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installation, operation and maintenance manual for air curtains

1. rior O O O FLAME FLAME FLAME FLAME O O MAIN man MAIN van O O ALARM OALARM O ALARM O ALARM TC BURNER BLOWER MOTOR 4 ECT SPARK IGNITION GAS A POST PURGE STANDBY POWER peang __ 1 uwrsmosuses commoner cose rockourmremockcoseo GTO C Lo asenne 50 60 HZ POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED A DO NOT CONNECT ANY WIRES TO UNUSED TERMINALS A ror EC7895 A 220 TO 240 VAC TO 120 VAC 10 VA MINIMUM STEPDOWN TRANSFORMER NOT PROVIDED MUST BE USED TO DRIVE THE SHUTTER ZA RM7896C D ONLY N RM7895 RM7896 120 VAC 50 60 HZ EC7895 220 240 VAC AsEE FLAME DETECTOR SPECIFICATIONS FOR CORRECT WIRING A AIRFLOW SWITCH CHECK FEATURE IS FOR THE RM7895D RM7896D A RM7895C 1020 RM7896C 1036 PFEP 10 SECONDS ONLY Z RM789501020 RM7896C 1036 DURING FIRST 8 SECONDS OF PFEP WHEN A FLAME SIGNAL IS DETECTED TERMINAL 10 IS DE ENERGIZED IF FLAME SIGNAL IS LOST TERMINAL 10 WILL RE ENERGIZE 14 M15124GR SECTION VII TROUBLE SHOOTING continued United Technologies Electronics Controls Operation of the Series 1016 400 Direct Spark Ignition Control On a call for heat a five second pre purge is initiated Upon completion of the pre p
2. 1 Open circuit in T5144 1 Measure resistance per item C3 If readings are incorrect replace the TS144 or repair wiring 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 mE Modulating Room Temperature Controls continued TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE Portions reproduced with permission from Maxitrol Company Symptom Possible Cause Field Test Remedy I Incorrect High Fire 1 Inlet pressure too low 2 Incorrect outlet pressure adjustment 1 Read inlet pressure at valve using a manometer with heater operating at full fire Pressure should be at least equal to the sum of outlet pressure setting and pressure drop of the valve plus 1 0 w c Read outlet pressure using manometer and compare with the pressure stated on the specification plate 1 Increase inlet pressure if possible or change to larger valve Consult factory about possibility of using special spring to reduce pressure drop on selected installations 2 See Valve Adjustments Section X J Continuous Maximum Discharge Air Temperature 1 Faulty amplifier 2 Open circuit in Room Sensor Selector or Room Temperature Sensor Room Tempera ture Selector 3 Incorrect space temperature calibration Follow procedures outlined
3. resilient mounted Recommendation See following note Mestex Sleeve or equal Recommendation See following note Dampers 29 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 motor 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 bearing grease such as Exxon Polyrex EM or equal with a low pressure grease gun Run the motor five 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 prelubricated with a number 2 lithium base grease Relubrication should be done with a similar grease using a low pressure grease gun Wipe all grease fittings clean before adding grease Grease sh
4. Open circuit in modulator coil Plunger missing jammed or improperly installed Ruptured main or balancing diaphragm Remove wires connected to amplifier terminals 6 amp 7 and measure resistance MR212 60 80 ohms M611 45 55 ohms Inspect plunger should be installed to operate freely in solenoid sleeve Disassemble valve for inspection of internal parts 1 If proper resistance values are not observed replace modulator head or repair wiring 2 Clean or replace plunger if necessary 3 Replace diaphragm if ruptured C Continuous Low Fire Electronics No voltage to the amplifier Check for 24V AC at amplifier terminals 8 amp 9 1 Provide 24V AC to amplifier adjustment Excessive negative burner pressure Problem Short in modulator Measure resistance per 2 If proper resistance values coil circuit item B1 are not observed replace the modulator head or repair wiring Short in Discharge Remove wires connected to 3 If readings are incorrect Air Sensor circuit amplifier terminals 1 2 amp 3 replace the TS144 or Measure resistance across repair wiring wires 1 amp 3 then 2 amp 3 Meter should read greater than 2500 ohms Faulty amplifier Follow procedures outlined 4 If power source and in Preliminary Circuit modulator coil check out Analysis in Section IX items 5 amp 6 but proper modulating voltages cann
5. in Preliminary Circuit Analysis in Section IX Measure resistance per item E2 Follow procedures outlined in Preliminary Circuit Analysis in Section IX 1 If amplifier is proven at fault install replacement amplifier 2 If reading is incorrect replace Room Sensor Selector Room Temperature Sensor Room Temperature Selector or repair wiring 3 If proper action is obtained first check item E2 Recalibrate if necessary K Burned out Transformer No Voltage to Amplifier 1 Short in modulator coil circuit Measure resistance per item B1 1 If proper resistances are not observed replace modulator head or repair wiring L Incorrect Space Temperature 1 Incorrect maximum discharge air temper ature setting at amplifier 2 Incorrect minimum discharge air temper ature setting at amplifier 3 Insufficient burner capacity 4 Incorrect space temperature calibration Check to see if heater is delivering air at maximum discharge air setting Check to see if heater is delivering air at minimum discharge air setting Check to see if heater is operating at high fire Place thermometer next to Room Sensor Selector or Room Temperature Sensor Compare space temperature reading with Room Sensor Selector or Room Temperature Selector dial setting 1 If desired temperature is not reached increase maximum discharge air temperature set
6. SLYUOd Biv 3244 DAS 1003 43d 22w nd 9 lt vo LT 3015 Loos 52778 21 cg 34 001003 MEW ROD V1 0216 00 6600000096060 6006000004808 3 1 BEND ROD AT A 45 AMGhE 6 VNAME ROD FROM PITTING DO MOT DAMAGE POROEMAIM SPARK IGMITOR AN OPENING V1 0216 12 S D PILOT N f lt WHEN REQUIRED GAS AM be STEP 2 OUT ROD A AEMGTH OF 2 AFTER THE 45 BEND P001117 Mestek Line Burners f MANIFOLD oOoooooooc db e Ss se 0505 PAAMP ROD 9e EEG AN D PIN VISE VIEW BORMER PNATES REMOVED PARK IGMITOR 88 0910 58 i vo l 48 DRILL PINOT TUBING 4 REQUIRED nOn nu nu m nOn n m m IL IL 1L lidi IL AE CH lE IE IE LIE c IEM A N GAS 35 SECTION IX MAXITROL VALVE ADJUSTMENTS AND PRELIMINARY CIRCUIT ANALYSIS MR212 Valve High Fire Manifold Adjustments 1 Disconnect wires from amplifier terminal 4 Series 1 14 2 and 4 Series 44 This causes the valve to call for continuous hig
7. and adjusting the position of the motor along its base NOTE A new drive can be tightened to two times the minimum value shown to allow for normal drop in tension during the run in period B Section small Pounds pulley Pounds Force for diameter Belt Force for 1 gt times range in 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 74 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 ltems 1 Coils Coil surfaces must be kept clean of dirt and lint in order to operate at rated efficiency Coils should be inspected on a regular basis and cleaned as required CAUTION Solutions used to clean coils must not be corrosive to metals or materials used in the manufacturer of this equipment If cleaning solutions are applied through means of high pressure spray care must be taken to avoid damaging the coil fins 2 Condensate Drain Pan Periodically flush the condensate pan and drain system with a water hose F Gaskets Gaskets are used on doors inspection covers some filter racks and some outdoor air dampers Inspect gaskets periodically and repair or replace as required Sole Heater 1 Atleast a yearly inspection is recommended for heating installations and more frequently for process applications in year round operation Your
8. check Discharge Air Sensor circuit for shorts Replace if necessary modulating voltages are still not obtained amplifier may be assumed faulty Replace C Continuous Low Fire Electronics OK 1 Short circuit or open circuit in Modulator Coil 2 Plunger missing jammed or improperly installed Measure resistance across modulator terminals with connecting wires detached Inspect Plunger should be installed to operate freely in solenoid sleeve Replace modulator head if Clean or replace plunger if not approximately 45 55 ohms for M611 Valve and 60 80 ohms for MR212 Valve necessary E oT Modulating Discharge Temperature Controls continued TROUBLESHOOTING GUIDE Portions reproduced with permission from Maxitrol Company Pulsating Flame 2 Excessive negative burner pressure Close main gas supply and measure manifold pressure with blower operating Reading should be less than 1 5 w c negative pressure Symptom Possible Cause Field Test Remedy D Incorrect 1 Incorrect by pass See valve adjustments in 1 Adjust to proper minimum Minimum Fire metering valve Section IX fire Erratic or adjustment 2 If reading is greater than 1 5 negative pressure check for clogged filters or other inlet air restrictions Consult factory for other solutions E Continuous High Fire Electronics Problem 1 Short circuit in Remote T
9. 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 quelconque des cables 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 Field Piping All gas piping must be in accordance with the require ments outlined in the National Fuel Gas Code ANSI 2223 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 avoid equipment damage possible personal injury disconnect gas piping to this unit until a supply line pressure leak test has been completed Connecting th
10. for each 3 5 5 or 8 outside temperature change from 60 predetermined turndown varies with model used Check wiring diagram for heater Sensed temperature thermometer next to Discharge Air Sensor does not correspond to Remote Temperature Selector setting Sensed temperature thermometer next to Discharge Air Sensor does not represent average discharge air temperature Remove Override Thermostat lead from terminal 2 of Remote Temperature Selector 1 Sensed temperature will vary from Remote Temperature Selector dial settings This is intentional 2 Correct wiring 3 See calibration procedure 4 Move Discharge Air Sensor to location where average representative temperature can be sensed 5 Remote Temperature Selector dial setting then check thermostat setting and or check wiring for shorts J Burned out Transformer 1 Short circuit in modulator coil 2 Short circuit between amplifier and modulator valve Measure resistance across modulator terminals with red lead wires disconnected Inspect wiring 1 Replace modulator head if less than 40 ohms 2 Correct wiring if short is found 24 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE Modulating Discharge MDT Temperature Controls continued Portions reproduced with permission from Maxitrol Company Symptom Possible Cause Field Test Remedy K Discharge Air 1 Overri
11. 90 80 130 120 170 160 210 200 250 40 4 4 11 214 11 250 50 10 0 11 029 11 050 60 15 6 10 835 10 850 70 21 1 10 635 10 650 80 26 7 10 429 10 450 10 380 90 32 2 10 219 10 250 100 37 8 10 005 9 980 110 43 3 9789 9 780 120 48 9 9573 9 580 9 590 130 54 4 9356 9 380 9 390 140 60 0 9142 9 190 150 65 6 8930 8 990 160 7414 8723 8 790 8 700 170 76 7 8521 8 590 8 500 180 82 2 8325 8 300 190 87 8 8138 8 100 200 93 3 7959 7 900 8 060 210 98 9 7791 7 700 7 860 220 104 4 7634 7 660 230 110 0 7490 7 460 240 115 6 7360 7 260 250 121 1 7246 7 060 _ 38 SECTION X 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 XI RECIRCULATION 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
12. Back Room Customer Discretion TC 52 Remote Temperature Selector Customer Discretion PS 04 Low Gas Pressure Switch 1 0 W C PS 07 High Gas Pressure Switch See Below PS 12 Clogged Filter Switch Adjust to field condition PS 13 Building Pressure Switch Adjust to field condition FL 02 High Temperature Limit Manual 185 F Note Set high gas pressure setting 125 above burner firing rate SECTION VI UNIT SHUTDOWN A Extended Shutdown Set the Heat On Off switch to the Off position for 30 seconds then turn the Fan On Off switch to Off position 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 SECTION VII TROUBLE SHOOTING HONEYWELL RM7895A B C D EC7895A C RM7896A B C D 7800 SERIES RELAY MODULES PRINCIPAL TECHNICAL FEATURES The RM7895 RM7896 provides all customary flame safeguard functions as well as significant advance ments 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 d AC line power errors occurred see Operation e Four minute INITIATE period has been exceeded 2 STANDBY
13. INTERLOCK CLOSED 6 TO 7 AFSC FLAME FLAME SIGNAL SAFE START CHECK PROVING 55 A RM7895 RM7896 120 VAC 50 60 HZ EC7895 220 240 VAC 50 60 HZ POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED A DO NOT CONNECT ANY WIRES TO UNUSED TERMINALS A FOR EC7895 A 220 TO 240 VAC TO 120 VAC 10 VA MINIMUM STEPDOWN TRANSFORMER NOT PROVIDED MUST BE USED TO DRIVE THE SHUTTER 13 ASEE FLAME DETECTOR SPECIFICATIONS FOR CORRECT WIRING RM7895A1048 ONLY IGNITION TERMINAL 10 IS DE ENERGIZED WHEN FLAME IS PROVEN AIRFLOW SWITCH CHECK FEATURE IS FOR THE RM7895B RM7896B RM7896A B ONLY M15123A SECTION VII TROUBLE SHOOTING continued Figure 3 Wiring Subbase and Sequence Chart for RM7895C D EC7895C D RM7896C D LED DISPLAY BURNER START OPERATING CONTROLS AND INTERLOCKS FLAME SIGNAL LINE VOLTAGE rn ALARM m BURNER MOTOR CES 10 SEC INTERRUPTED d PILOT IGNITION Q7800 IGNITION TRANSFORMER MAIN VALVE BLOWER BURNER CONTROLLER LIMITS max LOCKOUT INTERLOCK INCLUDING AIRFLOW SWITCH 00 000000Q MAIN FUEL VALVE S IGNITION FLAME DETECTOR 44 Ai I DELAYED 2ND STAGE MAIN VALVE MASTER SWITCH L1 HOT 00 B INITIATE STANDBY PURGE 408105 MFEP RUN 15SEC POWER POWER POWER POWER POWER Power 6 POWERF O O O O PILOT G
14. be provided and set to purge 4 times the inlet duct volume Purge time in seconds 4 x L x W x H 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 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 nameplate rating If voltage is over 10 of nameplate rating or phase voltage unbalance is over 2 notify contractor or power company Turn main disconnect switch on Turn Fan Off On switch to On position Damper opens if applicable Blower fan turns on Turn Fan Off On switch to Off position Check supply blower for proper rotation NOTE To change rotation of the blower simply interchange any two 2 of the line leads of the motor starter for three 3 phase motors On single phase motors refer to motor nameplate Turn Fan Off On switch to On position Check for proper blower rpm Check that all motor amp draws do not exceed nameplate ratings and overloads are set to motor nameplate amps Check all dampers for proper operation and linkage does not bind see Sequence of Operation Make sure all man
15. high low gas pres sure switches if applicable Check pilot and main gas lines for leaks using soap solution Turn Fan and Heat Off On switches to On position Blower fan will run Unit will run for 10 seconds before ignition trial if all safety and limits are made NOTE 3 OR 4 TRIALS MAY BE NEEDED TO PURGE AIR FROM PILOT LINE IF BURNER HAS MAIN FLAME ROD OR SCANNER YOU MAY NEED TO DISABLE TIMER CIRCUIT 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 slowly turn the needle valve in or out until satisfactory readings are obtained A keyboard display module Honeywell 578000 1001 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 NOTE Pilot regulator adjustment may be needed if the adjustment of the needle valve does not yield the required reading When pilot is adjusted shut the burner off by turning the Fan Off On and Heat Off On switches to Off Setting Main Flame 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 Restart fan and burner After pilot proven main gas valve opens and burner lights Adjust high gas pressure reading from manometer to match firing rate shown on unit namep
16. loose Check and or replace Check wiring Install correctly see manufacturer s cut sheet Check and or replace Check wiring Install bullb in correct location Check and or replace Check and or replace Check and repair J Burner will not come on in low speed 1 Low air flow switch open 2 Profile damper not closing if applicable Check to make sure velocity is correct Check and or replace K Flame length too long in low speed 1 Incorrect setting or defective MP 05 in electrical panel 2 Low speed high fire set incorrectly Check setting or replace Make normal maximum and minimum fire adjustments as outlined earlier Open switch and or relay RE 52 and remove wire from terminal 4 system or terminals 2 amp 4 system Adjust MP 05 located in electrical panel for approxi mately one half of the firing rate Reconnect wiring to amplier x System without Pilot TROUBLESHOOTING GUIDE Symptom Cause Remedy A If blower does not operate Low or no voltage Fuse s blown Check power source Check and replace 3 Customer interlock not closed or 3 Close or connect customer connected interlock 4 Fan Off On switch in Off position 4 Switch to On position 5 Time clock night setback 5 Check time clock night setback thermostat or field installed ther
17. own experience is the best guide in determining frequency of inspection but as a minimum the following procedure should be followed a Shut the system down totally disconnect ing or locking out power supply so there can be no accidental start up during inspection b Inspect the burner carefully including upstream and downstream sides of mixing plates as well as burner body face Note that complete burner assembly may have to be removed for proper inspection and cleaning Any accumulation of scale or foreign material on either side of the mixing plates should be removed with a wire brush Check visually that no holes in the mixing plates 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 may be drastically affected If any mixing plates are loose or missing fasteners tighten replace as necessary Always use zinc plated or stainless fasteners 2522 The mixing plates the burner may display hairline cracks These cracks are normal and caused by thermal stresses occurring during combustion The presence of these hairline cracks in no significant way affects the combus tion efficiency or performance of the heater Should a large opening develop it may cause difficulties in cross ignition of flame across the face of the burner If this does occur the specific mixing plate or plat
18. to give your Direct Gas Fired System the care and attention which any piece of equipment needs and deserves Table of Contents Section Forward and Table of Contents 2 Section Il General Information 2 Section Installation 3 Section IV Pre Start 6 Section VsUnit Start Up accen oret ettet 7 Section VI Unit Shut 9 Section VII Troubleshooting Guide 10 Section VIII Maintenance Schedule and Lubrication Requirements 29 Section IX Maxitrol Valve Adjustments and Preliminary Circuit Analysis 36 Section X Replacement Parts 39 Section XI Recirculation 39 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
19. 00 ohms The DC voltage should read 0 volts 4 Turn the Test Potentiometer slowly to maximum resistance 12 000 ohms The DC voltage should gradually increase to at least 18 volts If proper voltages are observed continue on with Section 2 If proper voltages are not observed the problem is identified with the Amplifier the 24 volt AC power supply or the circuit connected to terminals 6 and 7 Section 2 1 Turn power OFF wire system per Figure 2 turn power ON 2 Turn Test Potentiometer to minimum resistance Voltage should be 0 volts 3 Turn Test Potentiometer slowly to maximum resistance The DC voltage should gradually increase to at least 18 volts If proper voltages are observed in both Section 1 and 2 the amplifier is satisfactory If proper voltages are not observed continue testing to identify the difficulty Faults may be identified with the amplifier the 24V power supply or the circuit connected to terminals 6 and 7 Section 3 1 Observe burner flames and or burner pressure as Test Potentiometer is turned through full range NOTE From 0 5 volts heater should be at bypass or low 5 15 volts heater should respond with various input rates beyond 15 volts heater is at maximum input If proper operation is observed continue procedure to check operation of sensing and selecting components If proper operation is not observed see Trouble shooting Guide to test M or MR valves and con necting
20. 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 should 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 Mestex 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 90 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 bearin
21. Copies of the wiring diagram piping diagram and bill 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 III 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 dance with Canadian Electrical Code Part 1 CSA Standard C22 1 This equipment must be installed and wired in accor dance 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 l
22. IOMKDFAC 1 INSTALLATION OPERATION AND MAINTENANCE MANUAL FOR AIR CURTAINS WITH DIRECT GAS FIRED HEATERS 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 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 Eteindre toute flamme ouverte 4 Immediately call your gas supplier 4 Appelez imm diatement votre i e fournisseur de gaz WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or death Readthe installation operating and maintenance instructions thoroughly before installing or servi
23. MINARY CIRCUIT ANALYSIS MODULATING DISCHARGE TEMPERATURE MDT CONTROLS For ease in troubleshooting it is advisable to wire the system as follows this differs from the normal connec tion The Discharge Air Sensor is disconnected and replaced with a 10 700 ohm for DFC 1 RTC Solutions or 10 000 ohm for A1014L Maxitrol 1 2 watt test resistor terminals 3 and 4 If inlet air sensor is being used disconnect and replace with a jumper On units where the Remote Temperature Selector is located a considerable distance from the heater it may be advantageous to connect the selector at the heater location Connect a DC volt meter capable of reading 0 24V DC on the Modulator or Modulator Regulator Valve terminals Set the temperature to the minimum dial setting The DC voltage should read 0 volts The DC voltage should gradually increase to at least 20 volts as you slowly rotate the dial to the maximum dial setting If these voltages are obtained the valve function can now be checked out The operation of the Valve with regard to voltage is as follows from 0 volts to approximately 5 volts the modulating valve should be on bypass flow with the heater operating on low or minimum fire From ap proximately 5 volts to 15 volts DC the valve should be performing its modulating function and the heater should be firing at a modulated flow rate between low and high fire depending upon the voltage Above approximately 15 volts DC the Valve shoul
24. 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 30 seconds c Ignition pilot valve intermittent pilot valve terminal is energized d Main valve terminal is energized e Delayed 2nd stage main valve terminal is energized RM7895C D EC7895C RM7896C D f Internal system fault occurred g Purge card is removed h Purge card is bad 3 PREPURGE PERIOD a Airflow lockout feature is enabled and the airflow Switch opens b Ignition pilot valve terminal is not energized c No flame present at end of PFEP d Main valve terminal is energized e Delayed main valve terminal is energized RM7895C D f Internal system fault occurred g Purge card is removed h Purge card is bad 4 PILOT FLAME ESTABLISHING PERIOD PFEP 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 30 seconds c Ignition pilot valve intermittent pilot valve terminal is energized d Main valve terminal is energized e Delayed second stage main valve terminal is energized RM7895C D EC7895C RM7896C D f Internal system fault occurred g Purge card is removed h Purge card is bad 5 MAIN FLAME ESTABLISHING PERIOD MFEP RM7895C D EC7895C RM7896C D a Airflow lockout feature
25. SENSE terminal and the flame rod sensing wire Turn Fan and Heat OFF ON switches to ON position Open inlet manual gas shut off valve slowly Reset high and if applicable low gas pressure switches Check main gas line for leaks using soap solution Unit will run for 5 seconds before ignition trial NOTE OR 4 TRIALS MAY BE NEEDED TO PURGE AIR FROM GAS LINE United Technologies Electronic Controls Spark Ignitor Watch microammeter carefully Burner must hold in low fire for approximately 10 seconds before modulat ing up The reading should be at least 0 5 microamps If the reading is too low slowly turn the low fire adjustment on the modulating or two stage valve in or out until satisfactory readings are obtained When adjusting low fire there should be a continuous flame along the entire burner length without any blowout spots Low fire must be adjusted first on units without pilot and stay in low fire for approximately 10 seconds Refer to Maxitrol Valve Adjustment instructions in Section IX for setting high and low fire gas pressure settings When the flame is adjusted shut the unit off by turning the Fan and Heat switches to OFF Setting Main Flame Install manometer at test port on the last tee of the burner manifold or modulating valve Slowly open all manual gas shut off valves Restart fan and burner After main gas valves open and burner lights check gas lines for leaks Adjust high gas pressure readin
26. Symptom Cause Remedy A If blower does not 1 Low or no voltage 1 Check power source operate 2 Fuse s blown 2 Check and replace 3 Customer interlock not closed or 3 Close or connect customer connected interlock 4 Fan Off On switch in Off position 4 Switch to On position 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 6 Reset freeze stat by interrupting power Check for proper setting and burner operation 7 Damper motor not operating or 7 Check for power at damper motor its end switch not making and that end switch has 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 or 11 Turn power off and check motor incorrectly wired and wiring 12 Motor overheating 12 Check burner firing rate B If there is no voltage at 1 Heat Off On switch in Off position 1 Switch to On position flame safeguard relay 2 Auxiliary switch on starter not 2 Check auxiliary circuit wiring and input terminal closed contact 3 Air flow switches open 3 Adjust the air flow and external static pressure t
27. al 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 units 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 cr
28. am P 001003 No voltage on secondary side of ignition transformer 6a 6b Replace with factory 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 E If pilot does not light after prepurge has timed out and there is no voltage at flame safeguard relay output terminals Flame safeguard relay Run Test Switch in Test position or functioning problem Place in run position see technical cut sheet on flame safeguard relay F If there is no heat with pilot ok and voltage is present at flame safeguard relay output terminals 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 4a 4b 4 Turn Heat Off On switch to position Slowly open all manual gas shut off valves before restarting Clear obstruction in vent orifice line or replace if defective Turn Heat Off On switch to On postion After 10 seconds of prepurge pilot will light Then after 5 to 10 seconds main valve light will come on Check to see if allgas valves have opened If not check voltage at gas valve If voltage is found to be correct replace gas valve
29. 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 mounted and wired whenever possible within limita tions of shipping and handling Any optional accesso ries shipped separately are shipped as assembled sections Any wired accessories which have been disassembled for separate shipment require no additional conduit or wire for field reassembly All wire leads will be tagged for ease of reconnection in the field Shipments are made F O B Dallas Texas by flatbed 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
30. ated on the unit control wiring diagram 4 f the optional low temperature limit was not an integral part of the heater the factory recommends that a low temperature limit control be installed in areas where freeze protection is needed in the event of burner shut down 5 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 thermostats should be 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 bulbs require that the outdoor bulb be shielded from direct radiation from the sun Unit mounted sensors are factory located and mounted SECTION IV PRE START UP Do not attempt start up without completely reading and understanding this manual A Pre Start Up The owners representative or equipment operator should be present during start u
31. burner lights smoothly and that all ports remain lit 3 Check the full rate high manifold pressure listed on the appliance nameplate for high pressure The gas control full rate outlet pressure should match this rating 4 With main burner operating check the gas control flow rate using the meter clocking method or check pressure using a manometer connected to the outlet pressure tap on the gas control If necessary adjust the high pressure regulator to match the appliance rating a Remove the pressure regulator adjustment cap b Using a screwdriver turn the inner adjustment screw for HI pressure clockwise to increase or counterclockwise amp de crease the gas pressure to the burner After high pressure has been checked check low pressure regulation Two stage appliance operat ing sequences vary Consult the appliance manu facturers instructions for the specific operating sequence and regulator adjustment procedure for the appliance in which the control is installed and for instructions on how to prevent the control from moving to high stage while checking the low pressure regulator setting Check the low rate manifold pressure listed on the appliance nameplate Gas control low rate outlet pressure should match this rating With main burner operating check the gas control flow rate as before using the meter clocking method or check pressure using a manometer connected to the outlet pressure tap on th
32. cing this equipment AVERTISSEMENT Une installation d ficiente de qu un mauvais r glage modification entretien ou maintenance peuvent occasionner des dommages mat riels 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 n King 4830 Transport Drive Dallas TX 75247 Phone 214 638 6010 Fax 214 905 0806 SECTION I FORWARD 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 this machine This manual of instructions has been prepared in order for you to become well acquainted with those details and in doing so you will be able
33. ctory required at ignition control supplied different from factory type of gas required type 4 Auxiliary switch on starter not 4 Check for power and replace if closed necessary 5 Air flow switches not closing 5 Adjust the air flow and external static pressure to match rating plate 6 High temperature limit switch 6 Correct problem Reset by open pushing down the reset button 7 High or low gas pressure 7 Correct problem Reset both Switches open if applicable Switches 8 Main gas valve relay open 8 Check for power and replace if necessary 20 System without Pilot continued TROUBLESHOOTING GUIDE Symptom Cause Remedy C continued 10 11 12 13 14 Defective gas valve or actuator Defective spark rod or out of position see drawing P 001004 or P 00117 Flame rod not sensing flame see drawing P 001003 or P 00117 Defective regulator Blocked vent lines or vent limiters Low fire set too low or too high 12 13 Check power to gas valves If gas pressure matches unit rating plate and valve does not open replace gas valve or actuator Make sure spark rod is producing a sufficient spark to light off burner make sure porcelain is not cracked Check wiring or replace if necessary Make sure flame rod is in flame Make sure porcelain is not cracked Check wiring or replace if necessary Clean or replace regulator Check ve
34. d 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 de scribed the problem can be isolated to the valve itself or to the gas control manifold of the heater In the event proper voltages are obtained and the Valve responds correctly to these DC voltages the problem could well be in the wiring leading to the Discharge Air Sensor or the Discharge Air Sensor itself This should also be reviewed in the check list If the proper voltages are not obtained when wired as instructed the problem can be isolated to the electron ics and this may once again be reviewed in the check list After test remove the test resistor and reconnect the Discharge Air Sensor to terminals 3 and 4 If Remote Temperature Selector has been moved return it to its original position See following Resistance Lookup Table for RTC Solutions components PRELIMINARY CIRCUIT ANALYSIS MODULATING ROOM TEMPERATURE MRT CONTROLS This Preliminary Circuit Analysis will provide identifica tion of faulty components improper wiring or calibra tion and other difficulties when used with the tabulated Troubleshooting Guide NOTE voltages and resistance readings are approximate Section 1 1 Wire the system per Figure 1 2 Connect a DC voltmeter to amplifier terminals 6 and 7 3 Turn the Test Potentiometer to minimum resis tance 2 0
35. de Temperature 1 Check Override Temper 1 Reset to correct Temperature setting is too low ature Selector of Remote temperature too low when Temperature Selector Room Override 2 Burner capacity may be 2 Check for high fire Maxitrol 2 If on high fire control can Thermostat is insufficient manifold pressure specified do no more Heater unable operative for heater to furnish additional heat to raise temperature L Discharge 1 Duct Losses 1 RTC Solution should Temperature maintain an accuracy of not the same 3 F If not the controller as setpoint may be calibrated in two ways a The potentiometer on the face of the Direct Fired Control labeled ADJUST will adjust the discharge temperature by 10 F when rotated Rotating it clockwise will increase the temperature and counterclockwise will decrease the temperature b The system may also be adjusted from the Remote Temperature Selector by adjusting the potentiometer R3 on the back in the same procedure as shown above m _ Modulating Room Temperature MRT Controls TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE Portions reproduced with permission from Maxitrol Company Symptom Possible Cause Field Test Remedy A No Gas Flow Valve improperly installed Arrow on side of valve should point in direction of gas flow 1 Install properly B Continuous Low Fire Electronics Ok
36. 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 buildings where outside temperatures fall below 32 F 0 Excessive recirculation or insufficient ventilation air which results in inadequate dilution of combustion products generated by the heater may create hazard ous concentration of carbon monoxide nitrogen dioxide and other combustion products in the heated space 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 properly 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 regarding 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 39 4830 Transport Drive Dallas TX 75247 Phone 214 638 6010 Fax 214 905 0806
37. e 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 With modules that continue to spark until the pilot lights or the system shuts down manually the pilot should light when the manual gas control knob is opened 6 Set the thermostat below room temperature and wait one minute 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 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 AdaptAire Digital Control System User Manual as a troubleshooting guide for DDC system WARNING Many of the steps listed below require electrical cabinet 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 SECTION VII TROUBLESHOOTING continued System with Pilot
38. e con trol If necessary adjust the low pressure regulator to match the appliance rating a Remove the pressure regulator adjustment cap b Using a screwdriver turn the inner adjustment screw for LO pressure clockwise to increase or counterclockwise amp de crease the gas pressure to the burner Once high and low pressure have been checked and adjusted replace pressure regulator adjust ment cap If the desired outlet pressure regulator or flow rate cannot be achieved by adjusting the gas control check the control inlet pressure using a manometer at the inlet pressure tap of the control Take the necessary steps to provide proper gas pressure to the control 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 isdone 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 tempera ture to call for heat 3 Watch for ignition spark or for glow at hot surface igniter either immediately or following prepurge See IP module specifications 4 Time the length of the spark operation See th
39. e 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 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 maximum 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 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 G Field Wiring and Remote Control Installation 1 Connect the power lines to the line side of the main disconnect switch 2 Mount and wire remote control panel thermostats temperature sensors and any other field installed controls as indicated on the unit control wiring diagram 3 Connect the wires to the appropriate field wiring terminals as indic
40. ed 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 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 nameplate for minimum
41. emperature Selector circuit or wiring 2 Open circuit in Discharge or Inlet Air Sensor circuit or wiring 3 Jumper not connected across amplifier terminals 2 amp 3 Inspect for shorts at or between Amplifier terminals 1 amp 2 or Remote Temperature Selector terminals 1 amp 3 Check Discharge or Inlet Air Sensor for open internal circuit Connect test resistor as described in Preliminary Circuit Analysis Follow procedure outlined Inspect 1 Correct wiring if shorts exist 2 If modulating voltages are obtained check Discharge or Inlet Air Sensor for open circuits Replace TS114 TS1007 3 Correct the wiring F Continuous High Fire Electronics OK 1 Foreign object holding valve open 2 Plunger jammed Remove bottom plate and inspect valve and seat Inspect Plunger should be smooth and clean and operate freely in solenoid sleeve 1 Clean seat Clean valve or replace if necessary 2 Clean or if necessary replace plunger G Incorrect Maximum Fire 1 Inlet pressure too low 2 Incorrect outlet pressure adjustment of Pressure Regulator 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 Read manifold pressure using manometer and compare with the pressure stated on the specification p
42. es involvedmust be replaced c Put system back into operation and view burner while cycling through full firing range This will give a visual check for blocked burner ports Inspect the flame rod and ignition electrode for dirt and moisture Wipe off if necessary Examine for any evidence of premature arcing If in doubt check continuity of flame rod to be sure it is not grounding out Replace if required The porcelain on the ignition electrode must be intact not cracked The spark gap should be between 1 16 and 3 32 of an inch on Maxon burners or 1 8 of and inch on Mestek burners Replace all access panels which have been removed and operate the unit for a test period Check for normal response and function of all controls Check all gas piping for possible leaks using a soap bubble solution Inspect the support means to be sure that every thing is firmly anchored in place MIDCO BURNERS Inspection and Maintenance of Gas Ports Conduct initial inspection within the first month after commissioning Visually check the gas ports of new burner assemblies for any piping scale or debris Use Pin Vise with drill bit to remove Annual inspections are normally adequate once the initial piping debris is removed The operating conditions of the burner will determine how frequently maintenance is actually required Use of an electric drill motor is not suggested unless both Pin Vise and Drill as shown can be chucked up in a vari
43. g from manometer to match firing rate shown on unit nameplate Adjust the high fire setting according to the Maxitrol Valve Adjustment instructions in Section IX 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 length of the burner Main flame is now set Recheck the microamp signal on the ignition control throughout the full burner input range Re check low fire setting Cycle unit 2 or 3 times to insure good ignition Safety Controls Check A Flame Safeguard piloted systems only Close last manual gas valve before main burner Operate unit in Heat mode After pilot has been estab lished close manual pilot gas valve The flame safe guard must trip out within 15 seconds B Ignition Control pilotless system only Operate unit in Heat mode After flame has been established close last manual gas valve before main burner The ignition control must trip out within 15 seconds Reset the ignition control by turning the HEAT switch to the OFF position C Gas Pressure Switches The low pressure switch will trip out and must be reset before resuming opera tion 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 ori
44. ge across terminals 5 and 6 with a voltmeter The meter should read from 20 to 24 volts If it does not disconnect the wires from the valve and measure the output without the valve connected If it reads 20 to 24 volts refer to the valve manufac turer literature for troubleshooting the valve If it does not the control may be damaged Refer to following chart for other troubleshooting suggestions Modulating Discharge Temperature MDT Controls Portions reproduced with permission from Maxitrol Company Symptom Possible Cause Field Test Remedy A No Gas Flow 1 Modulating valve improperly installed Arrow on side of valve should point in direction of gas flow 1 Install properly B Continuous Low Fire Electronics Problem 1 Short circuit or no voltage to the amplifier 2 Open circuit in Remote Temperature Selector circuit or wiring 3 Short circuit in Discharge Air Sensor circuit or wiring 4 Faulty amplifier Check for 24V AC at amplifier terminals 7 amp 8 Inspect for loose or broken wires between amplifier terminals 1 amp 2 and Remote Temperature Selector terminals 1 amp 3 Connect test resistor as described in Preliminary Circuit Analysis in Section IX Follow procedures outlined Check items B1 3 Prove the power source Tighten connections or If modulating voltages are If items B1 3 check out and replace wiring obtained
45. ginal setting and reset to resume operation When checking operation of gas pressure switches on systems without pilot the heat switch will have to be turned off for approximately five seconds to reset the ignition control D Air Pressure Switches The high air pressure switch is checked by removing the sensing tube from the entering air side of the burner 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 When checking operation of air pressure switches on systems without pilot the heat Switch will have to be turned off for approximately five seconds to reset the ignition control 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 TC 01 Room Thermostat Customer Discretion RE 26 High Limit Discharge Ductstat 95 TC 03 On Off Inlet Ductstat 65 F RE 26 Low Limit Discharge Ductstat 55 F TC 08 Freeze Thermostat Min 45 F TC 09 Night Set
46. gs 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 unit 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
47. h fire 2 Remove seal cap A and turn regulator pressure 2 adjusting screw to obtain desired manifold pres sure Clockwise rotation increases pressure 3 3 Reconnect the wires to amplifier terminal 4 Series 14 or 2 and 4 Series 44 M411 511 611 Valve High Fire Manifold Adjustments Disconnect wires from amplifier terminal 4 Series 14 or 2 and 4 Series 44 This causes the valve to call for continuous high fire Adjust the pressure regulator to obtain the desired manifold pressure 7 w c maximum Reconnect the wires to amplifier terminal 4 Series 14 or 2 and 4 Series 44 Low Fire or Bypass Adjustments NOTE If low bypass is on maximum the desired 1 high fire outlet pressure may not be achieved Low Fire or Bypass Adjustments 1 Disconnect wire from amplifier terminal 8 This causes valve to call for continuous low fire 3 2 Remove cap B and loosen lock screw C Turn Disconnect wire from amplifier terminal 8 This causes the valve to call for continuous low fire Remove cap A and turn adjusting screw B to desired low fire adjustment Clockwise rotation reduces minimum flow rate Replace cap A and reconnect wire to amplifier terminal 8 D to desired low fire adjustment Clockwise rotation reduces minimum flow rate 3 Tighten screw C replace cap B and reconnect wire to amplifier to terminal 8 MODULATOR 36 PRELI
48. 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 No flame present at end of MFEP g Internal system fault occurred h Purge card is removed i Purge card is bad 6 RUN PERIOD a No flame present b Airflow lockout feature is enabled and the airflow switch opens c Interrupted pilot valve terminal is energized RM7895C D EC7895C RM7896C D d Main valve terminal is not energized e Delayed second stage main valve terminal is not energized RM7895C D EC7895C RM7896C D f Internal system fault occurred g Purge card is removed h Purge card is bad OPERATION Sequence of Operation The RM7895A B C D EC7895A C RM7896A B C D has the operating sequences listed below see Fig 2 and 3 The RM7895A B C D EC7895A C RM7896A B C D LED provide positive visual indication of the program sequence POWER PILOT FLAME MAIN and ALARM Initiate The RM7895A B C D EC7895A B C RM7896A B C D Relay Module enters the INITIATE sequence when the relay module is powered The RM7895A B C D EC7895A C RM7896A B C D 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 freque
49. itical 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 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 power
50. late 1 Increase inlet pressure if possible See valve adjustments in Section IX cm Modulating Discharge Temperature Controls continued TROUBLESHOOTING GUIDE Portions reproduced with permission from Maxitrol Company Symptom Possible Cause Field Test Remedy H Erratic or Pulsating Flame 1 Wiring is run next to high voltage switching circuits causing induced voltages 2 Faulty Amplifier or erratic voltage supply Temporarily wire each selector sensor and MR212 externally and observe heater equipment operation With test resistor connected as described in Preliminary Circuit Analysis and selector dial locally connected per Item 1 turn selector dial through entire modulating range Observe D C voltage across modulator terminals 1 If smooth operation results isolate effected wiring from source of induced voltage 2 If erratic or unstable D C voltages are obtained throughout the modulating range the amplifier may be assumed faulty Replace If erratic operation is noted only over a small range of 2 or 3 volts the voltage Sources may contain surges Consult factory for other solutions I Incorrect Discharge Air Temperature 1 Inlet Air sensor is used 2 Incorrect wiring 3 System out of calibration 4 Improper Discharge Air Sensor location 5 Room Override Thermostat circuit closed Inlet Air Sensor changes 1
51. late first Refer to Maxitrol Valve Adjustment instructions in Section IX for setting high and low fire gas pressure settings On systems with pilot 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 IX The high fire setting must not exceed the pressure stated on the specification 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 pilot and main gas lines for leaks Main flame is now set Make sure burner modulates and turn thermostat to the desired setting Cycle pilot and burner a number of times to insure smooth light off Check flame signal with burner cycling through full firing range and burner profile damper operation if applicable Unit Start Up Systems without Pilot Setting Burner NOTE To adjust gas pressure on supply lines where a regulator has been installed to reduce the inlet pressure to 1 2 PSIG or less remove dust cap of main gas regulator and turn adjusting screw clockwise to increase pressure or counter clock wise to decrease pressure Set all thermostats to call for heat Set inlet ductstat if applicable above outside air temperature Connect a DC microammeter between the
52. mostat and field installed controls open controls for proper settings 6 Freeze protection tripped 6 Reset freeze stat by interrupting power Check for proper setting and burner operation 7 Damper motor not operating or 7 Check for power at damper motor its end switch not making and that end switch has 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 or 11 Turn power off and check motor incorrectly wired and wiring 12 Motor overheating 12 Check burner firing rate B If there is no voltage at 1 Heat Off On switch in Off 1 Switch to On position ignition control position 2 Burner enable relay open if 2 Check for power and replace if applicable necessary 3 Outside air temperature higher 3 Lower On Off inlet ductstat than On Off inlet ductstat if setting applicable 4 Field purge timer open if 4 Check for power and replace if applicable necessary C Burner does not light 1 Manual gas shut off valve closed 1 Slowly open valve after 5 seconds pre 2 Inlet gas pressure lower than 2 Increase gas pressure purge of flame safeguard required gas pressure relay and there is voltage 3 Type of gas Natural LP 3 Replace with fa
53. nal 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 terminals 8 and 10 are energized The RM7895A B EC7895A and RM7896A B have an intermittent pilot valve terminal 8 The EC7895C RM7895C D and RM7896C D have an interrupted pilot valve terminal 8 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 b With flame proven the ignition terminal 10 is de energized 2 Main Flame Establishing Period MFEP a After Ignition Trials and with the presence of flame the main fuel valve terminal 9 is pow ered 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 RM7895C D EC7895C and RM7896C D have a ten second MFEP After the Ignition Trials and with the presence of flame the main fuel valve terminal 9 is powered If a flameout occurs the
54. ncy 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 min utes the RM7895A B C D EC7895A C RM7896A B C D locks out 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 RM7895A B C D EC7895A C RM7896A B C D is ready to start an operating sequence when the operat ing control input determines a call for 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 RM7895A B C D EC7895A C RM7896A B C D 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 termi
55. nt lines or replace limiters Adjust setting on modulating valve or two stage gas valve D Burner will not respond to temperature For Maxitrol system For RTC system For Honeywell system See following troubleshooting guide for Maxitrol or controls See following troubleshooting guide for RTC MDT controls See following troubleshooting guide for Honeywell 21 TROUBLESHOOTING GUIDE The Direct Fired Control RTC Solutions provides some diagnostics via the on board LED labeled POWER STATUS A system fault is indicated by a fast blinking LED about twice per second This usually indicates that the sensor or dial are either disconnected or improperly wired Check all connections per the included wiring diagrams The fault also may be caused by a damaged sensor or dial Both devices may be tested with an Ohmmeter by removing the wires from the Direct Fired Control and measuring across the device The devices should measure between 12 8K and 7K OHMS If there is a fault light and the devices measure the proper resistance then the control may be damaged If there is no fault light but the system is not modulating properly you may check the control output by repeating the start up procedure and measuring the voltage across terminals 5 and 6 on the Direct Fired Control as follows Remove the wire from terminal number 4 on the Direct Fired Control and measure the volta
56. o match the rating plate 4 Outside air temperature higher 4 Check stat for proper setting than on off inlet ductstat setting if applicable 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 C Ifthe flame safeguard 1 See technical cut sheet on flame 1 Determine the cause of lockout relay goes into saftety safeguard relay Push reset button on flame shutdown lockout safeguard relay D If pilot does not light after 1 Manual pilot shut off valve closed 1 Slowly open valve prepurge has timed out 2 Inlet gas pressure lower than 2 Increase gas pressure 10 seconds and voltage required gas pressure is present on flame 3 No gas through pilot regulator 3 Clear obstruction in vent orifice safeguard output with inlet gas pressure ok line or replace if defective terminals 4 No gas through pilot solenoid 4 Check for correct installation and voltage Correct or replace za SECTION VII TROUBLESHOOTING continued System with Pilot continued Symptom Cause Remedy D continued Type of gas natural LP supplied different from factory required type Note components may change Flame detection system not sensing pilot flame see spark rod diagr
57. ocal codes having jurisdiction Authorities having jurisdiction should be consulted before installa tions are made Local codes may require additional safety controls and or interlocks All installations in airplane hangers must be in accor dance with current ANSI NFPA No 409 All installa tions 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 When unloading and setting the unit use the lifting lugs provided 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 of the unit bolts and nuts may have become loosened particularly in the pillow block ball bearing assemblies in the fan sec
58. om Temperature Selector to maximum Temperature Selector Selector circuit setting Measure resistance or repair wiring across wires Meter should read 6000 ohms 1000 Room Sensor Selector If Room Temperature Sensor Room Temperature Selector are used meter should read 4500 ohms 1000 Room Temperature Sensor and 2100 ohms 150 Room Temperature Selector 3 Incorrect space 3 Follow procedures outline in If proper action is obtained temperature calibration Preliminary Circuit first check item E2 Analysis in Section IX Recalibrate if necessary F Incorrect 1 Improper Discharge 1 Compare sensed Move Discharge Air Sensor Maximum or Air Sensor location temperature reading at to location where average Minimum Discharge Air Sensor temperature can be sensed Discharge Air with average discharge Temperature air temperature 2 Follow procedures outlined in Preliminary Circuit Analysis in Section IX If proper temperatures are not observed refer to Discharge Air Temperature calibration procedures G Continuous High Fire Electronics OK 1 Foreign material holding valve open 2 Plunger jammed 1 Remove bottom plate and inspect valve and seat 2 Inspect plunger should be smooth and clean and operate freely in solenoid sleeve Clean replace valve and or Clean or if necessary seat if necessary replace plunger H Continuous High Fire Electronics Problem
59. or actuator see 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 G If there 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 position see technical cut sheet on flame safeguard relay 18 SECTION VII TROUBLESHOOTING continued System with Pilot continued Symptom Cause Remedy H Burner will not respond to temperature 1 For Maxitrol System 2 For RTC System Refer to following troubleshooting guide for Maxitrol MDT or MRT controls Refer to following troubleshooting guide for RTC MDT controls I 75 25 or 50 50 return air outside air or discharge air profile damper operation not functioning properly see sequence of operation for damper control Defective photohelic switch 2 Photohelic or null switch wired incorrectly 3 Phothelic or null switch not installed correctly 4 Temperature control defective 5 Temperature control wired up incorrectly 6 Temperature control bulb installed incorrectly 7 Two position switch defective 8 Damper motor and or potentiometer defective 9 Dampers binding and or
60. ors 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 3 Quarterly a Complete the monthly maintenance schedule b Check the belt tension for the main fan s and adjust if necessary 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 of the automatic gas shut off valves and check them for leakage at the pressure test ports provided k On vertical units inspect burner drip leg and drain if necessary 4 Off Season or Yearly a Complete the monthly and quarterly maintenance schedule b Inspect all fan wheels and housings Clean if necessary c Check that all fan wheels and sheaves are securely set on the shaft d Inspect all bearings and alignment Adjust if necessary To Inspect all V belts Replace if necessary Inspect all electrical com
61. ot be obtained then amplifier may be assumed at fault Install replacement amplifier D Incorrect Incorrect by pass See Valve Adjustments 1 Adjust to proper low fire Low Fire metering valve Section IX Close main gas supply and measure manifold pressure with blower operating Should be less than 1 5 w c negative pressure 2 If greater than 1 5 negative pressure check equipment for clogged filters and other inlet air restrictions For other solutions consult factory 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 26 Modulating Room Temperature Controls continued TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE Portions reproduced with permission from Maxitrol Company Symptom Possible Cause Field Test Remedy E Continuous 1 Faulty amplifier 1 Follow procedures outlined 1 If amplifier is proven at fault 2 Incorrect discharge air temperature calibrations Minimum in Preliminary Circuit install replacement amplifier Discharge Air Analysis in Section IX Temperature 2 Short in Room 2 Remove wires connected to 2 If reading is incorrect Sensor Selector or amplifier terminals 4 amp 5 replace the Room Room Temperature Set Room Sensor Selector Sensor Selector Room Sensor Room or Room Temperature Temperature Sensor Ro
62. ould 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 accompa nying normal bearing temperature indicates proper lubrication Normal temperature can range from cool to hot to the touch depending on size speed and surrounding conditions Excessive bearing tempera ture indicates faulty lubrication An insufficient amount of grease is suggested by a bearing showing no grease at the seals and a higher than normal tem perature 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 determining a relubrication schedule The following chart gives the frequency of relubrication based upon continuous 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 Up to 125 F Clean 6 months 500 RPM Up to 150 F Clean 2 months 1000 RPM Up to 210 F Clean 2 weeks 1500 RPM Over 150 F Clean weekly Any Speed Up to 150 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
63. out Failure IMPORTANT Clipping and removing a jumper after 200 hours of operation causes a nonresettable Fault 110 The relay module must then be replaced RUN TEST C D ONLY A RELAY MODULE CONFIGURATION SEQUENCE STATUS LED PANEL RESET BUTTON CAPTIVE MOUNTING SCREW FLAME a AMPLIFIER M15122 Figure 4 RM7895A B C D EC7895A C RM7896A B C D Relay Module Exploded View 12 SECTION VII TROUBLE SHOOTING continued Figure 2 Wiring Subbase and Sequence Chart for RM7895A B EC7895A RM7896A B LINE VOLTAGE ALARM EN BLOWER BURNER CONTROLLER LIMITS LOCKOUT INTERLOCK INCLUDING AIRFLOW SWITCH PILOT IGNITION MAIN FUEL VALVE S 00000 000000 FOR DIRECT SPARK IGNITION OIL OR GAS IGNITION TRANSFORMER MAIN VALVE MASTER SWITCH Li HOT 00 00 00 To TIMED PFEP POST PURGE DISPLAY INITIATE STANDBY START PURGE 408105 RUN 15 SEC STANDBY Power POWER POWER Power POWER POWER DWER O O O O PILOT POT O O O O O O FLAME FLAME Frame O O O O O OMAN O man O O O O O O ALARM OALARM O ALARM O O BURNER BURNER BLOWER MOTOR 4 5 START 10 IGN IGN PILOT 8 MAIN VALVE 9 OPERATING LIMITS AND BURNER CONTROLLER CLOSED 11 6 CONTROLS AND INTERLOCKS A RFLOW SW CHECK LOCKOUT
64. p to receive instruc tions on care and adjustments of the equipment 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 Thermometer Tachometer Ammeter Manometer 0 10 W C Microammeter Standard Hand Tools D C Volt Meter Gas Pressure Gauge 0 35 Ibs CAUTION Line side of disconnect may be energized Follow proper lockout tagout procedures NOTE servicing and adjustments of the Direct Gas Fired unit should be performed by a qualified service engineer This inspection is very important 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 o
65. ponents 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 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 Inspect fan motor wiring for loose connections Lightly oil all door latches Check that cabinet is weathertight replace door gaskets and recaulk as necessary x 5 NOTE Keep screened air intakes clear obstruc tions at all times B Lubrication Instructions ltem 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
66. relay module locks out within 0 8 or 3 seconds depending on the amplifier FFRT Run 1 The RM7895C D EC7895C RM7896C D 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 RM7896A B C D Only 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 for 15 seconds Run Test Switch RM7895C D EC7895C RM7896C D only The Run Test Switch is located on the top side of the relay module see Fig 5 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 position causes the PREPURGE timing to stop 2 In the 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 also allows for pilot turn down test and other burner adjustments This activates a fifteen second flameout timer that permits pilot flame adjustment without nuisance safety shutdowns The Run Test Switch is ignored during PFEP for the C and D relay mod
67. speed drill unit Use caution because it is easy to snap the bits off in a port when using a drill motor Removal of broken bits from the gas ports is difficult Alternate drill sizes which may be used are 47 P 001004 dell IGNITOR ASSY DETAIL lr S 00000000 0000000009 SS oooooooo oo000000 ROD ue V1 0818 00 V1 0216 00 a e e e e SPARK IGMITOR Lo 68 0910 60 ee K ene 00 0 O 000 0 0 PINOT TOBING WHEM REQUIRED VV 0600 20 Za GAS PINOTLESS SYSTEM zo 1 4 APPROX Pitt mia 919 DA TAMA ETS CA SADBMION MO 272920 Goa 0R QO6NeAN 01 LON EI LI B Qc MENADE OA AOA INSE EI DNAMVMO HIMA IM NI 8 MONI TAD wvumiwvNw 9 OCOD WNW do YW SLY Od uv 3I NI ONY SUBLNSD HINI dIIYdE A vnb5 S370H 2 TERI 021 ifs Sized Svo SYS nli SHIM NI ONY 23 10 32 HINI I NO sals HIV 2 LOO 93710H 17 30 S H2v3 lt 2 3 5o0H 22 Cero Cbo Trs SIYOd Bauli 21wlcawualnmi BOIS Horo DE Lood sad SIMON 7L
68. ting 2 If desired space temperature is not reached decrease minimum discharge air temperature setting 3 If desired space temper ature is not reached with heater at high fire it may be undersized Consult factory 4 If temperature reading is incorrect check items 1 2 amp 3 then recalibrate if necessary 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 28 SECTION VIII MAINTENANCE SCHEDULE AND LUBRICATION REQUIREMENTS 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 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 b Check set screws and bolts on the fan bearings and burner assembly CAUTION Do not overtighten belts 2 Monthly a Check all valves piping and connections for leaks b Check the flame setting c Check the fuel pressure in the fuel supply line to each heater Check the burner manifold pressure at full fire Clean the flame sensor s or UV sight tube s Inspect filters Clean or replace as necessary Inspect the main fan bearings Check all dampers damper actuat
69. tion 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 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 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 materi
70. ual gas valves are closed Reset flame relay Turn Fan and Heat Off On switches to Off position On units with Signal Conditioner the 0 10 VDC or 4 20 mA control signal by others must be applied to terminals 5 and 6 on the Signal Conditioner terminal strip For 0 10 VDC control signal place the three position DIP switch in the off position For 4 20 mA control signal place the three position DIP switch in the on position The manufacturer recommends a temperature sensor to be placed in the unit discharge to limit the supply air temperature to 95 F or less Unit Start Up Systems with Pilot 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 nameplate NOTE To adjust gas pressure on supply lines where a regulator has been installed to reduce the inlet pressure to name 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 Set all thermostats to call for heat Set inlet ductstat if applicable above outside air temperature 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
71. ules 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 codes SECTION VII TROUBLE SHOOTING continued SETTINGS AND ADJUSTMENTS Figure 6 Selectable Site Configurable Jumpers Selectable Site Configurable Jumpers The relay module has three site configurable jumper SELECTABLE CONFIGURATION JUMPERS RUN TEST SWITCH options see Fig 6 and Table 7 If necessary clip the Aa DS ANEC D site configurable jumpers with side cutters and remove the resistors from the relay module SERVICE NOTE Clipping and removing a site TT pere Tp configurable jumper enhances the level of safety ENE ELL mm RELAY WODULT Figure 5 Sequence Status LEDs RUN TEST SWITCH RM7895C D i CAPTIVE EC7895C MOUNTING RM7896C D SCREW PLUG IN PURGE CARD M7553A SEQUENCE LEDs INNER ur lt RELAY Table 7 Site Configurable Jumper Options MODULE Jumper RESET SAT Number Description Intact Clipped PUSHBUTTON AMPLIFIER JRI RORE ame 10 Seconds 4 Establishing Period PFEP FLAME VA SIMULATOR INPUT FLAME CURRENT Seconds TEST JACKS M7552A JR2 Flame Failure Action Recycle Lockout low Switch ILK Recycle Lock
72. urge the gas valve and 60 Hz spark are energized When flame is detected the control enters the steady state heating condition Steady state heating will continue until the call for heat is satisfied If ignition is not achieved within 10 seconds the control shuts off the gas and locks out If the trial for ignition has been accomplished without ignition the control shuts off all outputs and enters lockout Reset is accomplished by cycling the power off for a minimum of 5 seconds If flame is lost once it has been established the control will shut off the gas valve within 0 8 seconds and locks out If flame is sensed during a purge period when no flame should be present the control will remain in purge with the gas valve off until the false flame disappears If the gas valve is found to be powered when it should be off or not powered when it should be on the control will enter lockout with all outputs off Reset is accomplished by cycling the power off for a minimum of 5 seconds Honeywell Two Stage Valve Two stage models require that you check and adjust both high and low pressure regulator settings Two stage appliance operating sequences vary Consult the appliance manufacturer instructions for the specific operating sequence and regulator adjustment proce dure for the appliance in which the control is installed 1 Set appliance to operate on high 2 Carefully check the main burner lightoff Make sure that the main
73. vertighten belts 7 Check set screws on all bearings pulleys and fans for tightness 8 Check voltage supplied to disconnect switch the maximum voltage variation should not exceed 1096 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 14 Check that all accessories requiring field wiring have been properly installed 15 Check burner for proper location and alignment 16 Check that filters and accessories are installed correctly 17 Check that vent lines have been run to atmosphere on indoor units Note that some units will use vent limiters and vent lines are not required 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 If inlet duct is attached to the heater a purge timer must
74. wiring ate Section 4 1 With proper voltages observed thus far and modu lator responding correctly wire the system see Figure 1 except have Discharge Air Sensor connected in place of jumper Set MIN temperature selector on amplifier at least 10 F above outdoor temperature Set MAX temperature selector on amplifier at mid range Heater is now under control of Discharge Air Sensor 2 Turn Test Potentiometer to maximum resistance Delivered air temperature should be per MAX temperature setting Turn Test Potentiometer to minimum resistance Delivered air temperature should be per MIN temperature setting If proper delivered air temperatures are observed the problem is identified with the space temperature sensing and or temperature selecting components and circuits See Troubleshooting Guide If proper delivered air temperatures are not observed check calibration See Troubleshooting Guide Section 5 1 After test remove all test equipment and reconnect all components Figure 1 MT1 12 TS144 VALVE I 10K TEST PO 1 q Pes 3 RESISTOR ll JUMPER P I 10011000000 Figure 2 VALVE 14V20VA TRANS 10K TEST POT i 2K RESISTOR JUMPER 000000000 RESISTANCE LOOKUP FOR RTC SOLUTIONS Dial Resistance Temp F Temp C Sensor Resistance 40

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