IX 1500 Manual 2014 (Rev 3.1)
Contents
1. 3 1 P N 794 9464 Rev i KH S RR A120 Always 120VAC Sue i 11 Ka S120V Swiched 120VAC STAGE atio io DIN PLUG 325 F te 250F gt oM lanual Z M cri zl og e lt m lt s g une T U 9 PNK LU tnt ecd a s 3313 s SWITCH com E ERE e 9 z F 17 7 U Tilt Switch iRN YELLOW 28 k M M ED 7 F M SES MI GRY 1 H E M z H YEL Tt TAN PRL RL LU GRN av M M ER M T e m BLU RED LU sa d Ges ER y igp M I Em w SS S mn mme mms ar ar a N i 34 t E WHT az 35 f i ni ii pii ictus Bas EE BLK M Bad OO aro Programai ro Extension Cooler WIR ee See IGINTION Sc TRANSFORMER E v D k A t L D EG bk i t E 2 Los er rao KM BLU AA o E Re BLU A RED L D d RE S AM gt mn 4 h x S ia D g TO BURNER i S j eH JE H GROUND y I Hd BLU x 2 WHITE 3 RED O N var i SE e Zv ED T AK RED S e G z EN AAA 1 BLACK 4 GREEN BURNER A WHT 120VAC STAGE I I ES st x Sa P SR2. 20 F 10F OF 10F 20F 30F 214 900 187 900 161 800 148 000 134 700 132 400 108 800 107 100 288 100 251 800 216 800 198 400 180 6001 177 400 145 800 143 500 478 800 418 600 360 400 329 700 300 100 294 800 242 300 238 600 852 800 745 600 641 900 587 200 534 500 525 400431 600 425 000 Frosting on the outside of the tank acts as an insulator reducing the vaporization rate MAXIMUM BTU CONTENT PROPANE The following table shows the maximum BTU s that a cylinder contains CYLINDERSIZE BTU CONTENT 100 pound 2 159 100 250 gallon USA 22 922 500 500 gallon USA 45 845 000 1000 gallon USA 91 690 000 CAUTION In extremely cold weather it is impossible to completely empty a propane cylinder PRESSURE amp FLOW EQUIVALENTS 1 Std Atmosphere 14 73 Ib sg in 1 014 bar 1 Water Column W C 0 58 oz sq in 2 49 millibar 11 Water Column 0 4 Ib sg in 27 39 millibar 1 Ib sq in psig 27 71 W C 0 0689 bar 1 Mercury 0 49 psig 33 86 millibar 1 Std Cubic Ft Hr 2 500 BTU Hr 0 02832 cu m hr 1 BTU Hr 0 2931 Watts P N 794 9464 Rev 3 1 31 TRY bU TO B a gt 2 gt ad gt Sure Flame Products A Divison of Haul All Equipment 4115 18 Avenue North Lethbridge Alberta TIH 5G1 www sureflame com
3. On Coil Out 3 Overload Contact NC A gt Start Reset Light Green D urge Suppressor SN op Error Light Red A Blower Motor Coil Blower Light Blue L O Logic Relay Coil TAE Coil Logic Relay Contacts 2 ogic Relay 96 e Burner Motor Coil Contacts 1 O Overload Contact NC Thermostat Switch o r Surge Suppressor Burner Overload Overload Valve Contact NO i i 97 98 a f C gt First Stage Ignition Transformer Aaa top Rese Button i Exhaust 1 Air Switch Limit Switch Blower Button i i Blower Limit Switch Tilt Switch s 3 S Burner Limit Switch H z 61 Flame Controller 12 Input Programmable Controller CPU and Expansion Unit Overload Contact NO i Output Programmable Controller i CPU Unit Output Programmable Controller Out Expansion Unit P N 794 9464 Rev 3 1 21 EA Fan Limit Switch
4. Plate 2 2 6 9264 Relay 2 1 7 4658 Terminal Block 8 8 8 4655 End Plate Green 1 1 9 4668 Ground Terminal Block 1 1 10 9569 Programmable Controller 1 1 11 9568 Controller Extension 1 1 12 8651 Din Rail End Bracket 2 2 13 IX 5238 DIN Rail Top 1 1 14 4565 Pendulum Switch 1 1 15 IX 5709 Adjusted Air Switch 1 1 16 IX 5237 DIN Rail Bottom 1 1 17 9442 Ground Terminal Block 1 1 18 9938 Blower Overload Relay 1 1 19 8629 Blower Contactor 1 1 20 9444 End Plate 4 4 21 9440 Terminal Block 6 6 22 p WEE Burner Overload Relay 1 1 23 4719 Burner Contactor 1 1 24 4703 Circuit Breaker 1 1 25 9443 Ground Terminal Block 2 2 26 4622 Terminal Jumper 5 Pole 1 1 27 2502 Stepdown Transformer 1 1 28 4652 Terminal Jumper 3 Pole 3 3 P N 794 9464 Rev 3 1 27 SURE FLAME Burner Assembly Replacement Parts IX1500 Series Operation amp Service Manual mn N N O Je y S VG 15806 em P N 794 9464 Rev 3 1 28 SURE FLAME IX1500 Series Operation amp Service Manual Burner Assembly Parts List Ref Part Description Quantity 1 7751 Motor Bushing 1 2 1087 Burner Belt 1 3 9556 Motor Sheave 1 4 IX 3517 Bearing Mount 1 5 IX 3715 Turnbuckle Assembly 1 6 9453 Burner Motor 208 230 460 1 7 IX 3739 Blower Housing 1 8 8676 Ignition Transformer 1 9 IX 3712 Burner Head Assembl
5. Sx X 4 4 FRONT VIEW o I i Thermostat Receptacle 4 2 S14 T 5 Connect to primary side e se Cor 5 86 RN ER 5 ag 3 E Bre Cor Core s Power Switch a 5 E 5 o ings on transformer uz BLK og S G she i c i rire D E i dd i E I B LU I zg Q non I tre O ED I pou ED pg I o l j ed Li M pod E u R sa BE NEE E EN E po ei pes l O CONTROL BOX o LO A l M 3PMase 3PHASE i BURNER BLOWER X p NOTE All wires 18 Ga STR TEW 600V unless otherwise specified as MOTOR MOTOR Rev 30 22 SURE FLAME 1X1500 Series Operation amp Service Manual IX1500 Ladder Diagram 2 stage 1 Blower Motor Contacts Overload Relay I I I Power Switch L2 L1 Burner Motor Contacts Overload Relay L3 Stepdown Transformer L Lm OUT 120 V Breaker 96 95 Blower Motor Coll Out 3 Overload Contact NC A gt N Start Reset Light Green rge Suppressor Q4 top Error Light Red fi Q2 Blower Light Blue A Q5 O Q0 Logic Relay Coil sien Coll Logic Relay ogic Rela 96 95 ld ir Coil Gone 2 Contacts 1 First Stage Thermostat Switch Q1 Overload Contact NC PAM stk Second Stage Tharmostat Switch Second Stage Valve gt lt Suppressor Relay Contact YYY Second Stage Valve O Q6 PAN Second Stage Valve Burner 1 i Relay Coil Overload i H Contact NO i 2 i 98 97 15 07 Blower i i Overload Ib B H cou Conta
6. down transformer has 120VAC Heater will not run in Blower only Blower switch blue fails to make mode Blower does run when the contact fan limit switch is set to manual Heater will not start Main Blower Omron controller failure error red cannot be turned on manually LED OFF OFF INT Heater will not start Main Blower Fan amp heat button pressed together 2 cannot be turned on manually Push Stop Button to reset OFF OFF INT Neither the heater or the fan start Stop switch red failure Contacts 3 welded or push button jammed Main blower starts to run right e Blower switch blue failure Contacts after power is turn on After 30 welded or push button jammed seconds blower turns off Heater starts After 30 second e Start switch green failure Contacts Burner turns off welded or button jammed INT SOLID OFF Flame controller stays in P e Burner motor failure 0 5s position with error light on e Wrong voltage e Burner fan failure or foreign object in fan mechanism Flame controller stays in a e Air switch NC contact is open after position with error light on burner blower stops or burner blower fails to stop Flame controller stays in lt e Both Solenoids valve fails to close position with error light on Gas Flame not extinguished odor SOLID OFF OFF No reaction from thermostat but Defective thermostat works with jumper plug No function from Flame e High voltage Wrong power source controller fu
7. if applicable SOLID OFF OFF Heater will not turn off by pressing Stop switch red fails to closed the stop button SOLID OFF OFF Main blower works for a long time Fan limit switch fan break after the burner s turned off or never Set point set too low or Intake stops temperature too high Blowing cold air SOLID OFF OFF Main blower starts after a long delay Fan limit switch fan break set and cycles many times at shutdown point set too high SOLID OFF OFF Main blower starts after a long delay Fan limit switch fan make set signs of overheating discolored point set too high paint SOLID OFF OFF Main blower starts to soon blowing Fan limit switch fan make set cold air for long time at start up point set too low SOLID OFF OFF The burner cycles often Average Fan limit switch limit set point too output temperature lowered low SOLID OFF OFF Blower working all the time Fan limit switch fan contacts fail to open Fan button on fan limit switch is set to manual mode OMRON controller failure SOLID OFF OFF Unstable burner yellow flame and Exhaust Hi limit switch fails to Flame sense error neon light ON break Too long or to small vent pipe SOLID OFF OFF Blower motor runs continually as Blower motor relay contacts soon as the power switch is on welded SOLID OFF OFF No output temperature variation from Stage valve not adjusted to a low fire to high fire lower value if applicable Appliance regulator ad
8. mss E HI TEMP Be Nise Manual FAN UNE jol i SA PNK i RED no LU dd 4 AR 2 a 22 SWITCH cw FEE E e y I Tilt Switch Ps j m Ms 5s il s RED AM ED H GRY i M GRY T EL r TAN ff RL RL LU LE EEE AP ED T LK BLU ED aov e ZS l d HM S amp g tt 33 g alb E i WHT i SS RA S sf 2 ER 1 M E BLK TIE k p 23 Air Proof Tuo Eo i4 Sensor Logic Relay 2 s Naj EK INano Programai Nano Extension Controller Faso ER IGINTION TRANSFORMER i Gi D vil E hi io fo f 1 E E ESCH oe UTO a nt Tw T r S T RT ei bet nt A amp i aL B pr E a li E RN i 120v M l IN LEUI sl E PRL H k AAR m a RY M LU RED M A i PRL yi ER E ER BLU x WHT PNK EH BRN t M RN VELLOW E PNK RN z VEL TO BURNER 2 l EN MT P Lu GROUND 8 RM BROWN LBLUE i Lu M F wr A E ED w
9. power supply as indicated by the ELECTRICAL RATING information 4 Open gas supply 5 Press and release START HEATER switch START HEATER light will come on Set thermostat to desired setting Burner blower will start after about 5 30 seconds Flame will ignite after another 20 seconds If STOP RESET light comes on press STOP RESET switch then repeat the above sequence 6 Heater will switch between high flame low flame 2 stage models and no flame as required to maintain the desired temperature Stop 1 To stop press STOP RESET switch and turn off gas Burner blower will stop after about 20 sec onds Main blower will stop after heat exchanger has cooled down Turn off main electrical switch after the main blower has stopped Warning Do not stop the heater by turning off the main electrical switch Heat accumulated in the heater can damage burner or safety equipment Ventilator 1 2 Press START BLOWER switch Blower will start immediately To stop press STOP RESET switch Note When switching between HEAT mode and BLOWER mode unit must first be stopped by pressing the STOP RESET switch P N 794 9464 Rev 3 1 9 FE E IX1500 Series Operation amp Service Manual SURE FLAME SETTING FAN LIMIT SWITCH The fan limit switch is factory set and should not normally need to be adjusted If it is out of adjustment follow these procedures To set pointers hold dial securely with one hand and move the pointers wit
10. 290 cm x 83 cm x 197 cm P N 794 9464 Rev 3 1 0 2000 4 4 1100 Pa 3 7 925 Pa 2500 4 2 1050 Pa 3 6 900 Pa 3000 4 1 1025 Pa 3 5 875 Pa 3500 4 1 1025 Pa 3 5 875 Pa 4000 4 0 1000 Pa 3 5 875 Pa 4500 4 0 1000 Pa 3 5 875 Pa Inlet Pressure Maximum Minimum 5 psi 35 kPa 9 W C 2 2 kPa Manifold Pressure Altitude Max Min 2500 3000 4 2 1050 Pa 3500 42 1050 Pa 2000 Fuel Consumption Natural Gas 1500 ft h 42 5 m h Electrical Rating See specification decal on heater Fan 8000 cfm 3775 l s Temperature Rise 170 215 F 95 120 C Maximum Temperature Output 293 F 145 C Rated Flue Temperature 480 F 250 C Rated vent pressure Positive Category III Minimum Operating Temperature 22 F 30 C Dimensions LxWxH 114 x 32 5 x 77 5 290 cm x 83 cm x 197 cm FE E IX1500 Series Operation amp Service Manual SURE FLAME Installation The Sure Flame Model 1X1500 1X1500L IX1500NC is an indirect fired gas heater intended to be used primarily for the temporary heating of buildings under construction alteration or repair Since the products of combustion are released it is imperative that the flue stack is extended outside of the enclosed area when the heater is positioned indoors The flow of supply air and exhaust gasses must not be obstructed in any manner The equipment shall be installed in accordance
11. GREEN 120v ED YELLOW a FRONT VIEW ALL T Thermostat Receptacle BURNER M A TEE a o NES a a 1 QE H 2 A E i z om 2 12 S Bumermoor a A bio ich WHT Z Contactor 3 Blower Motor Connect ta primary side r t p sg Contactor D ap EFI 5 Cio Ce o CORSO s Power Switch ted voltage and a zy 5 195 on transformer uz og a k lu y G ve a ST N EM 1 D F 1 C Q EC OIL Relay I 1 Qn A A 3 seere we BY OW A 2 z I n C SS y A ED gp ED Ek x ox I R BB RED 10Ga u ED 10Ga RED A 306 d l 11 GRN Q 8 SS 8 CONTROL BOX 417 i J x d M 3PHASE 3PHASE BURNER M Brower NOTE All wires 18 Ga STR TEW 600V unless otherwise specified MOTOR SN MOTOR Rov 30 Thermostat 3 1 P N 794 9464 Rev 20 SURE FLAME 1X1500 Series Operation amp Service Manual IX1500L IX1500NC Ladder Diagram 1 stage Blower Motor Contacts Overload Relay 4 Burner Motor Contacts Overload Relay a Stepdown Transformer OUT 120 V 96 95 Blower
12. ORITY IF YOU HAVE QUESTIONS ABOUT LOCAL REGULATIONS Other standards govern the use of fuel gases and heat producing products in specific applications Your local authority can advise you about these P N 794 9464 Rev 3 1 3 TI X1500 Series Operation amp Service Manual SURE FLAME Table of Contents DPESCINCALONS NET OO ERERRREE 5 SA sn ke 6 Operating Ee ee 9 Setting Fan Limit SL a dia salou eka en 10 Ee To a 11 Troubleshooting WE 13 Wiring Diagrams saa O O 20 Parts DANE R id 24 Fuel Vaporization Rate A I A 31 4 P N 794 9464 Rev 3 1 SURE FLAME IX1500 Series Operation amp Service Manual Specifications 1X1500 1X1500L IX1500NC Fuel Fuel Natural Gas Natural Gas Vapour Propane Input Capacity Input Capacity Maximum 1 500 000 Btuh 440 kWh Maximum 1 500 000 Btuh 440 kWh Minimum 1 150 000 Btuh 337 kWh Inlet Pressure Maximum Minimum 5 psi 35 kPa 9 W C 2 2 kPa Manifold Pressure Natural Gas Propane Altitude Max Min Fuel Consumption Natural Gas Propane 1500 ft3 h 42 5 m h 69 2 Ib h 31 4 kg h Electrical Rating See specification decal on heater Fan 8000 cfm 3775 Us Temperature Rise 125 215 F 70 120 C Maximum Temperature Output 293 F 145 C Rated Flue Temperature 480 F 250 C Rated vent pressure Positive Category III Minimum Operating Temperature 22 F 30 C Dimensions LxWxH 114 x 32 5 x 77 5
13. Operation and Maintenance Manual SURE FLAME Model No 1X1500 IX1500L IX1500NC INDIRECT CONSTRUCTION HEATER 1 500 000 Btu h Retain these instructions for future reference A WARNING Read and follow all installation and operating instructions before first use of this product Sure Flame Products A Divison of Haul All Equipment 4115 18 Avenue North ee Alberta TIH 5G1 P N 974 9464 om Rev 3 1 Feb 14 2013 GENERAL HAZARD WARNING Failure to comply with the precautions and instructions provided with this heater can result in death serious bodily injury and property loss or damage from hazards of fire explosion burn asphyxiation carbon monoxide poisoning and or electrical shock Only persons who can understand and follow the instructions should use or service this heater If you need assistance or heater information such as an instruction manual labels etc Contact the manufacturer A WARNING Fire burn inhalation and explosion hazard Keep solid combustibles such as building materials paper or cardboard a safe distance away from the heater as recommended by the instructions Never use the heater in spaces which do or may contain volatile or airborne combustibles or products such as gasoline solvents paint thinner dust particles or unknown chemicals A WARNING Not for home or recreational vehicle use e SURE FLAME IX1500 Series Operation amp Service Manual Read th
14. ation must be provided This heater is for operation at a temperature rise from 125 F to 215 F 70 C to 120 C All gas inspection authorities in Canada require that the installation and maintenance of heaters and accessories shall be accomplished by qualified gas fitters Installation must comply with the Natural Gas and Propane Installation Code CSA B149 1 6 P N 794 9464 Rev 3 1 e SURE FLAME IX1500 Series Operation amp Service Manual Ducting The IX1500 series can be ducted on both the inlet and outlet The inlet duct can be up to 50 of smooth 24 x24 metal duct The outlet duct shall be of a material able to withstand temperatures of up to 450F Total outlet duct length may be up to 300 of straight smooth insulated metal duct 24 x24 For each elbow the allowable length is reduced by 50 Venting The flue material is to be constructed of a Type B Type BH in Canada Caterory lll venting material The vent connector should be designed for a positive pressure and be constructed from material having corrosion resistance and durability to heat at last equivalent to that of No 24 GSG galvanized steel The venting system must be in accordance with the Installation Codes for Gas Burning Appliances and Equipment As well as other local Regulations that may apply Flue Diameter 12 10 t Min vertical height 15 20 Max lateral length 19 0 Max of added elbows 2 0 Lateral lengths must have a minim
15. button Red 1 7 IX 5727 Blower Contact Block Assembly 1 Ta 9613 Blower Pushbutton Blue 1 8 WRS 145 Thermostat Receptacle IX1500 1 WRS 173 Thermostat Receptacle IX1500L NC 9 S1500 713 Thermostat Jumper Assy IX1500 1 SE 4716 Thermostat Jumper Assy IX1500L NC 10 9439 Disconnect Switch 1 11 IX 3037 Burner Gasket 1 12 FN12 517 Exhaust Limit Switch Cover 1 13 IX 5741 Heat Shield amp Air Deflector Assy 2 14 4712 Limit Switch 325 F 1 15 IX 5225 Combustion Chamber Panel 2 16 IX 5022 Outside Blower Panel 2 17 1097 Motor Sheve 1 18 1096 Blower Sheve 1 19 4709 Blower 1 20 4564 Belt 2 22 IX 5243 Motor Mounting 1 23 IX 5781 Belt Tensioner Assembly 1 24 4716 Blower Motor 208 230 460V 1 25 IX 4552 Combustion Chamber Exchanger 1 26 IX 5250 Inlet Screen 1 27 IX 5037 Control Box Cover 1 28 IX 5040 Valve Cover 1 29 S1500 714 Thermostat Assembly IX1500 1 SE 4715 Thermostat Assembly IX1500L NC P N 794 9464 Rev 3 1 25 ad Le SURE FLAME X1500 Series Operation amp Service Manual Control Box Replacement Parts P N 794 9464 Rev 3 1 SURE FLAME IX1500 Series Operation amp Service Manual Control Box Parts List ge Quantity Ref Part ff Description IX1500 IX1500L NC 1 8677 Flame Controller 1 1 2 8678 Flame Controller Base 1 1 3 4657 End Plate 1 1 4 4669 Terminal Block 5 5 5 4654 End
16. ct NO i 97 98 la i 6 i EL First Stage IN H i 77 Valve 8 i i Ignition i Transformer Qr i VV IN2 14159 i Heater 16 gt Limit Switch tart Button 10 2 i i top Rese i i Button i T I i Exhaust gr 12 i 12 i Limit Switch Blower Button i o o Blower Limit Switch vo 3 DE Burner Limit Switch E i 1 Flame Controller 19 i 9 i Input Programmable Controller ea i Flame Rod CPU and Expansion Unit H H Overload Contact NO i be Output Programmable Controller 3 a CPU Unit i Output Programmable Controller Out Expansion Unit P N 794 9464 Rev 3 1 23 E Le SURE FLAM X1500 Series Operation amp Service Manual P N 794 9464 Rev 3 1 i AR Jii Main Assembly Replacement Parts 24 SURE FLAME Main Assembly Replacement Parts IX1500 Series Operation amp Service Manual Ref Part Description Quantity 1 IX 3738 Shroud 1 2 IX 5542 Limit Switch Cover 1 3 4711 Limit Switch 250 F 1 4 4710 Fan Limit Control 1 5 IX 5726 Start Contaact Block Assembly 1 Sa 9612 Start Pushbutton Green 1 6 IX 5725 Stop Contact Block Assembly 1 6a 9611 Stop Push
17. damage to blower belt Belt tensioner not functioning properly Green Red Blue Start Stop Fan i Push Push Push Symptom Possible Problem Button Button Button SOLID OFF OFF Main blower fails to start The e Fan limit switch fan contacts fail to burner cycles often signs of close overheating discolored paint Main blower works when manual blue button is pressed SOLID OFF OFF Main Blower motor failure e Wrong voltage Foreign object in fan mechanism Fan failure SOLID OFF OFF No air blows when blower button e Blower Belt broken P N 794 9464 Rev 3 1 17 IX1500 Series Operation amp Service Manual SURE FLAME er problems Green Red Blue Start Stop Fan Push Push Push Symptom Possible Problem Button Button Button SOLID OFF OFF Main Blower and or Burner Blower Wrong Phase 3 PH reversed spin in reverse Low volume air phase coming from blowers yellow flame Incorrect wiring on motor and rumbling burner operation unstable burner or neon light ON SOLID OFF OFF Low temperature output High CO Changeover valve set to propane Combustion unstable rumbling when connected to natural gas if burner operation and or burner turns applicable of turns off moments later SOLID OFF OFF High temperature output High CO Changeover valve set to natural Fan limit switch Limit control cycles gas when connected to propane Yellow flame
18. e and set at 25 30 and that the tensioner roller is running smoothly Replace if worn Burner blower belt tension must be set according to the belt manufacturer s specification When replacing belts also inspect sheaves for wear and misalignment Replace if worn With burner shroud in place and heater operating look and listen for any unusual vibration or sound A well maintained drive will operate smoothly and quietly Adjusting Manifold Pressure Remove valve cover Connect manometer to the port on the inlet flange of the regulator While heater is operating verify that the inlet pressure is between 9 WC and 5 psi Connect manometer to manifold pressure tap on burner gas supply line Ensure that the gas selector valve is set to the proper fuel While the heater is operating check the manifold pressure If the manifold pressure differs from specifications re adjust Single stage models The adjusting screw is located on top of shutoff valve Use 2 5mm Allen wrench Dual stage models With thermostat set to high flame adjust manifold pressure on gas regulator using screwdriver adjusting screw located under black cup Then switch the heater to low flame and adjust manifold pressure on second stage shutoff valve turning black wheel to increase turn counterclockwise Lock the wheel by tightening small screw in front knob Reinstall valve cover remove the manometer and securely tighten the manifold pressure tap 12 P N 794 9464 Re
19. ev 3 1 11 EE z X1500 Series Operation amp Service Manual SURE FLAME Lubricating Bearings Warning Disconnect power before servicing bearings Two pairs of bearings are installed in the heater One pair is on the burner impeller the second is on the main blower impeller They need to be periodically lubricated according to the schedule below Some situations may require a change in lubricating periods as dictated by experience Generally a lower quantity of grease at frequent intervals is more effective than a greater quantity at extended lubrication intervals Select a grease that is compatible with a lithium or lithium complex grease Recommended Lubrication Schedule Lubrication Interval in Weeks Hours Run Per Day Main Blower Burner Blower 2 7 gram per bearing 1 0 gram per bearing 8 5 3 16 2 1 24 1 1 Storage If equipment will be idle for some time before shutting down add compatible grease to the bearing until grease purges from the seals This will ensure protection of the bearing particularly when exposed to severe environmental conditions After storage period add fresh grease to the bearings before starting Replacing Belts Warning Disconnect power before servicing belts There are two belt locations The main blower uses a double belt transmission It requires the belts to be paired and both need to be changed at the same time Ensure that the blower belt tensioner is in plac
20. h Push Symptom Possible Problem Button Button Button OFF OFF OFF Omron controller red error light Too much load on power supply on Low Voltage OFF OFF INT Noisy blower operation Damaged bearings 1 Overload on power relay Blower Belt too tight OFF OFF OFF Poor quality power Dirty power Heater will fail to stay lit Heater turns or such as from a generator off Excessive motor noise SOLID INT SOLID OFF Noisy burner operation Irregular Burner orifices plugged or dirty 0 5s flame burner observation window Heater turns off INT SOLID OFF Heater starts ok but fails in Too much load on power supply 0 5s function Low Voltage Propane tank too small not able to vaporize fast enough tank freezes up Too small of a hose too long of a hose blocked hose Too low of an inlet pressure INT SOLID OFF Yellow flame and rumbling Liquid propane entering heater 0 5s burner operation Damaged regulator POSSIBLE EXPLOSION Damaged solenoid valve INT SOLID OFF Combustion unstable burner Changeover valve set to propane when 0 5s fails to stay lit low outlet air connected to natural gas temperature INT SOLID OFF Combustion unstable rumbling Changeover valve set to natural gas 0 5s noises burner fails to stay lit when connected to propane high outlet air temperature INT SOLID OFF Burner doesn t cycle Fan limit switch limit contact fails to 0 5s The heater runs through one break Heater High limit switch opens Heater Hi lim
21. h the other hand Do not force the pointers past any stops on the dial even though the dial may be graduated beyond the stops Limit Move the right hand pointer so that its straight edge indicates 300 F Fan Move the Fan On pointer so that its straight edge indicates 100 F This is the temperature at which the blower will start Move the Fan Off pointer so that its straight edge indicates 90 F This is the temperature at which the blower will stop Right Hand Pointer Center Limit Opens Pointer CHANGING INDICATORS DO NOT ADJUST SAFETY STOP 10 P N 794 9464 Rev 3 1 SURE FLAME IX1500 Series Operation amp Service Manual Maintenance Warning Disconnect gas and electrical supplies before servicing Weekly Gas Hose Check for cracks and damaged connectors Air flow Remove any obstructions to air flow Bearings Lubricate bearings according to details below Monthly Cords and Connectors Check for cracks exposed wires and dirt in electrical connectors Physical Integrity Check for damage to body louvers and inlet screens that may obstruct air flow and impact combustion quality Belts Replace belts accordingly to details below End of Season Combustion Chamber Remove burner assembly and clean inside of combustion chamber with a wire brush Vacuum all ash and soot from combustion chamber Inspect combustion chamber for any damage Do not use a heater that has a hole i
22. is Warning First This heater is designed and approved for use as a construction heater under ANSI 283 7 2011 CSA 2 14 2011 The primary purpose of construction heaters is to provide temporary heating of buildings under construction alteration or repair and to provide temporary emergency heat Properly used the heater provides safe economical heating Since the products of combustion are released it is imperative that the flue stack is extended outside of the enclosed area when the heater is positioned indoors This heater is not designed as an Unvented Gas Fired Room Heater under ANSI Z21 11 2 and should not be used in the home ANSI A119 2 NFPA 501C 1987 Recreational Vehicle Standard prohibits the installation or storage of LP Gas containers even temporarily inside any recreational vehicle The standard also prohibits the use of Unvented Heaters in such vehicles Installation must comply with local codes or in the absence of local codes with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and the Standard for the Storage and Handling of Liquified Petroleum Gases ANSI NFPA 58 Gas inspection authorities in Canada require that the installation and maintenance of heaters and accessories be accomplished by qualified gas fitters Installation must comply with local codes and with the Natural Gas and Propane Installation Code CSA B149 1 We cannot anticipate every use which may be made for our heaters CHECK WITH YOUR LOCAL FIRE SAFETY AUTH
23. it switch failure too sensitive P N 794 9464 Rev 3 1 SURE FLAME IX1500 Series Operation amp Service Manual INT SOLID OFF Main blower does not cycle e Fan limit switch failure Contacts fail to 0 5s Burner cycles and then turns off close e Fan limit switch limit set point too high Hi limit switch opens INT SOLID OFF Flame sense error e Exhaust Hi limit switch fails to break 0 5s Too long or to small diameter vent pipe air starved flame e Too much back pressure in exhaust system Too long or too small vent pipe Exhaust Hi limit switch stopped the function e Unstable burner yellow flame INT SOLID OFF Burner will fail to stay lit at start e Exhaust Hi limit switch failure too 0 5s up or soon after with no or very sensitive sort exhaust pipe neon light ON INT SOLID OFF Flame controller in 2 position e Interruption in gas delivery 0 5s with error light on e clogged filter or strainer e defective safety solenoid valves e gas regulator vent is plugged SOLID INT INT Heater starts ok but fails in e Too much load on power supply 159 1m function e Main blower motor or burner motor overloaded e Low Voltage SOLID INT INT Burner starts ok but quits when e Too long or too light power cord Ewe rm Main blower attempts to start e Low Voltage E Burner blower starts Flame starts but main blower does not pressed motor turns Visible
24. justed to a lower value 18 P N 794 9464 Rev 3 1 SURE FLAME IX1500 Series Operation amp Service Manual SOLID OFF OFF Noisy burner fan operation Yellow e Burner blower belt too loose flame and high CO generation SOLID OFF OFF Noisy fan operation High vibration e Damaged or unbalanced fan Structural damage to fan and or blade bearing SOLID OFF OFF Fan limit switch limit switch opens e Inlet duct too long Burner cycles more often e Outlet duct too long SOLID OFF OFF Noisy operation heater body e Heater not positioned on a level vibration surface SOLID OFF OFF Fan limit switch Limit control opens e Wrong Phase 3 PH reversed phase SOLID OFF OFF Static charge Static shocks e Improper grounding UV Flame detection works ok SOLID OFF OFF Heater working all the time doesn t e Thermostat failure react to adjusted temperature on the thermostat stops if thermostat is disconnected SOLID INT OFF The heater runs properly intermittent e Burner stopped without post 0 5 0 5 sec red light purge or S a Thermostat turned on off do to cold drafts P N 794 9464 Rev 3 1 19 E Le lt 3 TR z wi IX1500 Series Operation amp Service Manual IX1500L IX1500NC Wiring Diagrams 1 stage A120V Always 120VAC S120V Swiched 120VAC GAS VALVE STAGE I DIN PLUG Fan Limit Switch
25. n the combustion chamber Heat Exchanger Inspect the heat exchanger for any damage Do not use a heater that has a hole in the heat exchanger Remove any dust or dirt from heat exchanger enclosure with a metal brush and compressed air blower Burner Remove burner from burner assembly Clean UV sensor and igniter with solvent or emery cloth Inspect for cracked ceramic Ensure the igniter is centered in the burner openings Inspect wires for cracks or evidence of overheating Ensure burner head screws are tight Ensure gasket is in place and not damaged Electrical components Check all wiring for loose cracked or overheated wires and connectors Replace if necessary Ensure ground wires are properly connected Ensure control box seal is in place and not damaged Electric Motors Wipe dirt from motors Motors do not require lubrication Valve Train Impellers Verify that manifold pressure matches the specification label Adjust regulator pressure if necessary accordingly to details below Inspect strainer and clean if necessary Using soapy water or gas leak detector check all gas connections for leaks Remove any dirt build up on both burner and blower impellers Inspect impellers for loose or damaged fins Run heater and check for vibration Replace impellers that are damaged or causing vibration Body Ensure all panels and shields are in place and that fasteners are tight P N 794 9464 R
26. rty SOLID OFF OFF Burner motor runs and Flame e Low voltage Burner blower controller dial turns thru cycles overload without starting up the burner e Wrong voltage setting on the transformer check for 120VAC on X1 to X2 terminal of the step down transformer SOLID INT OFF Burner motor runs and Flame e Low Voltage too long or too light Ewe controller dial turns thru cycles power cord Wrong power source without starting up the burner SOLID OFF INT The green push button turns on e Start switch green failure Contacts 30 3 immediately after powering up welded or push button jammed sec the heater The heater starts and OFF shuts down after 30sec P N 794 9464 Rev 3 1 15 X1500 Series Operation amp Service Manual SURE FLAME C Burner blower does start Flame does start but goes out after a few seconds Green Red Blue Start Stop Fan Push Push Push Symptom Possible Problem Button Button Button INT SOLID OFF Flame controller stay in 1 position UV Sensor failure 0 5s with error light on Flame Rod failure Improper Grounding Back pressure in exhaust system Damaged burner bearings Burner motor overloaded Burner fails to stay lit e Burner blower belt too tight D Burner blower does start Flame does start but fails during operation 16 cycle and then turns off Green Red Blue Start Stop Fan 3 Push Pus
27. se burned out and Wrong voltage setting on the or wrong voltage on transformer transformer X1 to X2 terminal Flame controller stays in lt e Exhaust Hi limit switch defective position error e Heater Hi limit switch defective Overheated Hi limit switches 14 P N 794 9464 Rev 3 1 SURE FLAME B Burner blower does start Flame does not start IX1500 Series Operation amp Service Manual Green Red Blue B E E Symptom Possible Problem Button Button Button INT SOLID OFF Flame controller stay in A e Interruption of startup sequence 0 5s position with error light on Flame controller jumper terminals 6 7 8 disconnected Flame controller stay in P e No air pressure indication position with error light on e Air tube leaking or disconnected e Air switch adjusted too high e Air tubes plugged in wrong position instead of Air switch defective NO contacts stay open when burner blower is working Flame controller stay in M e Flame supervision problem UV position with error light on sensor shorted e Defective flame rod circuit short dew in burner chamber e Defective Flame controller Flame controller stay in 1 e Inlet pressure too high over 5 psi position with error light on e regulator damaged e Solenoid valve damaged or valve electric circuit defective e Gas pressure too low Manual cut off valve closed e Interruption in flame continuity e Strainer plugged or di
28. u h input to the heater 4 Turn off the propane supply valve at the container when the heater is not in use 5 The installation must conform with local codes or in the absence of local codes with the Standard for the Storage and Handling of Liquedied Petroleum Gases ANSI NFPA 58 or the Natural Gas and Propane Installation Code CSA B149 1 6 When the heater is to be stored indoors the propane container must be disconnected from the heater and the container moved away and stored in accordance with the above national standards INSTALLATION FOR NATURAL GAS APPLICATIONS 1 When installing the heater for use with natural gas set the gas selector valve to the Natural position 2 Aregulator must be installed on the heater to ensure that the pressure to the heater does not exceed 5 psi inlet pressure 3 The installation of this heater to a natural gas Supply must conform with all applicable local codes or in the absence of local codes with the National Fuel Gas Code ANSI Z223 1 NFPA 54 or the Natural Gas and Propane Installation Code CSA B149 1 8 P N 794 9464 Rev 3 1 e SURE FLAME IX1500 Series Operation amp Service Manual Operating Instructions Start 1 Set GAS SELECTOR VALVE to gas being used dual fuel models NOTE When using Propane Gas the Selector valve must be locked in position 2 Ensure the firing valve manual valve nearest the burner is in the ON position 3 Connect power Use appropriate
29. um 10 rise A minimum vertical length of 3 is required before the first elbow and after the last elbow T A minimum 3 of 12 vertical flue should be installed before reducing to smaller diameters Consult the manufacturer for additional venting options Gas Connections Ensure the correct regulator is used to supply the heater with maximum inlet pressure of 5 psi Excessive pressure will damage components and void the warranty Visually inspect the fuel supply hose assembly Ensure that it is protected from traffic building materials and contact with hot surfaces Replace if there is evidence of excessive wear or abrasion After installation check for gas leaks by applying a soapy solution at each piping and hose assembly connection P N 794 9464 Rev 3 1 7 FE E IX1500 Series Operation amp Service Manual SURE FLAME INSTALLATION USING A PROPANE SUPPLY TANK When installing the heater for use with propane gas set the gas selector valve to Propane and lock in position 2 Arrange the propane supply system to provide for vapour withdrawal from the operating container Supplying liquid propane to the heater is dangerous and will damage the components Another regulator must be installed on the heater to reduce the pressure from this regulator to a maximum inlet pressure of 5 psi 3 Ensure that for the surrounding temperature the size and capacity of the propane supply container is adequate to provide the rated Bt
30. v 3 1 e SURE FLAME IX1500 Series Operation amp Service Manual Troubleshooting The troubleshooting section has been divided in to six tables Choose the appropriate table from the list below Chart A Burner blower does not start Flame does not start Chart B Burner blower starts Flame does not start Chart C Burner blower starts Flame starts but goes out after a few seconds Chart D Burner blower starts Flame starts but fails during operation Chart E Burner blower starts Flame starts but main blower does not Chart F Other problems P N 794 9464 Rev 3 1 13 X1500 Series Operation amp Service Manual A Burner blower does not start Flame does not start SURE FLAME Green Red Blue Start Stop Fan i Push Push Push Symptoms Possible Problem Button Button Button OFF OFF OFF Nothermostat power light when e No electrical supply applicable No Green POWER 8 Main power switch off RUN LED on OMRON controller e Transformer failure No power on secondary side of e Control box circuit breaker is OFF step down transformer check for e Overload in control circuit 120VAC on X1 to X2 terminal of e Omron controller defective the step down transformer e High voltage wrong power source e Wrong voltage connection on the transformer Heater will not start No green e Start switch green failure light Secondary side of step
31. with theNational Fuel Code ANSI 223 1 NFPA 54 and or the Natural Gas and Propane Installation Code CSA B149 1 and applicable local regulations which should be carefully followed in all cases Authorities having jurisdiction should be consulted before installations are made The heater shall be used in a horizontal position on a firm non combustible surface The electrical grounding of the appliance shall be in compliance with National Electrical Code ANSI NFPA 70 or the CSA C22 1 Canadian Electrical Code Part Warning The installation and maintenance of the heater must be accomplished by a qualified service person The heater should be inspected before each use and at least annually Warning Do not use this heater in a space where gasoline of other liquids with flammable vapours are stored or used Clearances Clearance required for combustibles Front Outlet 20 ft 6 m Sides 2ft 0 6m Intake 2ft 0 6m Top 5ft 1 5m Ducts 1ft 0 3m Floor Noncombustible Minimum clearance required to LP Gas containers Outlet 25 ft 7 6 m Top amp Sides 10 ft 3 0 m Position heater properly on a horizontal surface before use The hose assembly shall be protected from traffic building materials and contact with hot surfaces both during use and while in storage For use with or without ductwork Only ductwork supplied by the manufacturer shall be used with this heater For either indoor or outdoor use Adequate ventil
32. y IX1500 L 1 IX 3740 Burner head Assembly IX1500NC 10 1093 Trim Seal Band 5 11 8708 Test Nipple 1 12 IX 3512 Burner Housing 1 13 IX 3037 Burner Gasket 1 14 9475 Observation Port 1 15 WR9GER 18 Hi Temp Ground Wire 1 16 WRIXX 30 Ignition Wire 1 17 9005 UV Flame Sensor 1 18 9407 Flame Spark Rod 1 19 IX 3057 Motor Mount 1 20 4708 Fan Wheel 1 21 9411 5 8 Flange Bearing Unit 2 22 4707 Inlet Cone 1 23 IX 3902 Burner Impeller Shaft 1 24 7746 Impeller Sheave 1 25 6133 Impeller Bushing 1 IX 3257 Ag Reflector not 1 P N 794 9464 Rev 3 1 29 IX1500 Series Operation amp Service Manual Valve Train Replacement Parts IX1500L 8 IX1500NC SURE FLAME Ref Part Description Quantity 1 4723 1 2 NPT Flange 2 2 8685 Gas Regulator 1 3 8648 Second Stage Shutoff Valve 1 4 4725 Combination Valve 1 5 2539 1 77 Ball Valve 1 6 IX 3733 Changeover Valve not use in IX1500NC 1 7 SL11B 715 1 7 Strainer Assembly 1 30 P N 794 9464 Rev 3 1 e SURE FLAME IX1500 Series Operation 8 Service Manual LPG PROPANE FUEL VAPORIZATION RATE The following chart shows the amount of BTU s that various sizes of tanks will produce on the average at specific temperatures and regular atmospheric conditions Maximum intermittent withdrawal rate BTU hr without tank frosting if lowest outdoor temperature average for 24 hours reaches 40F 30F
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