATERS ...

Page 43: ...EATERS 16 0 VENTING This is a category lll appliance A BASIC FLUE VENTING Venting must comply with the latest edition of the National Fuel Gas Code ANSI Z223 1 latest edition or the authority having jurisdiction Other venting references are in the equipment volume of the ASHRAE Handbook ...

Page 44: ...g Aluminum or Teflon tape suitable for 550ºF 3M Company tapes 433 or 363 or silicone sealant is recommended 5 All portions of the vent pipe shall be supported to prevent from sagging 6 spacing is recommended 6 When the vent pipe passes through areas where the ambient temperature is likely to induce condensation of the flue gases the vent pipe should be insulated and a condensation drain should be ...

Page 45: ... 10 ft for each elbow beyond 15 ft from the heater Subtract 15 ft for each elbow within 15 ft of the heater 4 Limit to 2 90º elbows in the vent system 5 When venting through a sidewall the horizontal vent pipe shall fall 1 4 inch per 10 feet down from the start of the vent system to the vent terminal All portions of the vent pipe shall be supported to prevent sagging 6 spacing is recommended 6 A m...

Page 46: ...ctor diameter should be no less than that shown in the following Vent Sizing Table A Y connector must be used to the common vent 2 Material for connectors and Y connectors should be constructed of galvanized sheet metal or other approved noncombustible corrosion resistant material as allowed by state or local codes All common vent pipe should be insulated flue pipe or double wall Type B vent 3 Avo...

Page 47: ...e Heater Venting Number of Heaters Horizontal and vertical Vertical Only 1 2 3 4 R B S M S U 040 4 4 4 4 R B S M S U 050 4 4 4 5 R B S M S U 075 4 4 5 6 R B S M S U 100 4 5 6 6 R B S M S U 125 4 5 6 7 R B S M S U 150 4 6 7 7 R B S M S U 175 4 6 7 8 R B S M S U 200 4 6 7 8 COMMON VENT DIAMETER If a size is not available use the next larger size ...

Page 48: ... 17 1 DIRECT OUTSIDE AIR FOR COMBUSTION Outside combustion air should be supplied directly to the heater when the building is subject to negative pressure or when contaminants or high humidity are present in the building air These contaminants include paints solvents corrosive vapors or any other foreign particles that may cause damage to the heater or result in poor combustion Outside combustion ...

Page 49: ...ed in the same configuration as shown for venting in Section 16 0 For combustion air intake duct sizing please refer to the Vent Sizing Table and use the diameter indicated based on the number of heaters per duct All vent terminations and Combustion Air Intake Terminations must be at least 6 higher than anticipated snow depth ...

Page 50: ...lockout and the valve relay will be de energized immediately The blower will be turned off following a post purge period of approximately 30 seconds 5 If the heater does not light manually reset the thermostat or shut off power completely for 5 minutes before attempting to relight 6 To permanently shut down the heater turn off the gas and electrical supply NOTE The lighting and shutdown instructio...

Page 51: ...lame is not re established the heater will go to lockout 19 1 SEQUENCE OF OPERATION TWO STAGE N2 L2 The chart below shows the sequence of operation for the normal operating cycle of the R B S M N7 L7 when connected to a permanent 120V power supply and the heater is turned on and off by a remote 24V thermostat Note If the flame is not sensed during sequence T3 then the burner will automatically beg...

Page 52: ...Form 43343350 Dec 2017 51 20 0 CONTROL COMPONENT LOCATION ...

Page 53: ...of damage fatigue or corrosion If there are any signs of damage to the gas connection or leaks found in the gas piping immediately stop using the heater until the gas pipe and connections have been repaired or replaced Check that the gas lines are not bearing the weight of the heater See also Section 13 0 Burner Box In order to extend the longevity of the heater the heat exchanger tube and the bur...

Page 54: ...Form 43343350 Dec 2017 53 22 0 TROUBLESHOOTING GUIDE SINGLE STAGE N1 L1 ...

Page 55: ...Form 43343350 54 Dec 2017 TROUBLESHOOTING GUIDE SINGLE STAGE CONTINUED ...

Page 56: ...Form 43343350 Dec 2017 55 TROUBLESHOOTING GUIDE SINGLE STAGE CONTINUED ...

Page 57: ...Form 43343350 56 Dec 2017 22 1 TROUBLESHOOTING GUIDE TWO STAGE N2 L2 ...

Page 58: ...Form 43343350 Dec 2017 57 TROUBLESHOOTING GUIDE TWO STAGE CONTINUED ...

Page 59: ...Form 43343350 58 Dec 2017 TROUBLESHOOTING GUIDE TWO STAGE CONTINUED ...

Page 60: ... the gas manifold 3 Disconnect Spark lead and sensing wire 4 Pull burner forward from the gas manifold and then out through the side of the box as shown 5 Check that the spark gap is 1 8 between the electrode and the burner casting as shown Spark electrode should be clean and free from debris 6 Flame sensor should be clean and free from debris 7 Check ceramic on the spark electrode for replacement...

Page 61: ...Form 43343350 60 Dec 2017 23 2 REMOVING GAS VALVE AND MANIFOLD ASSEMBLY 23 3 AIR SWITCH PRESSURE CHECK ...

Page 62: ...rn off heater at thermostat b Connect a meter dc microammeter scale in series with the ground lead as shown in the diagram Connect the meter as follows Connect the black negative meter lead to the electronic control FC terminal Connect the red positive meter lead to the electronic control FC terminal c Restart the system and read the meter The flame sensor current must be steady and measure at lea...

Page 63: ...combustion blower will power off following the post purge period Fault Conditions Error Mode LED Indication Internal Control Failure Steady On Air Flow Fault 1 Flash Gas valve failure stuck open 2 Flashes Ignition Lockout 3 Flashes The LED located on the ignition module will flash ON for second then OFF for second during a fault condition The pause between fault codes is 3 seconds 24 0 INSTALLATIO...

Page 64: ...ting Machined 1 16 44146090 Manifold Support Bracket painted 1 17 44146060 Manifold Support Clamp 1 17a 44146058 Manifold Extension Bracket with set screw 1 18 30703000 Blower Assembly 1 19 30632510 Spark Module Fenwal 24V 35 615950 197 1 20 30702010 Flame Sensor PSE GF24 1 21 30702020 Electrode PSE GF25 1 21a 30743000 Terminal Block EL 3008 1 22 30281000 Terminal Block EK 204 1 22a 30738030 Termi...

Page 65: ...BEL 125 150 175 200 mbh 1 Labels Manual 49 42848220 Label Nameplate Sterling 1 Stage 1 49a 42848221 Label Nameplate Mestek 1 Stage 1 49b 42848222 Label Nameplate Beacon 1 Stage 1 49c 42848230 Label Nameplate Sterling 2 Stage 1 49d 42848231 Label Nameplate Mestek 2 Stage 1 49e 42848232 Label Nameplate Beacon 2 Stage 1 50 42013070 Label Logo Sterling Not Shown 1 50a 42013080 Label Logo Mestek Not Sh...

Page 66: ...Form 43343350 Dec 2017 65 ...

Page 67: ...tube 12a 44028010 5 Tube Assembly Kit 4 OD ALC steel without flanges extension tube exhaust tube 13 43208010 4 O D Elbow Package 14 02189020 10 x Self Drilling Screw 15 30462980 4 OD Tube Compression Coupling w bolts 16 43208020 4 OD U Bend 17 43488000 U Bend Reflector ALC Calorized Aluminized Steel 18 30504500 Flue Adapter Collar HRS Hot Rolled Steel 19 44152240 Turbulator See Section 5 0 for qua...

Page 68: ...Form 43343350 Dec 2017 67 26 0 WARNINGS CARD Copies of this card may be ordered at no charge under part no 43344970 for installation near the heater B ...