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1. 1 0 W C PS 07 High Gas Pressure Switch 125 above burner firing rate PS 12 Clogged Filter Switch Adjust to field condition PT 13 Building Pressure Transducer Adjust to field condition FL 02 High Temperature Limit Manual 185 F Cooling is Enabled By The Following MDT And MRT Standard To enable the cooling rotate the Temperature Setpoint knob MP 15 clockwise to the desired setpoint below the actual air temperature The allowable temperature range is 55 to 90 F MRT PRO With Smart Room Sensor To enable the cooling press the Warmer or Cooler button on the face of the remote MRT Pro room sensor TS 02 to the desired room setpoint Each push of the button changes the temperature setpoint by 1 F The setpoint can be changed a maximum of 10 F from the default of 73 F Changing the cooling setpoint also changes the heating setpoint MRT Expert With A BACview KP 01 To enable the cooling scroll through the Setpoints menu in the BACview and enter the desired room Cooling Occupied and Unoccupied Setpoints Energy Savings Mode Energy Savings Mode 4 can disable the cooling NOTE The cooling outputs are protected by an anti cycle timer which has a 3 minute off 3 minute on delay A BACview or PC is required to change Setpoints For a more detailed control sequence see the Digital Control User Manual SECTION VI UNIT SHUT
2. The high fire setting must be made before adjusting low fire Adjust the high fire setting according to the Maxitrol Valve Adjustment instructions in Section X The high fire setting must not exceed the pressure stated on the rating plate When adjusting low fire there should be a continuous flame along the entire burner length without any blowout spots Main burner flame sensor must be activated if applicable Burner must hold in low fire for approximately 10 seconds before modulating up Check flame signal with burner cycling through full firing range and burner profile damper operation if applicable Cycle pilot and burner several times to insure smooth light off There should be a continuous spark for ten 10 seconds with pilot gas supply turned off Check pilot and main gas lines for leaks Main flame is now set Make sure burner modulates and turn thermostat to the desired setting didi Safety Controls Check All A Flame Safeguard Close last manual gas valve before main burner Operate unit in Heat mode After pilot flame has been established close manual pilot gas valve The flame safeguard must trip out within 15 seconds B Firestats These limit controls are not adjustable and are checked at the factory Reset the red button s to be sure they are ready for operation Contact factory if these switches fail to reset C Gas Pressure Switches The low pressure switch will trip out and must be re
3. 4j Hi mel RUN 4 GAS MANIFOLD Eg SECTION X MANIFOLD AND VALVE ADJUSTMENTS The I O Zone 583 Controller UC 01 must be calling for the burner to be enabled The DO 2 light will be on and Burner Enable Relay RE 28 needs to be energized This will put power to the Burner Relay RE 02 If the outside air temperature is above the Heating Economizer 65 F Setpoint the burner will be disabled You will need to disconnect the plug where the Outside Air Temperature Sensor TS 01 and Discharge Air Temperature Sensor TS 03 are wired to the I O Zone 583 Controller UC 01 see High Fire and Low Fire Adjustment in following section Reconnect the plug if you are getting close to the Freezestat lockout time approximately 3 minutes To reset the Freezestat alarm simply turn the power off and back on at the disconnect switch NOTE A BACview or PC is required to change settings See the Digital Control System User Manual for a more detailed sequence of operation Prior to setting high and low fire you should have your test equipment installed and be familiar with the gas valve VG 07 and its adjustment see High Fire and Low Fire Adjustment in following section For High Fire Setpoint refer to rating plate on unit for Normal Manifold Pressure in inches of water column The typical high fire flame should be blue and approximately 12 to 18 inches long with short orange t
4. Inspectthe flame rod and ignition electrode for dirt and moisture Wipe off if necessary Examine for H Heater any evidence of premature arcing If in doubt check 1 Atleast a yearly inspection is recommended continuity of flame rod to be sure it is not grounding for heating installations and more frequently for out Replace if required process applications in year round operation Your own experience is the best guide in determining The porcelain on the ignition electrode must be frequency of inspection but as a minimum the intact not cracked The spark gap should be 1 8 following procedure should be followed of an inch on Mestek burners a Shut the system down totally disconnecting or locking out power supply so there can be no 3 Replace all access panels which have been removed accidental start up during inspection and operate the unit for a test period Check for b Inspect the burner carefully including upstream normal response and function of all controls and downstream sides of mixing plates as well as burner body face Note that complete burner 4 Check all gas piping for possible leaks using a soap assembly may have to be removed for proper bubble solution inspection and cleaning Any accumulation of scale or foreign material on either side of the 5 nspectthe support means to be sure that mixing plates should be removed with a wire everything is firmly anchored in place brush Check visually that no holes in the mixing plates
5. of the line leads of the motor starter for three 3 phase motors On single phase motors refer to motor nameplate Enable the fans Check for proper blower rpm Check that all motor amp draws do not exceed rating plate ratings and overloads are set to motor rating plate amps Check all dampers for proper operation and linkage does not bind see Sequence of Operation and Digital Control System user manual for damper control modes Disable the fans Setting The Pilot Flame NOTE Before attempting to light the pilot and main burner you need to review Section X for proper Manifold and Valve Adjustments A BACview 6 or PC will be required to change setpoints Check the gas supply pressure by replacing the plug fitting on tthe pilot line with a pressure gauge having appropriate range and opening the manual pilot valve Check that the pressure reading is within the specified range on the rating plate NOTE To adjust gas pressure on supply lines where a regulator has been installed to reduce the inlet pressure to rating plate maximum pressure remove dust cap of main gas regulator and turn adjusting screw clockwise to increase pressure or counter clockwise to decrease pressure Connect test instrument to pilot flame test jack located on flame safeguard relay 40 Honeywell Flame Safeguard Control Watch D C voltmeter carefully The reading should be steady and between 2 0 to 5 0 volts D C If the reading is too low
6. OK Short circuit or open circuit in Modulator Coil Plunger missing jammed or improperly installed Measure resistance across modulator terminals 5 amp 6 with connecting wires detached Inspect Plunger should be installed to operate freely in solenoid sleeve Replace modulator head if not approximately 45 55 ohms for M611 Valve and 60 80 ohms for MR212 Valve Clean or replace plunger if necessary Incorrect Minimum Fire Erratic or Pulsating Flame Continuous High Fire Electronics Problem Continuous High Fire Electronics OK Incorrect by pass metering valve adjustment Excessive negative burner pressure Open circuit in Outside Air Temperature Sensor TS 01 or Discharge Air Temperature Sensor TS 03 circuit or wiring Jumper not connected across amplifier RE 26 terminals 3 amp 4 Foreign object holding valve open Plunger jammed See valve adjustments in Section X Close main gas supply and measure manifold pressure with blower operating Reading should be less than 1 5 w c negative pressure Check Outside Air Temperature Sensor TS 01 or Discharge Air Temperature Sensor TS 03 for open internal circuit See Thermistor curve Inspect Remove bottom plate and inspect valve and seat Inspect Plunger should be smooth and clean and operate freely in solenoid Sleeve Adjust
7. Save your bill of lading It is a contract and you will need it provided you have to file a loss or damage claim Remember claims are outlawed after nine months Loss In Transit Before you sign for this shipment check against the bill of lading also the transportation company s delivery ticket Make sure that you get the exact total of articles listed Should the delivery ticket show more or less items than are offered then the carrier s agent must mark the difference on your freight bill before you sign Visible Damage In Transit If anything is damaged accept the shipment only if the carrier s agent places a notation on your freight bill explaining the nature and extent of damage Upon inspection of article make claim to the delivering carrier Concealed Damage In Transit Sometimes transit damage is not noticed until the goods are unpacked In such cases notification to the carrier must be made within fifteen 15 days of receipt of shipment In such cases save the packages and packing material then notify the transportation company at once and request an inspection When the inspector calls have him make out and leave a concealed bad order report He is obliged to give one to you Insist on it Disposition Of Damaged Atticles Never return damaged articles to us They are the property of the transportation company when the claim is filed They will give you disposition instructions Packing We comply with the pa
8. Site Configurable Jumpers SELECTABLE CONFIGURATION JUMPERS RUN TEST SWITCH EC7895C RM7895C D RM7896C D re DPER a ener rt Hirt l c Pa oa Y Em ra mt atl vis M7553A Table 7 Site Configurable Jumper Options MODULE Jumper RESET Eu DE Number Description Intact Clipped PUSHBUTTON AMPLIFIER JR1 Pilot Flame 10 Seconds A Spams FLAME Establishing Period PFEP SIMULATOR INPUT FLAME CURRENT TEST JACKS 7552 JR2 Flame Failure Action Recycle Lockout JR3 Airflow Switch ILK Recycle Lockout Failure IMPORTANT Clipping and removing a jumper after 200 hours of operation causes a nonresettable Fault 110 The relay module must then be replaced WIRING SUBBASE 7 RUN TEST C D ONLY SWITCH CONFIGURATION JUMPERS SEQUENCE STATUS LED PANEL RESET BUTTON KEYBOARD DISPLAY MODULE b EA Ven MOUNTING SCREW FLAME AMPLIFIER x M22827 Figure 4 RM7897A C Relay Module Exploded View 15 SECTION VII TROUBLE SHOOTING continued Figure 2 Wiring Subbase and Sequence Chart for RM7897A fio 2 22s Sok S425 FOR DIRECT SPARK IGNITION OIL OR GAS IGNITION TRANSFORMER LINE VOLTAGE ALARM BURNER MOTOR BLOWER MAIN VALVE PREIGNITION INTERLOCK BURNER CONTROLLER LIMITS RUNNING INT
9. T DFIM 2 E d INSTALLATION OPERATION AND MAINTENANCE MANUAL FOR TMC amp TMM DIRECT GAS FIRED HEATERS WITH DDC CONTROLS 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 FOR YOUR SAFETY The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous POUR VOTRE S CURIT L utilisation et l entreposage d essence ou d autres liquides ou produits mettant des vapeurs inflammables dans des r cipients ouverts proximit de cet appareil est dangereux FOR YOUR SAFETY POUR VOTRE S CURIT If you smell gas Si vous sentez une odeur de gaz 2 1 Open Windows 1 Ouvrez les fen tres 2 Don t touch electrical switches 2 Ne pas actionner d interrupteur 3 Extinguish any open flame 3 teindre toute flamme ouverte 4 Immediately call your gas supplier 4 Appelez imm diatement votre dire fournisseur de gaz WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury death Read the installation operating maintenance instructions thoro
10. The gas line should be supported so that no strain is placed on the unit Pipe compounds which are not soluble to liquid petroleum gases should be used on threaded joints Refer to the heater s rating plate for determining the minimum gas supply pressure for obtaining the maxi mum gas capacity for which this heater is specified Une tuyauterie ad quatement dimensionn e doit tre pos e jusqu l unit Veuillez noter que la pression de la tuyauterie d alimentation en gaz doit correspondre celle sp cifi e sur la plaque d identification lorsque l unit fonctionne plein rendement Refer to the heater s rating plate for determining the maximum supply pressure to the heater The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 PSIG The appliance must be isolated from the gas supply piping system by closing it s individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressure equal to or less than 1 2 PSIG Correctly sized piping must be run to the unit Please note that gas line pressure must be as shown on specification plate when unit is operating at full input The high pressure regulator and relief valve should be if possible mounted at least 5 to 10 feet upstream from the appliance regulator on the unit if possible Building Pressure Trans
11. With the use of a BACview 6 KP 01 place the unit in the Building Pressure mode See the Digital Control System User Manual 5 The voltage at COM and OUT will vary between 0 to 5 VDC means the building is in a negative pressure and should open the Outside Air Profile and close the Return Air damper 5 VDC means the building is in a positive pressure and should open the Return Air Damper and close the Outside Air Profile Damper To calibrate the Flow Station Pressure Transducer PT 15 1 Remove the tubes at the Low and High pressure fittings 2 The voltage at COM and OUT should be O VDC If not adjust Z do not adjust S 3 Make sure the Low and High fittings are clean do not insert any sharp objects into the pressure fittings make sure the static pressure sensing pitot tubes and all tubing is also clean clear of any debris and then reinstall the tubes on the transducer It is very important that the Low and High tubes from the Flow Station are installed on the transducer correctly see drawing C000643 below 4 With the use of a BACview 6 KP Ol place the unit in the Calibration Mode see the Digital Control System User Manual This will open the Return Air damper and close the Outside Air damper The unit will calibrate for 5 minutes IMPORTANT Be sure there is no blockage in the return air duct 5 The voltage at COM and OUT should be at least 2 VDC If the voltage is less than 2 VDC contact the factor
12. completion of setting the curb apply roofing material and flashing as required D Location of Accessories Where applicable standard or optional accessories will be placed inside the fan section of the unit for shipment and must be removed and installed by the mechanical or electrical contractor Remotely located discharge or inlet dampers must be equipped with an end switch and interlocked to insure maximum design opening before starting and running circuits may be energized Field constructed intake accessories should be properly designed to minimize the entry of rain and snow Adequate building relief must be provided so as to not over pressurize the building when the heater is operating at its rated capacity This can be accom plished by taking into account through standard engineering methods the structure s designed infiltra tion rate by providing properly sized relief openings by interlocking a powered exhaust system or by a combination of these methods E Electrical Connections WARNING Open all disconnect switches and secure in that position before wiring unit Failure to do so may result in personal injury or death from electrical shock WARNING Controls must be protected from water Do not allow water to drip on the ignition system NOTE Before installing any wiring check the unit rating plate for supply power rating All electrical connections must conform to the current edition of ANSI NFPA No 70
13. fire depending upon the voltage Above approximately 15 volts DC the Valve should be delivering full flow to the heater and the unit should be on full fire If the DC voltage is obtained on the Valve terminals but the heater does not respond as described the problem can be isolated to the valve itself or to the gas control manifold of the heater If the proper voltages are not obtained the problem can be isolated to the electronics and or electronic relay RE 26 See the Trouble Shooting Section and the Digital Control System User Manual See the Thermistor Output Curve in the following section SECTION XI THERMISTOR OUTPUT CURVE Typical 10 000 Ohm Thermistor Output Curve 30000 25000 20000 15000 10000 Resistance Ohms 5000 p 0 32 41 50 59 68 77 86 95 104 Temperature in Degrees F EH SECTION XII REPLACEMENT PARTS Replacement parts may be ordered from the factory All warranty parts will be shipped freight allowed from factory for normal ground service Warranty parts must be returned prepaid within 30 days Credit will be issued if part is complete defective and returned on time Dealer Contractor Name City When parts are ordered MODEL NUMBER SERIAL NUMBER FACTORY ORDER F O and PART NUMBERS are required Belts filters and fuses are not covered under warranty Address State Zip Ph SECTION XIII RECIRC
14. g Purge card is removed h Purge card is bad i Ignition terminal is energized OPERATION Sequence of Operation The RM7897A has the operating sequences listed below see Fig 5 and 6 The RM7897A LED provide positive visual indication of the program sequence POWER PILOT FLAME MAIN and ALARM Initiate The RM7897A Relay Module enters the INITIATE sequence when the relay module is powered The RM7897A can also enter the INITIATE sequence if the relay module verifies voltage fluctuations of 10 15 or frequency fluctuations of 10 during any part of the operating sequence The INITIATE sequence lasts for ten seconds unless the voltage or frequency tolerances are not met When not met a hold condition is initiated and displayed on the optional KDM for at least five seconds when met the INITIATE sequence restarts If the condition is not corrected and the hold condition exists for four minutes the RM7897A locks out d SECTION VII TROUBLE SHOOTING continued Causes for hold conditions in the INITIATE sequence 1 AC line dropout detection 2 AC line noise that can prevent a sufficient reading of the line voltage inputs 3 Low line voltage brownouts The INITIATE sequence also delays the burner motor starter from being energized and de energized from an intermittent AC line input or control input Standby The RM7897A is ready to start an operating sequence when the operating control input determines a call f
15. of material are included with each unit shipped If correspondence with the factory is necessary please provide the unit model and serial number C Optional Factory Service Periodic service on any piece of mechanical equip ment is necessary for efficient operation A nationwide service support network is available to provide quick and dependable servicing of make up air heating ventilating or air handling types of equipment Factory start up service is also available which includes the presence of a service engineer to supervise the initial start up and adjustment of the equipment and provide instructions for the owner s maintenance personnel in proper operations and maintenance Consult factory for quotations on start up or periodic service SECTION Ill INSTALLATION FOR CANADIAN INSTALLATIONS ONLY 1 All installations must conform with local building codes or in the absence of local codes with current CAN CGA B149 Installation Codes For Gas Burning Appliances and Equipment 2 All electrical connections must be in accor dance with Canadian Electrical Code Part 1 CSA Standard C22 1 This equipment must be installed and wired in ac cordance with regulations of the National Board of Fire Underwriters National Electrical Code and local governing bodies The following recommendations are not intended to supplant any requirements of federal state or local codes having jurisdiction Authorities having jurisdiction
16. required type of gas UV Sensor clean lens and sight tube and check wiring and spark plug Flame Rod assure rod is in flame check wiring and flame rod Check wiring or replace transformer if correct Place in run position see technical cut sheet on flame safeguard relay Disable the fan and heat Slowly open all manual gas shut off valves before restarting Clear obstruction in vent orifice line or replace if defective Enable the fan and heat After 10 seconds of prepurge pilot will light Then after 10 seconds main valve light will come on Check to see if all gas valves have opened If not check voltage at gas valve If voltage is found to be correct replace gas valve or actuator see Section X on Maxitrol troubleshooting Guide for modulating valve Check burner for low fire adjustment UV Sensor clean lens and sight tube and check wiring Flame Rod be sure flame rod is in main flame check wiring and flame rod See Digital Control System User Manual Refer to Digital Control System User Manual for additional troubleshooting suggestions 20s SECTION VII TROUBLESHOOTING continued Heat Mode continued Symptom Cause Remedy G Ifthere is no heat with pilot ok and no voltage is present at flame safeguard relay output terminals Flame safeguard relay Run Test switch in Test position or fucntioning problem Place in Run positio
17. slowly turn the needle valve in or out until satisfactory readings are obtained A keyboard display module Honeywell S7800A1 142 is recommended to read the flame signal and is a good troubleshooting device A V O M can also be used on the DC voltage test jacks marked and on flame amplifier Open pilot and first main gas shut off valves slowly Last main gas shut off valve before burner must remain closed at this time Reset high low gas pres sure switches if applicable Check pilot and main gas lines for leaks using soap solution Heat is Enabled By The Following And Standard To enable the heat rotate the Temperature Setpoint knob MP 15 clockwise to the desired setpoint above the actual air temperature The allowable temperature range is 55 to 90 F MRT PRO With Smart Room Sensor To enable the heat press the Warmer or Cooler button on the face of the remote MRT Pro room sensor TS 02 to the desired room setpoint Each push of the button changes the temperature setpoint by 1 F The setpoint can be changed a maximum of 10 from the default of 65 F Changing the heating setpoint also changes the cooling setpoint MRT Expert With A BACview KP 01 To enable the heat scroll through the Setpoints menu in the BACview and enter the desired room Heating Occupied and Unoccupied Setpoints Energy Savings Modes There are 3 Energy Savings Modes that could disable the b
18. to proper minimum fire If reading is greater than 1 5 negative pressure check for clogged filters or other inlet air restrictions Consult factory for other solutions Replace Outside Air Temperature Sensor TS 01 or Discharge Air Temperature Sensor TS 03 Correct the wiring Clean seat Clean valve or replace if necessary Clean or if necessary replace plunger Refer to Digital Control System User Manual for additional troubleshooting suggestions 25 Modulating Discharge Temperature MDT or VDT EXPERT Controls continued TROUBLESHOOTING GUIDE Portions reproduced with permission from Maxitrol Company Symptom Possible Cause Field Test Remedy G Incorrect Maximum Fire 1 Inlet pressure too low 2 Incorrect outlet pressure adjustment of Pressure Regulator 1 Read pressure at inlet to modulating valve using a manometer with unit operating at full fire Pressure should be equal to the sum of outlet pressure setting plus pressure drop of the valve 2 Read manifold pressure using manometer and compare with the pressure stated on the specification plate 1 Increase inlet pressure if possible See valve adjustments in Section X 2 Short circuit between amplifier and modulator valve lead wires disconnected 2 Inspect wiring H Incorrect 1 Unit Enable Potentiometer 1 Check setpoint on Unit Chang
19. 6 620 930 SPB 1000 NE 2 11 6 620 930 SPB 1000 NE 2 15 16 620 930 Sealmaster Sleevloc SPB 2115 C2 115 16 65 When replacing bearings refer to the manufacturers 20 installation instructions included with the bearing Procedure For Changing The Shaft And Bearings Remove protective shaft coating 2 Remove the drive side sheave 3 Disconnect the grease lines from the existing bearings 4 Identify the total shim thickness at each bearing and mark the bearing mount for future reference 5 Remove mounting bolts for bearings and remove any shims 6 Loosen bearing and blower wheel shaft setscrews 21 22 23 34 Remove the shaft from the unit by sliding the bearings and blower wheels along the shaft as the shaft is extracted Unless a blower wheel is damaged it should be unnecessary to remove the blower wheel from the blower housing Slide the new shaft through the first blower wheel hub Once the shaft is completely through the first blower wheel slide a bearing onto this end of the shaft Slide the shaft through the next blower wheel hub and add another bearing Continue this procedure until the shaft is through all of the blower wheels Place a bearing on each end of the shaft Replace the old shims with new Bolt the bearings in place and reattach the grease lines When installing a Sleevlock bearing see note at bottom of page Adjust the shaft so the blower hu
20. DOWN A Extended Shutdown 1 Disable the heating and cooling for 30 seconds then disable the fan 2 Close all manual gas valves 3 Open the main electrical disconnect switch B Emergency Shutdown ONLY 1 Open the main electrical disconnect switch 2 Close the main manual gas valve 12s SECTION VII TROUBLE SHOOTING HONEYWELL RM7897A1002 RM7897C1000 7800 SERIES RELAY MODULES PRINCIPAL TECHNICAL FEATURES The RM7897 provides all customary flame safeguard functions as well as significant advancements in safety annunciation and system diagnostics Safety Shutdown Lockout Occurs if 1 INITIATE PERIOD a Purge card is not installed or removed b Purge card is bad c Configuration jumpers have been changed after 200 hours Fault Code 110 d AC line power errors occurred see Operation e Four minute INITIATE period has been exceeded 2 STANDBY PERIOD a Airflow lockout feature is enabled and the airflow switch does not close after ten seconds or within the specified purge card timing b Flame signal is detected after 240 seconds c Ignition pilot valve terminal is energized d Main valve terminal is energized e Delayed main valve terminal is energized RM7897C f Internal system fault occurred g Purge card is removed h Purge card is bad i Preignition Interlock open 3 PREPURGE PERIOD a Airflow lockout feature is enabled and the airflow switch opens b Ignition pilot valve terminal
21. ERLOCK INCLUDING AIRFLOW SWITCH PILOT IGNITION gE A 10 SECOND INTERRUPTED ILOT MASTER SWITCH INITIATE A PFEP INITIAL 00 10 SEC 00 POWERUP TIMED O4 sEc p 10 20 ONLY STANDBY PREPURGE JR1CLIPPED MFEP RUN POSTPURGE STANDBY Power PowerR Power Powen PowerR PowerR PowerR Power LED O Opiot piot O DISPLAY Q Q OFLAME FLAME eriame FLAME Q O Oman man OALARM QALARM QALARM QALARM Q BURNER BURNER BLOWER MOTOR 5 10 IGN INTERMITTENTPILOT 8 INTERRUPTED PILOT 21 MAIN VALVE 9 OPERATING To CONTROLS LIMITS BURNER CONTROLLER CLOSED L1 6 AND INTERLOCKS RUNNING INTERLOCKS CLOSED 6 TO 7 CK CLOSED 5 PII FLAME SIGNAL SAFE START CHECK FLAME PROVING SSC 120 VAC 50 60 HZ POWER SUPPLY PROVIDE DISCONNECT MEANS A SEE FLAME DETECTOR SPECIFICATIONS FOR CORRECT WIRING AND OVERLOAD PROTECTION AS REQUIRED A PROGRAMMED ON SETUP USING S7800A1142 DISPLAY A DO NOT CONNECT ANY WIRES TO UNUSED TERMINALS A PURGE TIME DEPENDS ON WHICH ST7800 IS INSTALLED M22728B 16 SECTION VII TROUBLE SHOOTING continued The POWER LED provides fault identification when the Relay Module locks out on an alarm Fault identification is a series of fast and slow blinking LED lights The fast blinks identify the tens port
22. Incorrect Minimum Cooling 2 Decrease Minimum Cooling Discharge Temperature Setpoint Discharge Temperature Setpoint See Digital Control System User Manual 3 Unit Enable Potentiometer MP 15 3 Change to correct setpoints not set correctly See Digital Control System User Manual 4 Cooling Occupied and or 4 Change to correct setpoint settings Unoccupied setpoints not set See Digital Control System User correctly Manual 5 Insufficient cooling 5 If desired Space Temperature is not reached and cooling is at full capacity it may be undersized 6 Condensing section or evaporative 6 See Troubleshooting Guide for your condensing unit or evaporative cooler Refer to Digital Control System User Manual for additional troubleshooting suggestions 29 TROUBLESHOOTING GUIDE To Calibrate the Building Pressure Transducer PT 13 1 Remove the tubes at the Low and High pressure fittings 2 The voltage at COM and OUT should be 2 5 VDC If not adjust Z do not adjust S 3 Make sure the Low and High fittings are clean and clear do not insert any sharp objects into the pressure fittings Make sure the tubing is also clean clear of any debris and then reinstall the tubes on the transducer It is very important that the High tube be placed inside the building and positioned so that air movement does not affect it The Low side should be to atmosphere and positioned so it is not exposed to the weather 4
23. National Electrical Code and applicable state and local codes in Canada to the Canadian Electrical Code Part 1 CSA Standard C22 1 and applicable provincial and local codes Since shipment of unit may require disassembly after factory check and test reconnection of some electrical devices will be required in the field Connect electrical wires supplied in factory furnished conduit to appro priate terminals All leads are tagged to facilitate field connections See wiring diagram provided with equip ment Complete all wiring to any optional accessories as shown on unit bill of material and electrical wiring diagram as required before applying voltage to the unit Entry location for all field installed and control wiring is through the control panel If optional disconnect is not furnished with heater the field provided disconnect must be of the proper size and voltage Refer to unit rating plate for minimum circuit ampacity and voltage The disconnect must be installed in accordance with Article 430 of the current edition of ANSI NFPA No 70 National Electrical Code Check the supply voltage before energizing the unit The maximum voltage variation should not exceed 10 Phase voltage unbalance must not exceed 2 NOTE 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 REMARQUE Dans le cas un quelconque des cab
24. The unit will pause for 10 seconds after power is applied to begin driving the output Optional Span 0 24 VDC Gas Valve 20 VA Transformer 120 Volt AC Power Status LED A solid green LED indicates power and normal operation A slow blinking green LED indicates power but the 10 second start up delay has not completed A fast blinking green LED indicates the the inpput signal is out of range or may be reversed 24 TROUBLESHOOTING GUIDE Modulating Discharge Temperature MDT or VDT EXPERT Controls Portions reproduced with permission from Maxitrol Company Symptom Possible Cause Field Test Remedy A No Gas Flow Modulating valve Arrow on side of valve should Install properly with DO 2 improperly installed point in direction of gas flow or UC 01 energizes Continuous Low Fire Electronics Problem Short circuit or no voltage to the amplifier RE 26 Faulty amplifier RE 26 No output voltage on UC 10 Check for 24V AC at amplifier RE 26 terminals 7 amp 8 Check item B1 Check for 2 10 VDC input signal from UC 01 at terminals 1 amp 2 Check for 0 20 VAC output signal to gas valve at terminals 5 amp 6 Check DC Voltage on AO 1 Prove the power source If item B1 checks out and modulating voltages are still not obtained amplifier RE 26 may be assumed faulty Replace Contact Factory Continuous Low Fire Electronics
25. ULATION WARNING On Heaters which recirculate room air outside ventilation air must be provided in accordance with the information shown on the heater nameplate Recirculation of room air may be hazardous in the presence of flammable solids liquids and gases explosive materials such as grain dust coal dust gunpowder etc substances such as refrigerants or aerosols which may become toxic when exposed to heat or flame Recirculation is not recommended in uninsulated build ings where outside temperatures fall below 32 F 0 C Excessive recirculation or insufficient ventilation air which results in inadequate dilution of combustion products generated by the heater may create haz ardous concentration of carbon monoxide nitrogen dioxide and other combustion products in the heated space INDUSTRIES US 4830 Transport Drive Dallas TX 75247 Phone 214 638 6010 Fax 214 905 0806 www tempriteheating com If gas fork trucks or other fossil fuel powered equip ment are utilized in the conditioned area additional ventilation requirements for the facility must be ad dressed separately The heater inlet shall be located in accordance with applicable building code provisions for ventilation air Field constructed intake accessories should be prop erly designed to minimize the entry of snow and rain All ventilation air to the heater shall be ducted directly from the outdoors If in doubt rega
26. a 1 ADJOINING SECTION FIRST SECTION PPLY GASKET MATERIAL PRIOR TO ATTACH me SECTIONS THEN CAULK OR SEAL ALONG EACH SEAI Slide adjoining section against the tacky taped first FIG 1 section If bolt holes are provided bolt the sections pur TAPE together tightly If bolt holes are not provided use E furniture clamps to pull sections TIGHTLY together Sections whether bolted or not will be held together and sealed by the standing seams and hugger strips Fig 2 which will be attached later SCREWS 8 1 1 t i 1 1 1 1 1 1 1 I or silicone sealant along the standing roof seam idm Fig 3 and side seams where the sections come FIG 2 together Fig 1 It is mandatory to seal the roof and side seams along the entire outside of the unit and it is strongly suggested that the seams also be sealed along the inside of the unit if possible CAULK WA CAULK Apply caulking material along the top of both sides FEUD APELED CAULK on ROOF SEAM of the standing roof seam Fig 4 Place roof cap FIG 4 Fig 5 on top of the seam and secure it with two rows of TEK screws one down each side spaced approximately 8 10 inches apart down the entire length of the seam Apply two strips of tacky tape one down each side to the back side of each hugger strip Fig 2 Se cure hugger strip with two r
27. an of dirt and lint in order to operate at rated efficiency Coils should be inspected on a regular basis and cleaned as required 85 CAUTION Solutions used to clean coils must If any mixing plates are loose or missing not be corrosive to metals or materials used in fasteners tighten replace as necessary Always the manufacturer of this equipment If cleaning use zinc plated or stainless fasteners The solutions are applied through means of high mixing plates on the burner may display hairline pressure spray care must be taken to avoid cracks These cracks are normal and caused by damaging the coil fins thermal stresses occurring during combustion The presence of these hairline cracks in no 2 Condensate Drain Pan Periodically flush the significant way affects the combustion efficiency condensate pan and drain system with a water or performance of the heater Should a large hose opening develop it may cause difficulties in cross ignition of flame across the face of the burner If F Gaskets this does occur the specific mixing plate or plates Gaskets are used on doors inspection covers some involved must be replaced filtrer racks and some outdoor air dampers Inspect c Put system back into operation and view burner gaskets periodically and repair or replace as required while cycling through full firing range This will give a visual check for blocked burner ports G Caulking Inspect cabinet and add caulking as required 2
28. and should be completed with greatest care given to detail A good pre start inspection will insure against possible unit damage on start up and will save valuable analysis time 1 Check that the physical condition of the unit exterior is acceptable 2 Check that the insulation inside of unit is properly secured 3 Remove all shipping blocks brackets and bolts from supply fan base with optional isolation base 4 Check all wiring for loose connections and tighten if necessary 5 Inspect all fan and motor bearings and lubricate if necessary CAUTION DO NOT RUPTURE GREASE SEALS 6 Inspect pulleys and belts for tightness tension and alignment Do not overtighten belts 7 Check set screws on all bearings pulleys fans and couplings for tightness 8 Check voltage supplied to disconnect switch the maximum voltage variation should not exceed 10 Phase voltage unbalance must not exceed 2 9 Check thermostat s for normal operation 10 Check that system duct work is installed and free from obstructions 11 Check that fans turn free in housing 12 Check that the area around the unit is clear of flammable vapors or containers of flammable liquids 13 Check that all piping connections particularly unions are tight Check all gas piping for leaks using a soap bubble solution The most common types of problems found relative to the gas train itself is foreign material within the gas piping This will interfere wit
29. are blocked If any burner ports are plugged even partially clear them with a piece of wire See Maintenance of Gas Ports WARNING Do not enlarge burner ports or performance be drastically affected 36 SECTION IX MESTEK LINE BURNERS Inspection and Maintenance of Gas Ports Use of an electric drill motor is not suggested unless Conduct initial inspection within the first month after both Pin Vise and Drill can be chucked up in a vari commissioning Visually check the gas ports of new speed drill unit Use caution because it is easy to snap burner assemblies for any piping scale or debris Use the bits off in a port when using a drill motor Removal of Pin Vise with drill bit to remove broken bits from the gas ports is difficult Annual inspections are normally adequate once Alternate drill size which may be used is a 5 64 for the initial piping debris is removed The operating 45 conditions of the burner will determine how frequently maintenance is actually required P001117 Mestek Line Burners GAS MANIFOLD MN T FLAME ROD 9 979 71 0201 06 5 5266 Bi N oo PIN VISE ee PLAN VIEW N BURNER PLATES REMOVED SPARK IGNITOR 65 0910 28 i 1 445 DRILL PILOT TUBING i WHEN REQUIRED nnn on ow oM on on i 1 71 1L 1L u a d
30. ate and inspect valve and seat Clean replace valve and or seat if necessary capacity operating at high fire Problem Plunger jammed 2 Inspect plunger should be 2 Clean or if necessary smooth and clean and operate replace plunger freely in solenoid sleeve H Continuous High Open circuit in Outside 1 Measure resistance per 1 If readings are incorrect Fire Electronics Air Temperature Thermistor Curve replace Outside Air OK Sensor TS 01 Space Temperature Sensor TS Temperature Sensor 01 Space Temperature TS 02 or Discharge Sensor TS 02 or Discharge Air Temperature Sensor Air Temperature Sensor TS TS 03 03 or repair wiring I Incorrect High Inlet pressure too low 1 Read inlet pressure at 1 Increase inlet pressure Fire valve using a manometer if possible or change to with heater operating at full larger valve Consult factory fire Pressure should be at about possibility of using least equal to the sum of special spring to reduce outlet pressure setting and pressure drop on selected pressure drop of the valve installations plus 1 0 w c Incorrect outlet 2 Read outlet pressure using 2 See Valve Adjustments pressure adjustment manometer and compare Section X with the pressure stated on the specification plate J Continuous Open circuit in Space 1 Measure resistance per 1 If readings are incorrect Maximum Temperature Sensor Thermistor Curve replace S
31. ation Instructions Item Manufacturer Bearing Type All 3 phase US Baldor Single row ball fan motors or equal bearings 1 HP to 100 HP ODP TEFC Recommendation See following note All 1 phase Century G E Bronze sleeve motors or equal bearings Fractional HP ODP TEFC or TEAO Recommendation See following note Fractional HP Century G E Bronze sleeve single phase or equal bearings ODP or TEFC Recommendation See following note Fan shaft Fafnir Self aligning bearings or equal single row or double row ball bearings resilient mounted Recommendation See following note Dampers Factory Sleeve or equal Recommendation See following note 1 Blower Motors Some motors require lubrication while others do not Those that require lubrication can be identified by the presence of grease plugs in the motor casing at each end Motors that do not have grease plugs cannot be greased and are lubricated for the life of the motor bearing Lubrication of motors should be done while the mo tor is warm and at a standstill Remove and clean all grease plugs and insert a grease fitting in the upper hole in the motor casing at each end Viewed as if motor were sitting horizontally on its base There may be one or two plugs in each end casing of the motor Add a small amount of a clean good grade ball bear ing grease such as Exxon Polyrex EM or equal with a low pressure grease gun Run the motor f
32. ause severe injury death or property damage Internal Fault was on when it should Remove system power and turn off power supply be off 1 Remove system power and turn off fuel supply 2 Check wiring correct any errors 3 inspect Pilot Fuel Valve s both places and connections 4 Reset and sequence the relay module 5 Ifthe fault persists replace the relay module Code 4 3 Flame not sensed or 1 Check wiring correct any errors Flame sensed when it should 2 sure the flame amplifier and flame detector are compatible Amplifier be on or off 3 Remove the flame amplifier and inspect the connections Reseat the amplifier Problem 4 Reset and sequence the relay module 5 Ifthe code reappears replace the flame amplifier and or the flame detector 6 Ifthe fault persists replace the relay module Code 4 4 The configuration 1 Inspect the jumper connections Make sure the clipped jumpers were completely Configuration jumpers differ from the removed Jumper sample taken at startup 2 Reset and sequence the relay module Problem 3 Ifthe fault persists replace the relay module Code 5 1 Preignition Interlock 1 Check wiring and correct any errors Preignition fault 2 Check Preignition Interlock switches to assure proper functioning Interlock 3 Check fuel valve operation 4 Reset and sequence the relay module monitor the Preignition Interlock status 5 Ifthe fault persists replace the relay module Code 5 2 Either High Fi
33. b keyways are in the middle of the shaft keyways Adjust the shaft so it protrudes past the non drive end bearing the blower sheave keyway mates with the shaft keyway and the drive side sheave can be aligned with the motor sheave Ideally the blower sheave should be as close to the drive side bearing as possible the motor sheave should be as close to the motor housing as possible and the belts should be straight Be sure the shaft does not rub on or interfere with the closing of the access door Align all bearing setscrews so that the same set screw on each bearing is pointed in the same direction as the other bearings setscrews Place a drop of BLUE Loctite on the bearing setscrews and tighten all of the setscrews Follow the mounting instruction s procedure on the inside of the bearing box for the proper tightening and torque values Align the blower hubs keyway with those in the shaft Be sure the clearance between the blower wheel and blower housing is the same on each side Rotate the shaft by hand to insure free operation Correct any rubbing of the blowers on the housings Place a drop of BLUE Loctite on the blower setscrews and tighten all of the setscrews Align the blower and motor sheaves using a laser or straight edge and tighten the blower sheave to the shaft Replace the belts and tighten the motor base adjustment for the proper belt tension Over tightening the belt tension
34. binet and blower access while the unit is powered High voltage and moving parts are present and these steps should be performed by qualified service personnel If any of the controls requiring manual reset were at fault this is an indication of a problem with the system that should be investigated o SECTION VII TROUBLESHOOTING continued Fan and Heat Mode Symptom Cause Remedy A If blower does not 1 Low or no voltage 1 Check power source operate 2 Circuit breaker open 2 Check and replace 3 Customer interlock not closed or 3 Close or connect customer connected interlock 4 Fan is disabled 4 Enable the fan 5 Time clock night setback 5 Check time clock night setback thermostat or field installed thermostat and field installed controls open controls for proper settings 6 Freeze protection tripped low 6 Reset freeze stat by interrupting discharge temeprature power Check for proper setting and burner operation 7 Damper motor not operating its 7 Check for power at damper end switch not making or the motor and that end switch has damper is binding been wired correctly to the N O normally open contact Check that the linkage is clear and not binding 8 Overload Protection on motor 8 Push reset button on starter and starter tripped check amps 9 Belts loose or broken 9 Turn power off and check belts 10 Bearings seized 10 Check and replace 11 Motor may be burned
35. cking requirements of the transportation companies and your bill of lading proved that everything was in good condition when shipped That bill of lading contract requires them to deliver in perfect condition SECTION Il GENERAL INFORMATION A Purpose The purpose of this manual is to present a guide for proper installation maintenance and operation of the Direct Gas Fired System and supplement but not to replace the services of qualified field service person nel to supervise the initial start up and adjustment of the unit Persons without previous experience with large commercial and industrial heating equipment should not attempt the initial adjustment and checkout procedure which is essential before such installations may be considered ready for operation This manual should be made readily available to all operating personnel as an aid in troubleshooting and proper maintenance B Shipping Base Direct Gas Fired units are shipped completely assembled where shipping limitations allow Optional inlet hoods filter and or damper sections or other large accessories are assembled and shipped mount ed and wired whenever possible within limitations of shipping and handling Any optional accessories shipped separately are shipped as assembled sec tions Any wired accessories which have been disas sembled for separate shipment require no additional conduit or wire for field reassembly All wire leads will be tagged for ease of rec
36. clockwise will disable the fans MRT PRO With Smart Room Sensor To enable the fans and place the unit in the Occupied Mode press the Manual On button on the face of the TS 02 MRT PRO room sensor Pressing the Warmer button will add 30 minute increments of time for a total of 9 hours of operating time To disable the fans and place unit in the Unoccupied Mode press and hold down the Manual On button Alternately pressing the Manual On button will also decrease the amount of operating time until it reaches zero and turns the fan off MRT Expert With A BACview KP 01 To enable the fans go to Unit Modes and enter MANUAL this mode will enable the fans To also enable the fans go to Unit Modes and enter AUTO this mode has four different functions that control the fans and unit operation They are a Time Clock Heating and Cooling Night Setbacks and signal from an external source to an auxiliary digital input To disable the fans go to Unit Modes and enter OFF NOTE A BACview or PC is required to change Unit Modes For a more detailed control sequence see the Digital Control System User Manual Turn main disconnect switch on and Enable fans Damper opens if applicable Blower fan turns on see operating modes in Digital Control System user manual Disable the fans Check supply blower for proper rotation NOTE To change rotation of the blower simply interchange any two 2
37. d units which recirculate room air outside ventilation air must be provided in accordance with the information shown on the heater nameplate All ventilation air to the heater must be ducted directly from the outside See Section XIII If in doubt regarding the application of this appliance consult the factory Locate the unit exactly level Special attention should be given to the duct electrical and fuel connection points Install duct work with adequate flexible connec tions to isolate vibration from the duct work All duct work should have taped or caulked seams Duct work should be properly sized so as not to inhibit airflow This information should be cross checked with the position of support beams and stand pipes to insure that clearance dimensions coincide with those of the unit The minimum clearance to combustible material must be maintained as listed in Table 1 Table 1 Minimum clearance to combustible material also consult local codes and regulations Clearances to Combustible Material Vertical Units Horizontal Units Front 39 inches 39 inches Rear 6 inches 6 inches Right 6 inches 6 inches Left 6 inches 6 inches Top 12 inches 12 inches Floor Zero 6 inches Consider control side as front of unit Optimum clearance for shaft removal would be equivalent to cabinet width Make a visual inspection to insure no damage has occured to the unit during installation C Curb Mounted Units Outdoor un
38. ducer Piping PT 13 Pipe the high side to location inside the building that will not be affected by air movement Pipe the low side to the atmosphere positioned so it will not be affected by the wind and not exposed to the elements Be sure that all tubing is clean and clear of any debris before installing tubes on the transducer Flow Station Transducer Piping PT 15 Pipe the high side to the upstream connection and low side to the downstream connection of the Airflow Station as shown in Drawing C000643 below Be sure that all tubing is clean and clear of any debris before installing tubes on the transducer G Field Wiring and Remote Control Installation Connect the power lines to the line side of the main disconnect switch Mount and wire remote control panel thermostats temperature sensors and any other field installed controls as indicated on the unit control wiring diagram Connect the wires to the appropriate field wiring terminals as indicated on the unit control wiring diagram Field wiring shall have a temperature rating of at least 105 C The minimum size of the supply cable circuit shall be sufficient for the maximum ampacity of the heater L installation l ctrique d utilisateur aura une temp rature qui value d au moins 105 C La minimum de source du circuit de c blage sera suffisante pour le ampacity maximum de l appareil de chauffage H Locating Temperature Controls The room or outdoor sensors should be
39. dy If pilot does not light after prepurge has timed out 10 seconds and voltage is present on flame safeguard output terminals If pilot does not light after prepurge has timed out and there is no voltage at flame safeguard relay output terminals If there is no heat with pilot ok and voltage is present at flame safeguard relay output terminals Manual pilot shut off valve closed Inlet gas pressure lower than required gas pressure No gas through pilot regulator with inlet gas pressure ok No gas through pilot solenoid Type of gas natural LP supplied different from factory required type Note components may change Flame detection system not sparking or sensing pilot flame see spark rod diagram P 001117 No voltage on secondary side of ignition transformer Flame safeguard relay Run Test switch in Test position or functioning problem Manual gas shut off valve closed No gas on outlet side of regualtors with inlet pressure ok No gas on outlet side of valve or actuator with inlet pressure ok Main flame rod or scanner not sensing main burner 5 DO 5 or UC 01 not energized l 6a 6b 4a 4b 4C Slowly open valve Increase gas pressure Clear obstruction in vent orifice line or replace if defective Check for correct installation and voltage Correct or replace Replace with factory
40. e detector and or flame amplifier checkout procedures in the installation instructions 5 code reappears replace the flame amplifier and or the flame detector 6 Ifthe fault persists replace the relay module Code 3 1 Running or Lockout 1 Check wiring correct any errors Running Interlock fault during 2 Inspect the fan make sure there is no air intake blockage and that it is supplying air Interlock Switch Prepurge 3 Make sure the Lockout Interlock switches are functioning properly and the contacts Problem are free from contaminants 4 Reset and sequence the relay module to Prepurge place the TEST RUN Switch in the TEST position if available Measure the voltage between terminal 7 and G ground 120 Vac should be present Switch TEST RUN back to RUN 5 If steps 1 through 4 are correct and the fault persists replace the relay module Blinking Fault Codes and Recommended Troubleshooting Fault Code System Failure Recommended Troubleshooting Code 3 2 Lockout Interlock 1 Check wiring to make sure that the Lockout Interlocks are connected properly Running powered at improper between terminals 6 and 7 Correct any errors Interlock On point in sequence or On 2 Reset and sequence the relay module During in Standby 3 Ifthe fault persists measure the voltage between terminal 6 and G ground then Standby between terminal 7 and G If there is 120 Vac at terminal 6 when the co
41. e to correct setpoint Discharge Air MP 15 not set correctly Enable Potentiometer setting Temperature MP 15 2 Discharge Air 2 Check Discharge Air If readings are not correct Temperature Sensor Temperature Sensor TS 03 replace Discharge Air TS 03 not reading and wiring See Thermistor Temperature Sensor TS 03 correctly curve or repair wiring 3 The Heating Discharge 3 Check setpoint with BACview 3 Change to correct setpoint Air Setpoint on or PC See Digital Control System VDT EXPERT Control User Manual System is not set correctly l Burned out 1 Short circuit in 1 Measure resistance across Replace modulator head if Transformer modulator coil modulator terminals with red less than 40 ohms Correct wiring if short is found Refer to Digital Control System User Manual for additional troubleshooting suggestions 26 TROUBLESHOOTING GUIDE Modulating Room Temperature MRT MRT PRO or MRT EXPERT Controls Portions reproduced with permission from Maxitrol Company Symptom Possible Cause Field Test Remedy No Gas Flow with DO 2 on UC 01 energized Valve improperly installed Arrow on side of valve should point in direction of gas flow Install properly Continuous Low Fire Electronics Ok Open circuit in modulator coil Remove wires connected to amplifier terminals 5 amp 6 and measure resistance MR212 60 80 ohms M611 45 55 o
42. er length without any blowout spots e Clean the flame sensor s or UV sight tube s f Inspect filters Clean or replace as necessary g Inspect the main fan bearings lubricate is necessary See Section VIII on bearing maintenance h Check all dampers damper actuators and linkages Adjust and tighten if necessary i Ensure that there are no obstruction blocking the air supply to the heater or the air discharge from the heater j Inspect the area and make sure that no combustible or hazardous material has been stored within the clearances as shown on the unit nameplate k Check and clear all air sensing tubes and fittings CAUTION Remove tubes from switches transducers and flow station before using compressed air to blow through tubing l Test ignition spark There should be a continuous spark for 10 seconds with pilot gas turned off 5 Quarterly a Complete the monthly maintenance schedule b Inspect all drives for proper belt tension and wear c Check the alignment of the sheaves and adjust if necessary d Inspect all bearings set screws for tightness and lubricate bearings if necessary e Check the pilot electrical system Adjust if necessary f Check the pilot assembly Clean and adjust if necessary g Inspect the burner carefully Clean and adjust if necessary h Check voltages and amp draw on main fan motor i Check the operation of all safety controls individually j Check the operation o
43. f the automatic gas shut off valves and check them for leakage at the pressure test ports provided k On vertical units inspect burner clean out and drain if necessary 6 Off Season or Yearly a Complete the monthly and quarterly maintenance schedule b Inspect all fan wheels and housings Clean if necessary Check that all fan wheels sheaves and couplings are securely set on the shaft d Inspect all bearings and alignment Adjust if necessary e Inspect all V belts sheaves and coupling inserts Replace if necessary f Inspect all electrical components connections and terminals Clean and tighten where necessary g Test ignition spark Adjust gap if necessary h Clean ignition electrodes and check for cracks i Test flame safeguard relay and replace components if necessary j Inspect all regulators relief valves motorized valves solenoid valves vent valves manual shut off valves and safety shut off valves Check their operation and clean as necessary k Ensure all vents to the atmosphere are clean and free from obstruction I Inspect and clean all drip legs in the fuel line m Lubricate fan motor as directed by motor manufac turer n Inspect fan motor wiring for loose connections Lightly oil all door latches p Check that cabinet is weathertight replace door gaskets and recaulk as necessary NOTE Keep screened air intakes clear of obstruc tions at all times 32 B Lubric
44. h the proper operation of the gas train components and burner Purge all air from gas lines per gas codes 14 Check that all accessories requiring field wiring have been properly installed 15 Check burner for proper location and alignment 16 Check that filters filter stops accessories and ship loose items are installed correctly 17 Check that vent lines if applicable are run to atmosphere on gas regulators and pressure switches for indoor units Vent lines should terminate outside the building with a turndown elbow and bug screen Note that some units will use vent limiters and vent lines are not required If vent lines are even partially plugged this will interfere with proper venting of pressure control devices 18 Check that all manual gas shut off valves are closed 19 When failure or malfunction of this heater creates a hazard to other fuel burning equipment e g when the heater provides make up air to a boiler room the heater is to be interlocked to open inlet air dampers or other such devices 20 Motor overload relay setting should match the motor s nameplate full load amperage 21 Check that dampers and linkages are free to move and that linkages are tight 22 The unit may require that a Return Airflow Station be field installed Be sure all tubing connections are in the correct location as shown in drawing C000643 23 If inlet duct is attached to the heater a purge timer must be provided and set t
45. hms If proper resistance values are not observed replace modulator head or repair wiring Plunger missing 2 Inspect plunger should be 2 Clean or replace plunger if jammed or improperly installed to operate freely in necessary installed solenoid sleeve Ruptured main or 3 Disassemble valve for 3 Replace diaphragm if balancing diaphragm inspection of internal parts ruptured Continuous Low No voltage to the 1 Check for 24V AC at 1 Provide 24V AC to amplifier Fire Electronics amplifier amplifier terminals 7 amp 8 Problem Short in modulator 2 Measure resistance per 2 f proper resistance values coil circuit item B1 are not observed replace the modulator head or repair wiring Faulty amplifier RE 26 3 Check for 2 10 VDC input 3 If power source and signal from Unit Control modulator coil check out Module UC 01 at terminals items 5 amp 6 but proper 1 amp 2 Check for 0 20 VDC modulating voltages cannot output signal to gas valve at be obtained then amplifier terminals 5 amp 6 may be assumed at fault Install replacement amplifier No output voltage on 4 Check voltage on AO 1 4 Consult factory UC 01 Incorrect Incorrect by pass metering 1 See Valve Adjustments 1 Adjust to proper low fire Low Fire valve adjustment Section X Excessive negative 2 Close main gas supply and 2 If greater than 1 5 negative burner pressure measure manifold p
46. ice reapply power then reset and sequence the relay module 3 If fault does not repeat on the next cycle check for electrical noise being copied into the relay module through the external loads or possibly an electrical grounding issue 4 Ifthe fault persists replace the relay module Code 6 3 Fault with special OEM 1 Check wiring and operation of special OEM inputs Device input circuits 2 Reset and sequence the relay module Specific 3 If fault reappears remove power from the device reapply power then reset and sequence the relay module 4 Ifthe fault does not repeat on the next cycle check for electrical noise being copied into the relay module through the external loads or possibly an electrical grounding issue 5 Ifthe fault persists replace the relay module Code 6 4 Unused at this time Accessory Fault Code 7 7 Unused at this time Unused 19 SECTION VII TROUBLE SHOOTING continued Check Safety Shutdown Performace WARNING Fire or explosion hazard Can cause property damage severe injury or death Perform the safety shutdown test any time work is done on a gas system NOTE Read steps 1 through 7 before starting and compare to the safety sutdown or safety lockout tests recommended for the intermittent pilot IP ignition module Where diffferent use the procedure recommended for the module 1 Turn off gas supply 2 Set thermostat or controller above room te
47. ing Period MFEP a After PFEP and with the presence of flame the main fuel valve terminal 9 is powered If a flameout occurs the relay module locks out or recycles depending on status of jumper JR2 within 0 8 or 3 seconds depending on the Flame Failure Response Time FFRT of the amplifier b The RM7897A terminal 21 has a ten second MFEP After the Ignition Trials the interupted pilot valve terminal 8 is de energized If a flameout occurs the relay module locks out or recycles depending on status of jumper JR2 within 0 8 or 3 seconds depending on the amplifier FFRT Run 1 The RM7897C has a delayed main valve that is energized once the RUN period is entered 2 The relay module is now in RUN and remains in RUN until the controller input terminal 6 opens indicating that the demand is satisfied or a limit has opened Post Purge After demand is satisfied or a limit opens de energizing terminal 6 the Ignition Pilot valve main valve and delayed main valve terminals 8 9 and 21 are de energized The blower motor terminal 4 remains powered during the specified programmed time The Pre Ignition Interlock closes within the first five seconds of Post Purge Run Test Switch The Run Test Switch is located on the top side of the relay module see Fig XX The Run Test Switch allows the burner sequence to be altered as follows 1 In the measured PREPURGE sequence the Run Test Switch placed in the TEST positi
48. ion of the fault code three fast blinks is 30 while the slow blinks identify the units portion of the fault code two slow blinks is 2 Three fast blinks followed by two slow blinks would be fault code 32 This identifies a running interlock on during STANDBY See following Table for Blinking Fault Code List The LED code repeats as long as the fault exists To clear the fault press the RESET button Blinking Fault Codes and Recommended Troubleshooting Fault Code System Failure Recommended Troubleshooting Code 1 1 Low AC Line detected 1 Check the relay module and display module connections Low AC Line 2 Reset and sequence the Relay Module Voltage 3 Check the 7800 power supply and make sure that frequency and voltage meet specifications Code 1 2 Excessive noise or 4 Check the backup power supply as appropriate AC Quality device running on slow Problem fast or AC line dropout detected Code 2 1 Flame sensed when no 1 Check that flame is not present in the combustion chamber correct any errors Unexpected flame is expected during 2 Make sure that the flame amplifier and flame detector are compatible Flame Signal STANDBY or PURGE 3 Check the wiring and correct any errors 4 Remove the flame amplifier and inspect its connections Reseat the amplifier 5 Reset and sequence the relay module 6 Ifthe code reappears replace the flame amplifier and or the flame detector 7 Ifthe fault persi
49. is energized c Main valve terminal is energized d Delayed main valve terminal is energized RM7897C e Internal system fault occurred f Purge card is removed g Purge card is bad h Flame signal is detected for 30 seconds i Preignition interlocks open durning stand by 4 PILOT FLAME ESTABLISHING PERIOD PFEP a Airflow lockout feature is enabled and the airflow switch opens b No flame signal at end of PFEP c Ignition pilot valve intermittent pilot valve terminal is not energized d Main valve terminal is energized RM7897A e Delayed second stage main valve terminal is energized RM7897C f Internal system fault occurred g Purge card is removed h Purge card is bad 5 MAIN FLAME ESTABLISHING PERIOD MFEP RM7897A teminal 21 a Airflow lockout feature is enabled and the airflow switch opens b Ignition terminal is energized c Ignition pilot valve terminal is not energized d Main valve terminal is not energized e Delayed main valve terminal is energized f Loss of flame signal g Internal system fault occurred h Purge card is removed i Purge card is bad 6 RUN PERIOD a No flame present JR2 removed b Airflow lockout feature is enabled and the airflow switch opens c Interrupted pilot valve terminal is energized RM7897A terminal 21 d Main valve terminal is not energized e Delayed main valve terminal is not energized RM7897C f Internal system fault occurred
50. it to be rendered OUT OF AIR BALANCE Do not overtighten belts Suggested Belt Tension Method 1 Check tension frequently during the first 24 48 hours of run in operation Ideal tension is the lowest tension at which the belt will not slip under peak load conditions Over tensioning shortens belt and bearing life 2 To properly tension a conventional V belt drive use the following procedure a Measure the span length b At the center of the span apply a force perpen dicular to the span to deflect the belt 1 64 inch for every inch of span length For example for a 40 inch span apply a force that will deflect the belt 40 64 or 5 8 of an inch c Compare the force you have applied with the values given in the table below If the force is between the values for normal tension and 1 1 2 times normal tension the belt tension should be satisfactory If the belt tension is not within this range it can be adjusted by loosening the motor mounting bolts and adjusting the position of the motor along its base B Section small Pounds pulley Pounds Force for diameter Force for 1 times rangein Manufacturer Normal Normal Inches amp Type Belt Tension Tension 3 4 4 2 Gates Hi Power 4 4 6 6 4 4 4 6 Gates Hi Power 4 9 7 4 5 8 8 6 Gates Hi Power 5 8 8 7 Note For recommendation of other types of belts consult respective manufacturers E Optional Coils And Related Items 1 Coils Coil surfaces must be kept cle
51. its can be supplied with an optional roof curb The curb greatly facilitates installation thereby reducing installation costs All connections to the unit duct piping electrical power and control wiring can be made through the roof opening The curb may be shipped prior to unit shipment All curbs are shipped un assembled from the factory Use extreme caution in handling the curb Proper handling and positioning will assure a water tight curb unit installation Re check approval prints prior to installation Be sure that there are no obstructions to ducting and that proper planning has been exercised in connection of piping and or electrical services The curb assembly may be bolted or welded to either trusses or roof decking however connection to roof trusses is recommended The curb is designed to carry the weight of the unit Additional support is required for certain applications Placement of the curb is critical in squareness and leveling Shims for leveling must be applied to the curb application of shims to the unit will tend to destroy the sealing effect after installation Make sure sealing tape is in place before unit is set Be careful not to allow gaps where two pieces of sealing tape meet A bubble level must be used in the leveling process Measure across diagonals to check for squareness Allowable tolerance is 1 4 difference between diagonal measurements Double check approval prints before setting the unit Upon
52. ive minutes before removing the grease fittings and replacing the plugs CAUTION An excess of grease will overheat the bearings NOTE On totally enclosed fan cooled TEFC motors the rear end fan housing must be removed to expose the grease plugs 2 Pillow Block Bearings Pillow block bearings are used on supply blower s Bearings have been prelu bricated with a number 2 lithium base grease Relu brication should be done with a similar grease using a low pressure grease gun Wipe all grease fittings clean before adding grease Grease should be added slowly in small amounts at frequent intervals while the shaft is being manually rotated A slight showing of grease at the seals with accom panying normal bearing temperature indicates proper lubrication Normal temperature can range from to hot to the touch depending on size speed and sur rounding conditions Excessive bearing temperature indicates faulty lubrication An insufficient amount of grease is suggested by a bearing showing no grease at the seals and a higher than normal temperature and noise level Excessive leakage of grease at the seals and a high operating temperature suggest too much grease Frequency of Lubrication Frequency of lubrication depends upon operating conditions The bearing operating temperature is the best index for determin ing a relubrication schedule The following chart gives the frequency of relubrication based upon c
53. justments Note Low fire may need to be set first to get the burner to light off properly 1 Disconnect the plug where the Temperature Sensors TS 01 and TS 03 are wired to the unit control module UC 01 A minimum of 15vdc is required at terminals 5 and 6 on electric relay RE 26 This causes the valve to call for continuous high fire Caution The unit will shutdown on freezestat after approximately 3 minutes 2 Adjust the gas pressure regulator GP 05 to obtain the normal manifold pressure Low Fire or Bypass Adjustments 1 Disconnect wire from RE 26 terminal 8 This causes valve to call for continuous low fire 2 Remove cap A and turn adjusting screw B to desired low fire adjustment Clockwise rotation reduces minimum flow rate 3 Replace cap A and reconnect wire to RE 26 terminal 8 4 Reconnect the plug back into the jack on the unit control module UC 01 CIRCUIT ANALYSIS MAXITROL GAS VALVES Connect a DC volt meter capable of reading 0 24V DC on the Modulator M611 or Modulator Regulator MR212 Valve terminals The operation of the Valve with regard to voltage is as follows from 0 volts to approximately 5 volts the modulat ing valve should be on bypass flow with the heater operating on low or minimum fire From approximately 5 volts to 15 volts DC the valve should be performing its modulating function and the heater should be firing at a modu lated flow rate between low and high
54. ld be equipped with a manometer or differential pressure switch to indicate when the filters are dirty Filters should be replaced when the differential pressure across them reaches the manufacturer s recommended final value Dirty filter elements should be replaced with a clean element of the same type and size In addition the factory not only suggests but insists that air filters be checked every 30 days and replaced with new filters throw away type or cleaned washable type as required Cleanable filters should be given new application of filter coating after washing to maintain optimum filter performance The frequency of cleaning and replacing air filters applies twelve months of the year where blowers are used for ventilation and heating D Belt Tensions and Adjustments Belt tension is adjusted during the initial run in and test periods at the factory However the belts are run as slack as possible to prevent excessive damage to the bearings yet tight enough to prevent slippage It is necessary therefore to tighten all belts during the first few months of operation and to check for proper tension weekly during the first 60 days after which 30 day check intervals are sufficient NOTE Turn off all power to the equipment before checking belt tensions CAUTION Do not attempt to tighten any belt or belts by changing the pitch of an adjustable pulley as this will change the speed of a driven pulley causing the un
55. les livr s avec l unit devait tre remplac il doit tre remplac avec des c bles pr vus pour r sister une chaleur d au moins 105 C F Field Piping Gas Piping All gas piping must be in accordance with the require ments outlined in the National Fuel Gas Code ANSI Z223 1 It is required that a ground union be installed adjacent to the manifold for easy servicing A drip leg and or filter should be provided upstream of the unit s inlet gas connection An additional shut off must be located external of the unit s enclosure The location of this valve must comply with all local codes A 1 8 inch N P T plugged tapping accessible for test gauge connection must be installed immediately upstream of the gas supply connection to the unit WARNING To avoid equipment damage possible personal injury disconnect 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 DANGER Never use an open flame to detect gas leaks Explosive conditions may exist which would result in personal injury or death On vertical units there is a factory installed Burner Cleanout pipe located on the opposite end of the gas piping compartment This is a clean out to drain any condensate that may have collected in the line burner WARNING DO NOT connect supply gas to this pipe
56. mounted where they will not be subjected to direct impact of the heated air or radiant heat from the sun It is also recommended that thermostats especially those with mercury bulb contacts be mounted on a vibration free surface The side of building columns away from the heater or interior walls are usually the location best suited for mounting thermostats Controls with outdoor sensors require that the outdoor sensor be shielded from direct radiation from the sun Unit mounted sensors are factory located and mounted AIRFLOW STATION LAYOUT 4 NOTE RUN TUBE CONNECTIONS S TO TRANSDUCER PT 15 IN SIS UNIT CONTROL ENCLOSURE RA DAMPER LOW PRESSURE HIGH PRESSURE TUBE CONNECTION TUBE CONNECTION TOTAL PRESSURE SENSING TUBE STATIC PRESSURE SENSING TUBE AIR FLOW aa BULLET AMPLIFIER WING AIRFLOW STATION SHEET METAL STRIP EXTERIOR INSULATION FIELD PROVIDED WHEN MOUNTED OUTDOORS C000643 7 1 NOTE One roof cap is attached to a standing seam on each section for shipping purposes N only It will be necessary to remove this PRIOR TO SLIDING SECTIONS TOGETHER Failure to do so ADJOINING SECTION may damage seams preventing proper seal 2 Once the sections are connected apply caulking DIRECTIONS FOR FIELD ASSEMBLING AND WEATHERPROOFING SECTIONS Apply tacky tape gasket to the end of the first section blower discharge heater ets See Fig P i E
57. mpera ture to call for heat 3 Watch for ignition spark following prepurge See IP module specifications 4 Time the length of the spark operation See the IP module specifications 5 After the module locks out open the manual gas cock and make sure no gas is flowing to the pilot or main burner 6 Reset the flame safeguard relay RE 02 7 Operate system through one complete cycle to make sure all controls operate properly This equpipment has been electrically and fire tested prior to shipment However during transit control setpoints can change and wiring can come loose Do not assume controls are defective until all associated setpoints and wiring are checked If you do not have the optional BACview 6 KP 01 keypad display it will be difficult to troubleshoot any alarm that may occur on the unit To reset most alarms on the I O Zone 583 Controller UC 01 without a BACview 6 keypad display simply turn the power off and back on at the unit disconnect If you have a BACview 6 keypad display the alarm can be reset remotely or at the I O Zone 583 Controller The following is a simplified list of possible problems and typical causes and remedies However it does not cover all possibilities and is intended as a guide only You might also need to reference the Digital Control System User Manual for additional trouble shooting and diagnostics WARNING Many of the steps listed on the following pages require electrical ca
58. n see technical cut sheet on flame safeguard relay H Burner will not respond to temperature For DDC System See Digital Control System User manual Refer to following troubleshooting 2 For RTC RE 26 guide for RTC controls l Mixing Box with Airflow 1 Defective or misadjusted 1 Check and or replace See Station dampers not transducer PT 15 section on troubleshooting PT 15 functioning properly See 2 Transducer PT 15 wired 2 Check wiring Sequence of Operation incorrectly for damper control 3 Transducer PT 15 not installed 3 Install correctly See section on correctly troubleshooting PT 15 4 Unit Control Module UC 01 4 Check and or replace Contact defective Factory 5 Unit Control Module UC 01 not 5 Check wiring wired correctly 6 Damper motor defective 6 Check and or replace 7 Dampers binding and or loose 7 Check and repair J Return air outside air 1 Building Pressure Transducer 1 Check and or replace or discharge air profile PT 13 Damper Control components See section on damper operation not Potentiometer or null switch trouble shooting PT 13 functioning properly see defective or not calibrated sequence of operation 2 Building Pressure Transducer 2 Check wiring for damper control PT 13 Damper Control Potentiometer or null switch not wired correctly 3 Building Pressure Transducer 3 Install correctly See section PT 13 Damper Control on t
59. ntroller is off the controller switch may be bad or is jumpered 4 If steps 1 through are correct and there is 120 Vac at terminal 7 when the controller is closed and the fault persists check for a welded or jumpered Running Interlock or Airflow Switch Correct any errors 5 If steps 1 through 4 are correct and the fault persists replace the relay module Code 3 3 VPS Valve Proving 1 Check wiring making sure upstream valve is connected to terminal 9 and VPS in Switch in wrong state downstream valve is connected to terminal 17 Improper State during VPS Test 2 Conduct Valve Seat leakage test using a manometer 3 Reset and sequence the relay module if fault repeats test VPS connected to terminal 16 is functioning properly replace if necessary 4 Reset and sequence the relay module 5 If fault persists replace the relay module Code 4 1 No purge card or the 1 sure the purge card is seated properly Purge Card purge card timing has 2 Inspect the purge card and the connector on the relay module for any damage or Problem changed from the contaminants original configuration 3 Reset and sequence the relay module 4 Ifthe fault code reappears replace the purge card 5 Reset and sequence the relay module 6 Ifthe fault code persists replace the relay module Code 4 2 Pilot ignition valve WARNING Wiring terminal main valve Electrical Shock Hazard Fire or Explosion Hazard Problem ignition or Main Valve 2 Can c
60. o purge 4 times the inlet duct volume Purge time in seconds 4 x L x W xH x 60 SCFM L duct length in feet W duct width in feet duct height in feet SCFM rating plate air throughput Refer to the electrical schematic for the proper circuit placement Purge timer P N 65 0711 00 SECTION V UNIT START UP GENERAL Before attempting to start the heater read and understand the the sequence of operations and electrical schematic and the Digital Control System user manual WARNING During installation testing servicing trouble shooting of this product it be necessary to work with live electrical components Have a qualified licensed electrician or other individual who has been properly trained in handling live electrical components to perform these tasks Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury Make sure all manual gas valves are closed Make sure all doors and service panels have been closed or replaced Turn main disconnect switch off Check the incoming line voltage to match unit rating plate rating If voltage is over 10 of nameplate rating or phase voltage unbalance is over 2 notify contractor or power company Fans Are Enabled And Disabled By The Following MDT And MRT Standard By rotating the remote Temperature Setpoint knob MP 15 Clockwise will enable the fans Counter
61. o yellow tips After high fire has been set low fire may need to be re adjusted Cycle the burner several times to be sure it lights off reliably Low fire is a visual setting CAUTION There should be a con tinuous flame along the entire burner length without any blow out spots HIGH AND LOW FIRE MANIFOLD ADJUSTMENT FOR MAXITROL VALVES WITH DDC MR212 High Fire Manifold Adjustments Note Low fire may need to be set first to get the burner to light off properly 1 Disconnect the plug where the Temperature Sensors TS 01 and TS 03 are wired to the unit control module UC 01 A minimum of 15vdc is required at terminals 5 and 6 on electric relay RE 26 This causes the valve to call for continuous high fire Caution The unit will shut down on freezestat after approximately 3 minutes 2 Remove seal cap A and turn regulator pressure adjusting screw to obtain normal manifold pressure clockwise rotation increases pressure Low Fire or Bypass Adjustments 1 Disconnect wire from RE 26 terminal Z8 This causes valve to call for continuous low fire 2 Remove cap B and loosen lock screw C Turn D to desired low fire adjustment Clockwise rotation reduces minimum flow rate 3 Tighten screw C replace cap B and reconnect wire to RE 26 terminal 8 4 Reconnect the plug back into the jack on the unit control module UC 01 38 M611 High Fire Manifold Ad
62. of the unit bolts and nuts may have become loosened particularly in the pillow block ball bearing assemblies in the fan section It is recommended that all nuts and set screws be tightened Turn fan shaft by hand to make certain that blower does not rub against blower housing and that bearing set screws are tight If units are not set immediately cover all openings that might be exposed to the weather Open the cover on the electrical control box located on the unit Inspect all wire terminals and wiring termina tions to ensure that all connections are tight If units are not set immediately cover all openings that might be exposed to the weather Rotate fans monthly RIGGING AND MOUNTING DATA DIRECT FIRED UNITS LIFTING LUGS PROVIDED IN ONE OF TWO LOCATIONS A USE WHEN LIFTING OVER 3 000 LBS B USE WHEN LIFTING UNDER 3 000 LBS 08 16 07 C000539A WARNING To insure that a proper unit lift is made lift unit approximately 24 inches and verify proper center of gravity lift point To avoid dropping of unit reposition lifting point if unit is not level Failure to properly lift unit could result in death or serious injury or possible equipment or property only damage B Locating the Unit Prior to locating the unit authorities having jurisdiction should be consulted before installations are made Approval permits should be checked against the unit received On Direct Gas Fire
63. on causes the PREPURGE timing to stop 2 Inthe Pilot Flame Establishing Period the Run Test Switch placed in the TEST position stops the timer during the first eight seconds of a ten second PFEP selection or during the first three seconds of a four second PFEP selection It allows for pilot turn down test and other burner adjustments This activates a fifteen second flameout timer that per mits pilot flame adjustment without nuisance safety shutdowns The Run Test Switch is ignored during PFEP for the C relay module if terminals 8 and 9 or 9 and 21 are jumpered IMPORTANT When the relay module is switched to the TEST mode it stops and holds at the next Run Test Switch point in the operating sequence Make sure that the Run Test Switch is in the RUN position before leaving the installation ada SECTION VII TROUBLE SHOOTING continued SETTINGS AND ADJUSTMENTS Selectable Site Configurable Jumpers The relay module has three site configurable jumper options see Fig 6 and Table 7 If necessary clip the site configurable jumpers with side cutters and remove the resistors from the relay module SERVICE NOTE Clipping and removing a site con figurable jumper enhances the level of safety Figure 5 Sequence Status LEDs RUN TEST SWITCH s RM7895C D EC7895C CAPTIVE MOUNTING RM7896C D SCREW PLUG IN PURGE CARD pu DUST COVER SEQUENCE STATUS RELAY Figure 6 Selectable
64. onnection in the field If the unit and or accessories cannot be installed immediately they should be stored in a clean dry environment If this is not possible and the unit must be stored outdoors it should be protected from the weather with tarpaulins or plastic coverings Do not assume that simply covering a unit will keep insects dust and condensation out of the unit and critical components Rotate the fan s monthly Prior to beginning installation of a unit that has been in storage for weeks or months the unit and its compo nents should be closely inspected Shipments are made F O B Dallas Texas by flat bed truck The unit is securely strapped tied and blocked to prevent shipping damage All shipments are checked by an inspector before they are accepted by the carrier Parts that are shipped unmounted are noted on the bill of lading These parts where feasible are packaged and shipped with the units Upon receipt of shipment all units should be checked against the bill of lading to insure all items have been received All equipment and any optional accessories should be checked carefully for physical damage in the presence of the carrier s representative If parts are missing or damage has occurred a claim should be filed immedi ately with the carrier All Direct Gas Fired units are given a complete opera tions test and control circuit checkout before shipment Copies of the wiring diagram piping diagram and bill
65. ontinuous operation for various operating temperatures and can be used as a satisfactory guide for determining when all ball and roller bearings should be relubricated Speed Temperature Cleanliness Interval 100 RPM Upto125 F Clean 6 months 500 RPM Upto150 F Clean 2 months 1000 RPM Upto210 F Clean 2 weeks 1500 RPM Over150 F Clean weekly Any Speed Upto150 F Dirty 1 week to 1 month Any Speed Over 150 F Dirty daily to 1 week Any Speed Any Temp Very Dirty daily to 1 week Any Speed Any Temp Extreme daily to Conditions 1 week gd Browning Bearing Set Screw Torque Values 7 Model Shaft Size Torque in Ibs Set Screw VPS 212 3 4 66 85 VPS 214 7 8 66 85 8 VPS 116 1 66 85 VF2S 116 1 66 85 9 VPS 219 13 16 66 85 VF4S 219 13 16 66 85 VPS 220 11 4 126 164 10 VPS 223 17 16 126 164 VPS 323 17 16 126 164 VF4S 227 111 16 126 164 11 VPS 327 111 16 228 296 12 VPS 231 115 16 228 296 13 VF4S 231 115 16 228 296 VPS 331 115 16 228 296 VPS 235 2 3 16 228 296 14 VF4S 235 2 3 16 228 296 VPS 236 2 1 4 228 296 15 VPS 239 27 16 228 296 VF4S 243 211 16 348 452 VPS 343 2 11 6 348 452 VPS 347 215 16 348 452 BOA Concentric 231 115 16 220 240 VPB 331 115 16 220 240 16 Spherical Roller SPB 1000 NE 13 16 290 380 17 1000 1716 290 380 SPB 1000 NE 111 16 290 380 SPB 1000 NE 1 15 16 290 380 18 SPB 1000 NE 3 16 290 380 SPB 1000 NE 27 1
66. or heat is present The burner switch limits operating limit control and all microcomputer monitored circuits must be in the correct state for the relay module to continue into the PREPURGE sequence Normal Start Up Prepurge The RM7897A Relay Module provides PREPURGE timing selectable from two seconds to thirty minutes with power applied and the operating control indicating a call for heat 1 The Airflow Interlock burner switch Run Test switch and all microcomputer monitored circuits must also be in the correct operating state 2 The motor output terminal 4 is powered to start the PREPURGE sequence 3 The Airflow Interlock input closes ten seconds into PREPURGE or within the specified purge card timing otherwise a recycle to the beginning of PREPURGE or lockout occurs depending on how the Airflow Switch selectable jumper JR3 is configured Ignition Trials 1 Pilot Flame Establishing Period PFEP a When the PFEP begins 1 The pilot valve and ignition transformer terminal 21 is energized The RM7897A has an intermittent pilot valve terminal 8 and interrupted pilot valve terminal 21 2 Flame must be proven by the end of the ten second PFEP four seconds if Configuration Jumper JR1 is clipped to allow the sequence to continue If a flame is not proven by the end of PFEP a safety shut down occurs 3 The pre ignition interlock is ignored throughtout the trial for ignition state 2 Main Flame Establish
67. or 11 Turn power off and check motor incorrectly wired and wiring 12 Motor overheating 12 Check burner firing rate 13 DO 1 or UC 01 not energized 13 See Digital Control System User Manual B If there is no voltage at 1 Heat mode is disabled 1 Enable the heating mode flame safeguard relay 2 Auxiliary switch on starter not 2 Check auxiliary circuit wiring and RE 02 input terminal closed ST 01 contact and the fan is enabled 3 Air flow switches open 3 Adjust the air flow and external static pressure to match the rating plate Do not adjust switch setpoint 4 Outside air temperature higher 4 Check stat for proper setting than Heating Economizer Setpoint 5 High temperature limit thermostat 5 Reset control and correct prob open lem before restarting 6 High low gas pressure switch 6 Check gas pressure and reset open If applicable switch 7 Field purge timer open 7 Check for power or replace if If applicable necessary 8 DO 2 or UC 01 not energized 8 See Digital Control System User Manual C If the flame safeguard 1 See technical cut sheet on flame 1 Determine the cause of lockout relay RE 02 goes into safety shutdown lockout safeguard relay Push reset button on flame safeguard relay Refer to Digital Control System User Manual for additional troubleshooting suggestions Dd SECTION VII TROUBLESHOOTING continued Heat Mode continued Symptom Cause Reme
68. ou may want to change the speed of the fan if the unit has adjustable sheaves Don t forget to remove the jumper and reconnect the sensing tubes to the switch Call factory with any questions Profile Plates 31 SECTION VIII MAINTENANCE SCHEDULE AND LUBRICATION REQUIREMENTS WARNING Failure to comply with the general safety information may result in extensive property damage severe personal injury or death Periodic maintenance is essential to the efficient operation and extended service life of this equipment Failure to provide maintenance as recommended may void the equipment warranty A Maintenance Schedule 1 Daily a Check gauges monitors instruments and equipment settings 2 After 8 hours of operation a Check that fan belts are tight and sheaves are aligned The fan belts can be checked every 30 days after the first 60 days of new belt run in CAUTION Do not overtighten belts b Check set screws and bolts on the fan bearings couplings and burner assembly c Check gas pressure at regulator 3 After 48 hours of operation check bearings for any unusual vibration or excessive temperature 4 Monthly a Check all valves piping and connections for leaks b Check the flame signal c Check the fuel pressure in the fuel supply line to each heater d Check the burner manifold pressure at full fire and low fire At low fire setting be sure there is a continuous flame along the entire burn
69. ows of TEK screws one down each side spaced approximately 8 10 inches apart down the entire length of the seam After hugger strips are installed caulk around the edges to complete the seal Repeat this process for each section as it is at tached The number of sections varies by applica tion NOTE HOOD REQUIRES ADDITIONAL INSTALLER PROVIDED SUPPORT Lk bu CAP cs SECTION IV PRE START UP Do not attempt start up without completely reading and understanding this manual along with the Digital Control Sysem user manual A Pre Start Up The owners representative or equipment operator should be present during start up to receive instruc tions on care and adjustments of the equipment All equipment has been factory tested adjusted metered and inspected to meet conditions set at the time the order was placed Only minimal adjustments should be required All information in this service manual is typical All products are semi custom and changes may occur Suggested Tools and Instruments Volt Ohm Meter Tachometer Manometer 0 10 W C Standard Hand Tools Gas Pressure Gauge 0 35 Ibs Thermometer Ammeter Microammeter D C Volt Meter BACview 6 CAUTION Line side of disconnect may be energized Follow proper lockout tagout procedures NOTE All servicing and adjustments of the Direct Gas Fired unit should be performed by a qualified service engineer This inspection is very important
70. pace Temperature Discharge Air TS 02 or Discharge Sensor TS 02 or Discharge Temperature Air Temperature Sensor Air Temperature Sensor TS 03 TS 03 or repair wiring K Burned out Short in modulator 1 Measure resistance per 1 If proper resistances are not Transformer Coil circuit item B1 observed replace modulator No Voltage to head or repair wiring Amplifier L Incorrect Space Incorrect Maximum 1 Check to see if heater is 1 If desired temperature is Temperature Heating Discharge delivering at Maximum not reached increase Temperature Setpoint Heating Temperature Maximum Heating Discharge Discharge Setpoint Temperature Setpoint Incorrect Minimum 2 Check to see if heater 2 If desired Space Heating Discharge is delivering at Minimum Temperature is not reached Temperature Setpoint Discharge Setpoint increase Minimum Heating Discharge Setpoint Incorrect space setpoint 3a Check Unit Enable 3a Change to correct setpoint Potentiometer MP 15 Setpoint 3b Check Heating Occupied 3b Change to correct setpoint and or Unoccupied setpoint Insufficient burner 4 Check to see if heater is 4 If desired Space Temper ature is not reached with heater at high fire it may be undersized Consult Factory Refer to Digital Control System User Manual for additional troubleshooting suggestions Control circuits external to MRT Controls can cause burner malfunction Always check manual valve to be certain gas i
71. rding the application consult the heater manufacturer ETL labeled heaters must be equipped with a control system and an air measuring station provided by the heater manufacturer and installed on the return air damper or duct IN 7555 Tranmere Drive Mississauga ON L5S 114 Phone 905 672 6123 Fax 905 672 6124
72. re Switch 1 Check wiring and correct any errors High Fire Sw or Low Fire Switch 2 Reset and sequence the relay module or Low Fire failure 3 Use manual motor potentiometer to drive the motor open and closed Verify at Sw motor switch that the end switches are operating properly Use RUN TEST switch if manual potentiometer is not available 4 Reset and sequence the relay module 5 Ifthe fault persists replace the relay module Blinking Fault Codes and Recommended Troubleshooting Fault Code System Failure Recommended Troubleshooting Code 5 3 Man Open Switch Start 1 Check wiring and correct any errors Man Open Switch or Control On in 2 Make sure that the Manual Open Valve Switch Start Switch and Control are Sw Start Sw the wrong operational operating properly or Control On state 3 Stat Switch held iOni too long 4 Reset and sequence the relay module 5 Reset and sequence the relay module If the fault persists replace the relay module RM7838A1014 RM7838B1013 or RM7838C1004 only Code 6 1 Relay Module self test 1 Reset and sequence the relay module Internal Faults failure 2 If fault reappears remove power from the device reapply power then reset and sequence the relay module 3 Ifthe fault persists replace the relay module Code 6 2 Relay Module Self Test 1 Reset and sequence the relay module Internal Faults failure 2 If fault reappears remove power from the dev
73. ressure pressure check equipment with blower operating for clogged filters and other Should be less than 1 5 w c inlet air restrictions For other negative pressure solutions consult factory Continuous Incorrect room 1a Check Outside Air Sensor 1a Replace Sensors if reading is Minimum temperature TS 01 Space Temperature incorrect or correct wiring Discharge Air Sensor TS 02 and Temperature Discharge Air Sensor TS 03 for correct readings See Thermistor curve 1b Check Space Temperature 1b Change to correct setpoint Sensor TS 02 setpoint 1c Check Heating Occupied 1c Change to correct setpoint and or Unoccupied setpoint Incorrect Maximum or minimum 1 Install a BACview 6 or PC 1 Change to correct setpoints Maximum heating discharge or Minimum temperature setpoint Discharge Air not set correctly Temperature Refer to Digital Control System User Manual for additional troubleshooting suggestions Control circuits external to MRT Controls can cause burner malfunction Always check manual valve to be certain gas is on and check limit controls for normal operation 27 Modulating Room Temperature MRT MRT PRO or MRT EXPERT Controls continued TROUBLESHOOTING GUIDE Portions reproduced with permission from Maxitrol Company Symptom Possible Cause Field Test Remedy G Continuous High Fire Electronics Foreign material holding valve open 1 Remove bottom pl
74. rouble shooting PT 13 and Potentiometer or null switch not manufacturer s cut sheet installed correctly 4 Unit Control Module UC 01 4 Check and or replace Contact defective Factory 5 Unit Control Module UC 01 not 5 Check wiring wired correctly 6 Two position switch defective 6 Check and or replace 7 Damper motor defective 7 Check and or replace 8 Dampers binding and or loose 8 Check and repair K Burner will not come on 1 Low air flow switch open 1 Check to make sure velocity is in low speed correct 2 Profile damper and or motor not 2 Check and or replace closing L Flame length too long 1 High fire set incorrectly 1 See Section X for Manifold and in low speed Valve Adjustments 2 Profile damper not operating 2 Check and or replace correctly and or damper motor defective Refer to Digital Control System User Manual for additional troubleshooting suggestions TROUBLESHOOTING GUIDE FOR AMPLIFIER RE 26 The SC 1 signal conditioner provides signal conversion for a high impedance 2 10VDC signal Source to drive a 24VDC solenoid The control should be powered by Override Switch an isolated 24VAC transformer to p 4 drive up to a 5A dc solenoid i o ol i 2 10 VDC f Input Span Override Switch When terminals 3 amp 4 are shorted together the span setting is ignored forcing the ratio to 10096 Start Up Delay
75. s machine This manual of instructions along with the Digital Control System user manual has been prepared in order for you to become well acquainted with those details and in doing so you will be able to give your Direct Gas Fired System the care and attention which any piece of equipment needs and deserves Table of Contents Section I Foreword Table of Contents and Important Notice 2 Section Il General 3 Section III Installation 4 Section IV Pre Start Up 9 Section V Unit Start Up 10 Section VI Unit Shut Down 12 Section VII Troubleshooting Guide 13 Section VIII Maintenance Schedule and Lubrication Requirements 32 Section IX Mestek 37 Section X Manifold and Valve Adjustments 38 Section Thermistor Curves 39 Section XII Replacement Parts 40 Section XIII Recirculating 40 IMPORTANCE NOTICE Temprite assumes no responsibility for loss or damage in transit therefore you should protect yourself by following these instructions Bill Of Lading
76. s on and check limit controls for normal operation 28 Cooling Mode TROUBLESHOOTING GUIDE Symptom Cause Remedy A There is no voltage at cooling relays Cooling mode is disabled Enable the cooling mode cooler is not operating correctly RE 34 RE 35 and or RE 33 and 2 Auxiliary switch on starter ST 01 2 Check auxiliary circuit wiring and the fan is enabled is not closed contact 3 Air flow switches open 3 Adjust the air flow and external static pressure to match the unit rating plate DO NOT ADJUST SWITCHES 4 Cooling Changeover and or 4 Change to correct setpoints See Economizer Setpoints not set Digital Control User Manual correctly 5 DO 3 and or DO 4 are not 5 See Digital Control System User energized Manual B Cooling relays RE 34 RE 35 1 Cooling relays RE 34 RE 35 1 Check and or replace and or RE 33 are energized and and or RE 33 contacts are not condensing unit or evaporative closed cooler is not on 2 Cooling relays RE 34 RE 35 2 Correct wiring and or RE 33 contacts are not wired correctly 3 Compressors or evaporative pump 3 See Troubleshooting Guide not running for your condensing unit or evaporative cooler C Incorrect Space Temperature 1 Incorrect Maximum Cooling 1 Decrease Maximum Cooling Discharge Temperature Setpoint Discharge Temperature Setpoint See Digital Control System User Manual 2
77. set before resuming op eration when the inlet gas valve is turned off during operation The high pressure switch may be checked out by reducing the setting of its trip point to unit operating pressure It should then trip out and shut off the burner Return the adjustment to its original setting and reset to resume operation D Air Pressure Switches The high air pressure switch is checked by removing the sensing tube from the entering air side of the burner and gently blow into the switch connection Switch operation will shut off the burner Recycle is automatic when the sensing tube is replaced The low air pressure switch is checked by removing the sensing tube from the leaving air side of the burner Switch operation will shut off the burner Recycle is automatic when the sensing tube is replaced E Adjustable temperature and limit Controls The limit controls are checked by adjusting control settings to a lower temperature setting while the unit is operat ing on high fire and observing cutoff The controls should be reset to settings shown below Suggested Control Settings Refer to Digital Control System user manual for default settings TS 02 Space Temperature Sensor Customer Discretion KP 01 Keypad Display Module Customer Discretion MP 05 Damper Control Potentiometer Customer Discretion MP 15 Unit Enable Potentiometer Customer Discretion PS 04 Low Gas Pressure
78. should be consulted before instal lations are made Local codes may require additional safety controls and or interlocks All installations in airplane hangers must be in ac cordance with current ANSI NFPA No 409 All instal lations in public garages must be in accordance with current NFPA No 88A and NFPA No 88B CAUTION Do not install heating system in corrosive or flammable atmospheres Premature failure of or severe damage to the unit will result CAUTION Heating system 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 A Handling the Equipment The Direct Gas Fired unit has been designed for rigging and handling through the use of special lifting lugs installed on the sides of each unit As explained previously the basic unit is designed for shipping in one piece where shipping limitations allow Some optional accessories may require field mounting The Direct Gas Fired unit has been designed for rigging and handling through the use of special lifting lugs installed on the top and or sides of each unit When unloading and setting the unit use the lifting lugs provided as shown in Drawing C000539A or move the equipment on rollers Hooks jacks or chains must not be used around the casing main control panel or exterior mounted controls During transit unloading and setting
79. sts replace the relay module Code 2 2 No flame time present 1 Measure the flame signal If one exists verify that it meets specifications Flame Signal at the end of the Pllot 2 Make sure that the flame amplifier and flame detector are compatible Absent Flame Establishing 3 Inspect the main fuel valve s and valve connection s Period lost during the 4 Verify that the fuel pressure is sufficient to supply fuel to the combustion chamber Main Flame Establishing Inspect the connections to the fuel pressure switches Make sure they are Period or during RUN functioning properly 5 Inspect the Airflow Switch and make sure that it is functioning properly 6 Check the flame detector sighting position reset and recycle Measure the flame signal strength Verify that it meets specifications If not refer to the flame detector and or flame amplifier checkout procedures in the installation instructions 7 Replace the flame amplifier and or the flame detector if necessary 8 Ifthe fault persists replace the relay module Code 2 3 Flame signal value is 1 sure the flame detector and flame amplifier are compatible Flame Signal too high to be valid 2 Remove the flame amplifier and inspect its connections Reset the flame amplifier Overrange 3 Reset and sequence the relay module 4 Check the flame detector sighting position reset and recycle Measure flame strength Verify that it meets specifications If not refer to the flam
80. ughly before installing or servicing this equipment AVERTISSEMENT Une installation d ficiente de m me qu un mauvais r glage modification entretien ou maintenance peuvent occasionner des dommages mat ri els corporels voire causer la mort Lire attentivement les instructions d installation d utilisation et d entretien avant d installer ou d intervenir sur cet appareil WARNING 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 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 TEMPRITE Y MZ 4830 Transport Drive Dallas TX 75247 Phone 214 638 6010 Fax 214 905 0806 INDUSTRIES p 7555 Tranmere Drive Mississauga ON L5S 1L4 Phone 905 672 6123 Fax 905 672 6124 www tempriteheating com SECTION I FOREWARD As is the case with any fine piece of equipment care must be taken to provide the proper attention to the operation and maintenance details of thi
81. urner NOTE A BACview or PC is required to change Setpoints For a more detailed control sequence see the Digital Control System Users Manual Enable the fans and burner then reset burner relay RE 02 Unit will run for 10 seconds before ignition trial if all safety and limits are made CAUTION You will have approximately three 3 minutes before the unit shuts down on Freezestat Low Discharge Temperature if you have disconnected plug wires TS 01 and TS 03 Referred to in Section X NOTE 3 OR 4 TRIALS MAY BE NEEDED TO PURGE AIR FROM PILOT LINE IF BURNER HAS MAIN FLAME ROD OR SCANNER YOU WILL NEED TO DISABLE TIMER CIRCUIT RE 75 NOTE Pilot regulator adjustment may be needed if the adjustment of the needle valve does not yield the required reading Typical adjustment of the needle valve is 1 1 2 to 2 turns open When pilot is adjusted shut the burner off by disabling the fans and heat Setting Main Flame Reconnect power to main flame sensor RE 75 if applicable Install manometer at test port on the last tee of the burner manifold or MR valve test port Slowly open all manual gas shut off valves Enable fan and heat After pilot proven main gas valve opens and burner lights Adjust high fire pressure reading from manometer to match Normal Manifold Pressure firing rate shown on unit rating plate Refer to Valve Adjustment instructions in Section X for setting high and low fire gas pressure settings
82. will severely reduce belt and bearing life Belt deflection should be approximately 1 64 inch of the belt span 24 Monitor for excessive heat or vibration during operation 25 All bearings are pre lubricated and should not require greasing Refer to the bearing manufacturer s instructions or the unit manufacturer s instructions for proper bearing maintenance Note Drive side Sleevlock bearing installation SPB 2115 C2 1 Mount all the bearings and leave all the bolts and setscrews loose 2 Tighten setscrews on Sleevlock bearing to the tightening pattern as described in the installation sheet that comes with the bearing to a final 65 inch Ibs while rotating the shaft Check to make sure the insert of the bearing is centered in the bearing housing and then bolt bearing down 3 Tighten down the bolts and setscrews on the remaining bearings per installation sheet starting from the end bearing back toward s the Sleevlock while rotating the shaft 3 Dampers Dampers should be inspected monthly daily in icy weather for securely fastened linkages and smooth operation If dampers are binding or excessively noisy then lubrication may be required Place one drop of 20 wt machine oil on each blade bearing and linkage ball joint Do not over lubricate and wipe any excess from the area Be sure to note that dampers over 49 inches long have intermediate bearings which require lubrication C Air Filters All filter banks shou
83. y PT 13 PT 15 SETRA P N MESTEX P N RANGE SETRA P N MESTEX P N RANGE 26510R1WBABT1C 68 0330 69 1 INWC 26510R1WDABT1C 68 0330 66 0 0 1 INWC 2651R25WDABT1C 68 0330 67 0 25 INWC 26510R5WDABT1C 68 0330 68 0 5 INWC 30 TROUBLESHOOTING GUIDE Checking The Burner Velocity Pressure PS 10 amp PS 11 air switches are factory calibrated Do not adjust Check the velocity pressure by disconnecting both pressure sensing tubes from one of the high airflow Switch Connect one end of your manometer to each sensing tube and start the fan The permissible pressure range should be marked on the switches If it s close to the high or low trip points of the airflow Switches you could have a problem High pressure Switch open means too much velocity low pressure Switch open means not enough velocity Jumper the switch from which you ve disconnected the sensing tubes and get the burner running in high fire Your differential pressure should have dropped If it is near the low switch trip point you need more air Some adjustments can be made by repositioning the burner profile plates If the high switch is open you can open the profile plates If the low switch is open you can close the profile plates Remember to keep the distance between the burner and profile plates the same opening on both the top and bottom of the burner when making these adjustments Depending on the motor amps y

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