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ifl series comfort systems

1. 4 This manual of instructions has been prepared in order Section IV Pre Start Up 11 for you to become well acquainted with those details Section V Unit Start Up 13 and in doing so you will be able to give your Packaged Section VI Unit Shut Down 17 Comfort System the care and attention which any Section VII Troubleshooting 17 piece of equipment needs and deserves Section VIII Flue Gas Analysis 39 Section IX Maintenance Schedule and Itisthe customer andinstallation personnel Lubrication Requirements 40 responsibility to determine if the unit is equipped Section X Mestek Line Burner 45 With all of the safety devices required for the Section XI Circuit Analysis particular application Safety considerations amp Sequence and Burner Setup 46 include the accessibility of the unit to non service Section XII Thermistor Curve 47 personnel the provision of electrical lockout Section XIII Replacement Parts 47 switches maintenance procedures and automatic control sequences Clearly mark allemergency shutoff devices IMPORTANT NOTICE The factory assumes no responsibility for loss or
2. 2 Connect the other end of the cable to the igniter or igniter sensor stud on the pilot burner igniter sensor CONNECT IGNITION MODULE NOTE Refer to Fig 2 and Table 4 for the location of each connection Connect remaining system components to the ignition module terminals as shown in the appropriate wiring diagram Fig is a basic circuit for the H and M models used heating systems with atmospheric burners Fig 4 shows the basic circuit for the B and C models with separate sensor and igniter in a heating system with atmospheric burners Fig 5 8 show typical circuits for power assisted combustion applications and two stage gas control with power assisted combustion applications MAKE FLAME SENSE CONNECTION For B C J and K models These models have remote flame sensing two rod Connect the flame sensor wire from the Pilot burner igniter to the SENSE connector on the ignition module For H M D and E models These models have local flame sensing single rod The spark lead carries the flame signal CONNECT GAS CONTROL Use 18 gauge solid or stranded wire Use 1 4 in female quick connects for module connections Connect to gas control terminals as shown in wiring diagrams using terminals appropriate to the gas control GROUND CONTROL SYSTEM The igniter flame sensor and ignition module must share a common ground with the pilot burner Use thermoplastic insulated wire with a minimum rating
3. Failure to provide maintenance as recommended may void the equipment warranty A Maintenance Schedule 1 Daily a Check gauges monitors instruments and equipment settings 2 After 8 hours of operation a Check that fan belts are tight and sheaves are aligned The fan belts can be checked every 30 days after the first 60 days of new belt run in CAUTION Do not overtighten belts b Check set screws and bolts on the fan s bearings couplings and burner assembly c Check gas pressure at regulator 3 After 48 hours of operation check bearings for any unusual vibration or excessive temperature 4 Monthly a Check all valves piping and connections for leaks b Check the flame signal and safety lockout circuit c Check the fuel pressure in the fuel supply line to each heater d Check the burner manifold pressure and draft e Do a llue gas analysis f Inspect filters Clean or replace as necessary g Inspect the main fan bearings lubricate if necessary See following section on bearing maintenance h Check all dampers damper actuators and linkages Adjust and tighten if necessary i Ensure that there are no obstructions blocking the discharge air opening condensor fans coil s or heater j Inspect the area and make sure that no combustible or hazardous material has been stored within the clearances as shown on the unit nameplate k Check and clear all air sensing tubes and fittings CAUTION Remove t
4. These controls provide flame sense and operating sequences suitable for the application Table 1 Intermittent Pilot Ignition Models Valve Igniter Current Trial for Ignition Sensor Rating Prepurge Pilot Sequence Type 024 Timing Ignition Type Ignition Sequence Description S8600B Separate 1 0 A Pilot 15 or 90 Lockout Spark and pilot gas ON until lightoff or trial for ignition and seconds as ends If pilot fails to light pilot gas and spark OFF 1 0 A Main ordered 100 shutoff and lockout Cycle Call for Heat to restart ignition sequence lightoff or Call for Heat is removed 58600 Combination 1 0 A Pilot 15 or 90 Lockout Spark and pilot gas ON until lightoff or trial for ignition and seconds as ends If pilot fails to light pilot gas and spark OFF 1 0 A Main ordered 100 shutoff and lockout Cycle Call for Heat to Separate 1 0 A Pilot 15 or 90 Continuous Spark and pilot gas ON until lightoff or trial for ignition and seconds as Retry ends If pilot fails to light pilot gas and spark OFF 1 0 A Main ordered 100 shutoff After 5 minute delay a new trial for ignition is initiated This sequence continues until 58600 restart ignition sequence S8600M Combination 1 0 A Pilot 15 or 90 Continuous Spark and pilot gas ON until lightoff or trial for ignition and seconds as Retry ends If pilot fails to light pilot gas and spark OFF 1 0 A Main ordered 100 shutoff After 5
5. replace it If the appliance is likely to be cleaned with water or steam protect cover the controls and wiring from water or steam flow Mount the controls high enough above the bottom of the cabinet so they do not get wet during normal cleaning procedures Use a NEMA 4 enclosure for the ignition control High Humidity or Dripping Water Dripping water can cause the control to fail Never install an appliance where water can drip on the controls In addition high ambient humidity can damage the control If the appliance is in a humid atmosphere make sure air circulation around the controls is adequate to prevent condensation Also regularly check out the system A NEMA 4 enclosure is recommended for the ignition module Corrosive Chemicals Corrosive chemicals can attack the module and gas control eventually causing a failure If chemicals are used for routine cleaning make sure they do not reach the controls Where chemicals are suspended in air as in some industrial or agricultural applications use a NEMA 4 enclosure for the ignition module Dust or Grease Accumulation Heavy accumulations of dust or grease can cause controls to malfunction Where dust or grease can be a problem provide covers for the module and the gas control to limit contamination A NEMA 4 enclosure is recommended for the ignition module Heat Excessively high temperatures can damage controls Make sure the maximum ambient temperature at the co
6. screws one down each side spaced approximately 8 10 inches apart down the entire length of the seam 5 Apply two strips of tacky tape one down each side to the back side of each hugger strip Fig 2 Secure hugger strip with two rows of TEK screws one down each side spaced approximately 8 10 inches apart down the entire length of the seam 6 After hugger strips are installed caulk around the edges to complete the seal 7 Repeat this process for each section as it is at tached The number of sections varies by applica tion NOTE HOOD REQUIRES ADDITIONAL INSTALLER PROVIDED SUPPORT DETAIL A DETAIL A lt NIV TACKY TAPE 8 O C TACKY TAPE FIGURE 2 DETAIL B CAULK ROOF CAP STANDING FIGURE 4 C 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 Adequate building relief must be provided so as to not over pressurize the building when the system Is operating at its rated capacity This can be accomplished by taking into account through standard engineering methods the structure s designed infiltration rate by providing properly sized re
7. Green LED Flash Code X No Call for Heat 5 minute Retry Delay Pilot flame not detected during trial for ignition Recycle Flame failed during run Flame sensed out of sequence Flame sense leakage to ground Low secondary voltage supply below 15 5 Vac 5 minute Retry Delay On every third retry on the same Call for Heat On every 6th flame failure during run on the same Call for Heat Flame sensed out of sequence longer than 10 seconds Soft lockout due to error detected during self check sequences a Flash Code Descriptions Flash Fast rapid blinking Next System Action Recommended Service Action Napa NOM Flash Fast Startup Flame sense Not applicable None calibration Heartbeat Normal operation Not applicable Initiate new trial for ignition after retry delay completed Initiate new trial for ignition Flash code will remain through the ignition trial until flame is proved If situation self corrects within 10 seconds control returns to normal sequence If flame out of sequence remains longer than 10 seconds control goes to Flash code 6 4 see below Control remains in wait mode When the fault corrects control resumes normal operation after a one minute delay Control remains in wait mode When the fault corrects control resumes normal operation after a one minute delay Initiate new trial for ignition after retry delay completed 5 minute re
8. be checked by reducing the setting of its trip point lower than the burner operating pressure The switch should trip out and shut off the burner Return the adjustment to its original setting and reset to resume operation Temperature Controls The temperature controls are checked by adjusting control to a higher temperature to allow burner to cycle on Adjust control to a lower temperature to allow burner to cycle off Return the adjustment to its original setting Limit Controls The limit controls are checked by adjusting control to a lower temperature setting while the unit is operating on high fire and observe cut off Return the adjustment to its original setting Manual reset may be required on some controls Make sure all the safeties and controls are working properly 15 SECTION V continued UNIT START UP COOLING Before attempting to start the cooling read and understand the sequence of operations and electrical schematic and the Digital Control System user manual WARNING During installation testing servicing and troubleshooting of this product it may be necessary to work with live electrical components Have a qualified licensed electrician or other individual who has been properly trained in handling live electrical components to perform these tasks Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury Make sure
9. components connections and terminals Clean and tighten where necessary g Test ignition spark Adjust gap if necessary h Clean ignition electrodes and check for cracks i Testignition control and replace components if necessary j Inspect all regulators relief valves motorized valves solenoid valves vent valves manual shut off valves and safety shut off valves Check their operation and clean as necessary k Ensure all vents to the atmosphere are clean and free from obstruction Inspect and clean all drip legs in the fuel line Lubricate fan motor as directed by motor manufacturer Inspect all motor wiring for loose connections Lightly oil all door latches Check that the battery on the UC 01 has 3 VDC Do not remove or replace the battery with the power turned off to the control q Check all nuts and bolts for tightness O23 NOTE Keep screened air intakes clear of obstruc tions at all times r Check the condensate lines for any leaks or blockage s Inspect the combustion chamber and vent for any signs of carbon deposits soot or scale Clean if necessary 40 Lubrication Instructions Item Manufacturer Bearing Type All 3 phase US Baldor Single row ball fan motors or equal bearings 1 HP to 100 HP ODP TEFC Recommendation See following note Bronze sleeve bearings All 1 phase motors Fractional HP ODP TEFC or TEAO Century G E or equal Recommendatio
10. damage in transit therefore you should protect yourself by following these instructions Failure to do so is your responsibility BILL OF LADING Save your bill of lading It is a contract and you will need it provided you have to file a loss or damage claim Remember claims are outlawed after nine months LOSS INTRANSIT Before you sign for this shipment check against the bill of lading also the transportation company s delivery ticket Make sure that you get the exact total of articles listed Should the delivery ticket show more or less items than you are offered then the carrier s agent must mark the difference on your freight bill before you sign VISIBLE DAMAGE IN TRANSIT If something is damaged accept the shipment only if the carrier s agent places a notation on your freight bill explaining the nature and extent of damage Upon inspection of article make claim to the delivering carrier CONCEALED DAMAGE IN TRANSIT Sometimes transit damage is not noticed until the goods are unpacked In such cases notification to the carrier must be made within fifteen 15 days of receipt of shipment In such cases save the packages and packing material then notify the transportation company at once and request an inspection When the inspector calls have him make out and leave a concealed bad order report He is obliged to give you one Insist on it DISPOSITION OF DAMAGED ARTICLES Never return damaged articles to us T
11. heat APPEARANCE CAUSE SMALL BLUE FLAME CHECK FOR LACK OF GAS FROM CLOGGED ORIFICE FLTER CLOGGED PILOT FILTER LOW GAS SUPFLY PRESSURE PILOT ADJUSTMENT AT MINIMUM LAZY YELLOW FLAME CHECK FOR LACK OF AIR FROM DRTY ORIFICE DRTY LINT SCREEN IF USED DRTY PRIMARY AIR OPENING IF THERE IS ONE PILOT ADJUSTMENT AT MINIMUM WAVING BLUE FLAME CHECK FOR EXCESSIVE DRAFT AT PILOT LOCATION RECIRCULATING PRODUCTS OF COMBUSTION NOISY LIFTING BLOWING FLAME CHECK FOR HIGH GAS PRESSURE HARD SHARP FLAME THIS FLAME IS CHARACTERISTIC OF MANUFACTURED GAS CHECK FOR HIGH GAS PRESSURE ORIFICETOO SMALL M2233B Fig 11 Examples of unsatisfactory pilot flames Recheck ignition sequence as follows Reconnect main valve wire Set thermostat to call for heat Watch ignition sequence at burner If spark still doesn t stop after pilot lights replace ignition control e f main burner doesn t light or if main burner lights but system locks out check the control ground wire and gas control as described in Troubleshooting on page 11 and refer to the Troubleshooting Guide Fig 13 69 1954 LED Status and Troubleshooting The control has two LEDs one for flame sensing and one for system status m i SPARK j D Pir Pte YA Man LL UC fac Trad z igs one 59 FLAME LED STATUS LED M23440 Fig 12 Lo
12. it The Low side should be to atmosphere and positioned so it is not exposed to the weather 4 With the use of a BACview 6 01 place the unit in the Building Pressure mode See the Digital Control System User Manual 5 The voltage at COM and OUT will vary between 0 to 5 VDC O VDC means the building is in a negative pressure and should open the Outside Air Profile and close the Return Air damper 5 VDC means the building is in a positive pressure and should open the Return Air Damper and close the Outside Air Profile Damper PT 13 SETRA P N MESTEX P N RANGE 26510R1WBABT1C 68 0330 69 1 IN WC 30 MULTIPLEXED VOLTAGE CHART HE amm VALUE RESISTOR ID CLOSED CIRCUIT VOLTS DC RS1 2 3 4 RS2 3 4 RS1 3 4 RS3 4 RS1 2 4 52 4 51 4 RS4 RS1 2 3 RS2 3 RS1 3 RS3 RS1 2 RS2 RS1 NONE UNPLUGGED MULTIPLEXED VOLTAGE VALUES IN 3 JUMPER RS 04 MIXED AIR TEMP IN 4 RE 56 RE 09 SW 2 RE 27 RE 65 RE 12 SW 09 RS 03 RS 02 RS 01 RS 04 RS 03 RS 02 RS 01 41 SAFETY STATUS FLAME FAILURE 100 OA or 100 OUTPUT BURNER STATUS FAN STATUS CLOGGED FILTER AUXILIARY UNIT ENABLE SECTION VII TROUBLE SHOOTING continued Fan and Heat Mode A Supply blower does not operate Burner motor MT 08 does not run or operate correctly and supply fan is enabled Low or no voltage Fuse s blown or circuit breaker open Customer s interlock not closed or conn
13. or to the gas control manifold of the heater See the Troubleshooting Guide for replacement of motor If the proper voltages are not obtained and the wiring is correct the problem can be isolated to the electronics See the Troubleshooting section and the Digital Control User Manual CIRCUIT ANALYSIS BURNER MOTOR Connect a DC voltmeter capable of reading 0 10 VDC on the input terminals to Burner Blower Motor Control 01 The operation of the burner motor MT 08 with regard to voltage is as follows For a furnace size 160 it is 1 to 7 25 VDC For a furnace size 320 it is 1 to 5 VDC Fora furnace size 480 it is 1 to 7 5 VDC With these voltages present the burner motor should be performing its modulating function and the motor should be running at a modulated flow rate between low and high speed depending upon the voltage At the highest volts DC the motor should be delivering full airflow to the heater and the burner should be in high fire If the DC voltage is obtained on the burner blower motor control input terminals and the burner motor does not respond as described the problem can be isolated to the motor itself burner blower motor control or the incoming power supply NOTE With the incoming power applied and if the feedback signal wires are loose or disconnected the burner motor will run at maximum speed TACH MONITOR The operation of the burner motor MT 08 with regard to the minimum fan speed is a
14. that all piping connections particularly unions are tight Check all gas piping for leaks using a soap bubble solution The most common types of problems found relative to the gas train itself is foreign material within the gas piping This will interfere with the proper operation of the gas train components and burner Purge all air from gas lines per gas codes 14 Check that all accessories requiring field wiring have been properly installed 15 Check that burner is securely mounted 16 Check that filters filter stops accessories and ship loose items are installed correctly 17 Check that vent lines if applicable are run to at mosphere on gas regulators and pressure switches for indoor units Vent lines should terminate out side the building with a turndown elbow and bug screen Note that some units will use vent limiters and vent lines are not required If vent lines are even partially plugged this will interfere with proper venting of pressure control devices 18 Check that all manual gas shut off valves are closed 19 When failure or malfunction of this unit creates a hazard to other fuel burning equipment e g when the unit provides make up air to a boiler room the unit is to be interlocked to open inlet air dampers or other such devices 20 Motor overload relay setting should match the mo tors nameplate full load amperage 21 Check that dampers and linkages are free to move and that linkages are tight 2
15. 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 He check approval prints prior to installation Be sure that there are no obstructions to ducting and that proper planning has been exercised in connection of piping and or electrical services The curb assembly may be bolted or welded to either trusses or roof decking however connection to roof trusses is recommended The curb is designed to carry the weight of the unit Additional support is required for certain applications Placement of the curb is critical in squareness and leveling Shims for leveling must be applied to the curb application of shims to the unit will tend to destroy the sealing effect after installation Make sure sealing tape is in place before unit is set Be careful not to allow gaps where two pieces of sealing tape meet A bubble level must be used in 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 On outdoor curb mounted installations flash and seal the roof curb to prevent leakage The cross section of factory provided curb is fo
16. to control valve MT 11 Incorrect VDC output voltage on UC 01 Incorrect room temperature Maximum or minimum heating discharge temperature setpoint not set correctly Foreign material holding ball valve open Open circuit in Outside Air Temperature Sensor TS 01 or Discharge Air Temperature Sensor TS 03 circuit or wiring Incorrect VDC output voltage on UC 01 1 Arrow on side of valve should point in direction of gas flow Check for 24 VAC Measure VDC across valve terminals Check for 24V AC at TR 08 Check voltage on AO 01 Check Outside Air Sensor TS 01 Space Temperature Sensor TS 02 and Discharge Air Sensor TS 03 for correct readings See Section XII for Themistor curve use a BACview 6 to read the space temperature TS 02 Check Space Temperature Sensor 75 02 setppoint Check Heating Occupied and or Unoccupied setpoint Install a BACview 6 or PC Remove and inspect valve and seat Check Outside Air Temperature Sensor 75 01 or Discharge Air Temperature TS 03 for opern internal circuit See Section XII for Thermistor curve 2 Check voltage on AO 01 Install properly Check and or replace valve Replace MT 11 if proper voltage is measured See troubleshooting guide and Section XI Prove the power source See Section XI Consult factory Replace Sens
17. 2 Check to make sure all manual reset safety devic es have been reset and limits are in their normal operating position 23 Check to make sure flue stack is installed properly and free from obstruction 24 Do not attempt to start the burner when furnace is full of vapor or combustion chamber is very hot 11 Suggested Tools and Instruments Volt Ohm Meter Tachometer Stack and Temperature Thermometer Gas Pressure Gauge 0 35 Ibs Ammeter Manometer 0 10 W C Flue Gas Test Equipment Draft Gauge Standard Hand Tools D C Voltmeter Microammeter BACview 6 Suggested Control Settings FL 02 High Limit Horz Discharge 200 F FL 02 High Limit Down Discharge 165 F FL 04 Auxiliary High Limit Horz Discharge 210 F FL 04 Auxiliary High Limit Down Discharge 175 F KP 01 Keypad Display Module Customer Discretion MP 05 Damper Control Potentiometer UOTE Customer Discretion MP 15 Unit Enable Potentiometer m Customer Discretion Low Gas Pressure Switch 1 0 W C High Gas Pressure Switch 125 above burner firing rate Clogged Filter Switch Adjust to field condition Building Pressure Transducer T RO Adjust to field condition Time Clock Customer Discretion Night Setback Thermostat Customer Discretion See Digital Control System User s Manual for
18. BER FACTORY ORDER F O and PART factory for normal ground service Warranty parts must be NUMBERS are required Belts filters and fuses are returned prepaid within 30 days Credit will be issued if not covered under warranty part is complete defective and returned on time Dealer Contractor Name Address City otate Zip Ph 47 e Applied 4830 Transport Drive Dallas TX 75247 Phone 214 638 6010 Fax 214 905 0806
19. DDC Controller default settings PS 04 PS 07 PS 12 PT 13 RE 21 TC 09 BEFORE ATTEMPTING TO START THE HEATER READ THE TYPICAL SEQUENCE OF OPERATION AS SHOWN BELOW Typical Sequence of Operations Note This sequence is written for only the burner safety and operating portion of the heater Other control systems for dampers mixing boxes and temperature controls are included in the unit typical sequence of operation and or wiring diagram 1 With main supply air blower on and DO 2 on UC 01 Unit Control Module is energized and all switches and operating controls in their normal position the burner motor will run and pre purge the combustion chamber Pre purge timing is not adjustable and is approximately 30 seconds 2 With pre purge timing complete the pilot and or gas valve along with the spark source are ener gized If the pilot and or burner does not light off or sense a flame before the end of the 15 second trial for ignition time the control will shut off the spark and pilot and or gas valve 100 shutoff Remove and restore the power source to reset the control 3 With the pilot and or burner flame established and when a sufficient flame current is sensed the spark source is de energized and the pilot and or gas valve remains on 4 The system is now in the run mode with the presence of the flame being continuously monitored by the flame rectification circuit If the flame goes out the control sens
20. E A BACview or PC is required to change settings See the Digital Control System User Manual for a more detailed sequence of operation HIGH FIRE MANIFOLD ADJUSTMENT Prior to setting high fire you should have your test equipment installed and be familiar with the gas valve VG 02 and its adjustment Check to make sure the correct DC voltage is present at the input terminals to the MT 11 Modulating Motor and MT 08 Burner Motor see Circuit Analysis Modulating Gas Valve Motor and Burner Motor The modulating motor should be fully open and the burner motor should be at full speed Adjust the regulator on VG 02 for the high fire setpoint refer to the rating plate on unit for Normal Manifold Pressure in inches of w c The typical high fire flame should be blue and approximately 12 to 18 inches long with short orange to yellow tips Ensure proper overfire draft in high fire at test port in heat exchanger is set per rating plate After high fire has been set low fire requires no further adjustment Cycle the burner several times to be sure it lights off reliably 46 SECTION XII THERMISTOR OUTPUT CURVE Typical 10 000 Ohm Thermistor Output Curve o z O Q c G o o tc Temperature in Degrees F SECTION XIII REPLACEMENT PARTS Replacement parts may be ordered from the factory When parts are ordered MODEL NUMBER SEHIAL All warranty parts will be shipped freight allowed from NUM
21. ION REMOVE MV LEAD AT MODULE IF VALVE CLOSES RECHECK TEMPERATURE CONTROLLER AND WIRING IF NOT REPLACE GAS CONTROL YES REPEAT PROCEDURE UNTIL TROUBLE FREE OPERATION IS OBTAINED M23441 Fig 13 Troubleshooting Guide 69 1954 29 TROUBLESHOOTING GUIDE Modulating Gas Valve Motor Replacement Siemens actuator MT 11 1 RED G 24 VAC 2 BLACK GO 24 VAC Signal ground 8 GRAY Y 0 10 VDC Signal 9 PINK U 0 10 VDC Output Feedback Shaft adapter Ps 6 32 Hex nut 10 32 x 1 2 in hex bolt Sheet metal mounting bracket 6 32 x 5 16 in hex bolt 10 32 Hex nut Ball valve When replacing the modulating gas valve motor MT 11 make sure the ball valve is in the closed position Rotate the shaft adapter until the notches located on top of the ball valve and the shaft adapter indicate that the ball valve is in the closed position To Calibrate the Building Pressure Transducer PT 13 1 Remove the tubes at the Low and High pressure fittings 2 The voltage at COM and OUT should be 2 5 VDC If not adjust Z do not adjust S 3 Make sure the Low and High fittings are clean and clear do not insert any sharp objects into the pressure fittings Make sure the tubing is also clean clear of any debris and then reinstall the tubes on the transducer It is very important that the High tube be placed inside the building and positioned so that air movement does not affect
22. MAIN GAS VALVE FLAME STABILIZATION 2 SECONDS NO MORE THAN 5 FLAME LOSSES IN THIS CALL FOR HEAT CLOSE MAIN GAS VALVE AND PILOT GAS VALVE NO YES YES YES LOCKOUT CLOSE MAIN GAS VALVE AND PILOT GAS VALVE RETRY OR LOCKOUT MODEL RETRY Fig 10 Normal Operating Sequence for Prepurge Models 69 1954 25 S8600B C H M S8610B C H M S8670D E J K INTERMITTENT PILOT GAS IGNITION CONTROL TROUBLESHOOTING WARNING Fire Explosion or Electrical Shock Hazard Can cause severe injury death or property damage Do not attempt to modify the physical or electrical characteristics of this device in any way Replace it if troubleshooting indicates a malfunction IMPORTANT 1 The following service procedures are provided as a general guide Follow appliance manufac turer s service instructions if available 2 Meter readings between the gas control and igni tion control must be taken within the trial for igni tion period Once the ignition control shuts off lockout models must be reset by setting the ther mostat down for at least 30 seconds before con tinuing On retry models wait for retry or reset at the thermostat 3 If any component does not function properly make sure it is correctly installed and wired before replacing it 4 The ignition module cannot be repaired If it mal functions it must be replaced 5 Only trained experienced service te
23. MPERATURES SPARK OK NO REPLACE MODULE TURN GAS SUPPLY ON AND RECYCLE CALL FOR HEAT CHECK THAT ALL MANUAL GAS VALVES ARE OPEN SUPPLY TUBING AND PRESSURES ARE GOOD AND PILOT BURNER ORIFICE IS NOT BLOCKED CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND PILOT OPERATOR ON GAS CONTROL CHECK FOR 24 VAC ACROSS PV MV PV TERMINALS ON MODULE IF VOLTAGE IS OKAY REPLACE GAS CONTROL IF NOT PILOT BURNER LIGHTS REPLACE MODULE NOTE IT MAY BE NECESSARY TO RECYCLE THE CALL FOR HEAT TO CLEAR THE PILOT SUPPLY TUBES OF AIR YES NOTE IF CONTROL GOES INTO LOCKOUT OR RETRY DELAY RESET THE CALL FOR HEAT CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE CLEAN FLAME ROD CHECK ELECTRICAL CONNECTIONS BETWEEN FLAME ROD AND MODULE SPARK STOPS WHEN PILOT IS LIT NO CHECK FOR CRACKED CERAMIC FLAME ROD INSULATOR CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE ADJUST PILOT FLAME IF PROBLEM PERSISTS REPLACE MODULE YES MAIN BURNER LIGHTS YES NOTE IF CONTROL GOES INTO LOCKOUT OR RETRY DELAY RESET THE CALL FOR HEAT CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE NOTE IF GROUND IS POOR OR ERRATIC SHUTDOWNS MAY OCCUR OCCASIONALLY EVEN THOUGH OPERATION IS NORMAL NO AT THE TIME OF CHECKOUT CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE ADJUST PILOT FLAME IF CHECKS ARE OKAY REPLACE MODULE SYSTEM CHECK FOR PROPER THERMOSTAT CONTROLLER OPERAT
24. N VII TROUBLE SHOOTING continued Cooling Mode A There is no voltage at Cooling mode is disabled Enable the cooling mode cooling relays RE 34 RE 35 and or RE 33 and fan is enabled Cooling relays RE 34 RE 35 and or RE 33 are energized and condensing unit or evaporative cooler is not on Incorrect Space Temperature Auxiliary switch on starter ST 01 is not closed Cooling Changeover and or Economizer Setpoints not set correctly DO 3 and or DO 4 are not energized Open circuit in TS 01 and or TS 03 Cooling relays RE 34 RE 35 and or RE 33 contacts are not closed Cooling relays RE 34 RE 35 and or RE 33 contacts are not wired correctly Compressors or evaporative pump not running Incorrect Maximum Cooling Discharge Temperature Setpoint Incorrect Minimum Cooling Discharge Temperature Setpoint Unit Enable Potentiometer MP 15 not set correctly Cooling Occupied and or Unoccupied setpoints not set correctly Insufficient cooling Condensing section or evaporative cooler is not operating correctly 2 Check auxiliary circuit wiring and contact Change to correct setpoints See Digital Control User Manual See Digital Control System User Manual Mesure resistance per Thermistor Curve in Section XII replace if necesary Check and or replace Correct wiring See Troubleshootin
25. ONOXIDE Your venting system must not be blocked by any snow snow drifts or any foreign matter Inspect your venting system to ensure adequate ventilation exists at all times Failure to heed these warnings could result in carbon monoxide poisoning symptoms include grogginess lethargy inappropriate tiredness or flu like symptoms The venting system shall terminate at least four feet below four feet horizontally from or one foot above any door window or gravity air inlet into any building The Canadian B149 1 Natural Gas Installation Code specifies a six foot 1 83m horizontal vent terminal clearance to gas and electric meters and relief devices Through the wall vents for these heaters shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators relief valves or other equipment The vent pipe diameter must be as shown in following chart The stack diameter should be increased one size if the vent pipe is over fifty 50 feet in equivalent length Minimum Stack Diameter 200 MBH Input 160 MBH Output 400 MBH Input 320 MBH Output 6 600 MBH Input 480 MBH Output The vent pipe should be fitted with a drip leg with a clean out and a drain plug in the bottom The vent pipe shall be constructed so that any water that collects in the stack will remain in the stack drip leg and not drain back into the he
26. Over150 F Clean weekly Any Speed Upto150 F Dirty 1 week to 1 month Any Speed Over150 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 41 Model Shaft Size Set Screw VPS 212 3 4 VPS 214 7 8 VPS 116 1 VF2S 116 1 VPS 219 1 3 16 VFAS 219 1 3 16 VPS 220 1 1 4 VPS 223 1 7 16 VPS 323 1 7 16 VF4S 227 1 11 16 VPS 327 1 11 16 VPS 231 1 15 16 VF4S 231 1 15 16 VPS 331 1 15 16 VPS 235 2 3 16 VF4S 235 2 3 16 VPS 236 2 1 4 VPS 239 27 16 VF4S 243 2 11 16 VPS 343 2 11 16 VPS 347 2 15 16 BOA Concentric VPB 231 1 15 16 VPB 331 1 15 16 Spherical Roller SPB 1000 NE 1 3 16 SPB 1000 NE 1 7 16 SPB 1000 NE 1 11 16 SPB 1000 NE 1 15 16 SPB 1000 NE 2 3 16 SPB 1000 NE 2 7 16 SPB 1000 NE 2 11 16 SPB 1000 NE 2 15 16 Sealmaster Sleevloc SPB 2115 C2 1 15 16 When replacing bearings refer to the manufacturers Browning Bearing Set Screw Torque Values 7 Remove the shaft from the unit by sliding the Torque in Ibs 66 85 66 85 66 85 66 85 66 85 66 85 126 164 126 164 126 164 126 164 228 296 228 296 228 296 228 296 228 296 228 296 228 296 228 296 348 452 348 452 348 452 220 240 220 240 290 380 290 380 290 380 290 380 290 380 620 930 620 930 620 930 65 bearings and blower wheels along the shaft as the shaft is extracted Unless a blower wheel is damaged it shou
27. Potentiometer not wired correctly Buidling Pressure Transducer Install correctly See section on PT 13 or Damper Control trouble shooting PT 13 Potentiometer not installed correctly Unit Control Module UC 01 Check and or replace Contact defective Factory Unit Control Module UC 01 not Check wiring wired correctly Damper motor defective Check and or replace Dampers binding and or loose Check and repair as necessary Refer to Digital Control System User Manual for additional troublehooting suggestions 34 SECTION VII TROUBLE SHOOTING continued Modulating Discharge Temperature MDT or VDT EXPERT Controls Portions reproduced with permission from Maxitrol Symptom Possible Cause Field Test No Gas Flow with DO 2 on UC 01 energized No Gas Flow or Continuous Low Fire on MT 11 Electronics Problem Continuous Low Fire Electronics OK Continuous High Fire Electronics Problem Continuous High Fire Electronics OK Incorrect Maximum Fire G Incorrect Discharge Air Temperature Main gas valve improperly installed Defective main gas valve No voltage to modulating motor 11 Incorrect VDC output voltage on UC 01 Short circuit or open circuit in modulating motor MT 1 1 Open circuit in Outside Air Temperature Sensor TS 01 or Discharge Air Temperature Sensor TS 03 circuit or wiring Incor
28. SHEHSH Applied Air INSTALLATION OPERATION AND MAINTENANCE MANUAL FOR IFL SERIES COMFORT SYSTEMS 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 fournisseur de gaz WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or death Read the installation operating and maintenance instructions thoroughly before installing or servicing this equipment AVERTISSEMENT Une installation
29. WER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED ALTERNATE LIMIT CONTROLLER LOCATION A MAXIMUM CABLE LENGTH 3 FT 0 9 M A CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO TRANSFORMER M23436 Fig 8 S8600 B C S8610 B C S8670 J K connections with remote flame sensing in a heating system with a two stage gas control and power assisted combustion CHECKOUT Check out the gas control system At initial installation of the appliance As part of regular maintenance procedures Maintenance intervals are determined by the application See Planning the Installation on page 2 for more information As the first step in troubleshooting Any time work is done on the system A WARNING Fire or Explosion Hazard Failure to heed these warnings may cause fire or explosion with property damage injury or loss of life 1 If you smell gas or suspect a gas leak turn off gas at manual service valve and evacuate the building Do not try to light any appliance do not touch any electrical switch or telephone in the building until you are sure no spilled gas remains 2 Gas leak test must be done as described in the steps below on initial installation and any time work is done involving the gas piping Step 1 Perform Visual Inspection a With power off make sure all wiring connec tions are clean and tight b Turn on power to appliance and ignition module c Open manual shutof
30. able the fan MRT PRO With Smart Room Sensor To enable the fan and place the unit in the Occupied Mode press the Manual On button on the face of the TS 02 MRT PRO room sensor Pressing the Warmer button will add 30 minute increments of time for as total of 9 hours of operating time To disable the fan and place the unit in the Unoccupied Mode press and hold down the Manual On button Alternately pressing the Manual On button will also decrease the amount of operating time until it reaches zero and turns the fan off MRT Expert or VDT Expert With A BACview KP 01 To enable the fan go to Unit Modes and enter MANUAL this mode will enable the fan To also enable the fan go to Unit Modes and enter AUTO this mode has four different functions that control the fan and unit operation They are a Time Clock Heating and Cooling Night Setbacks and signal from an external source to an auxiliary digital input To disable the fan go to Unit Modes and enter OFF NOTE A BACview or PC is required to change Unit Modes For a more detailed control sequence see the Digital Control System user manual Turn main disconnect switch on and Enable fan When DO 1 fan relay is energized on UC 01 the damper opens if applicable after end switch has proven damper is open the blower will start see operating modes in Digital Control System user manual Disable the fan Check supply blower for pr
31. all cooling valves are open Make sure all doors and service panels have been closed or replaced Prior to unit start up condensate trap should be filled with water and checked for leaks Turn main disconnect switch off Check the incoming line voltage to match unit rating plate If voltage is over 10 of nameplate rating or phase voltage unbalance Is over 2 notify contractor or power company Cooling Is Enabled By The Following MDT amp MRT Standard To enable the cooling rotate the remote Temperature Setpoint knob MP 15 clockwise to the desired set point below the actual air temperature The allowable temperature range is 55 F to 90 F MRT PRO With Smart Room Sensor To enable the cooling press the Warmer or Cooler button on the face of the remote TS 02 MRT PRO room sensor to the desired room setpoint Each push of the button changes the temperature setpoint by 1 F The setpoint can be changed a maximum of 10 F from the default of 73 F Changing the cooling setpoint also changes the heating setpoint MRT or VDT Expert With a KP 01 BACview To enable the cooling for MRT Expert scroll thru the SETPOINTS menu in the BACview and enter the desired room Cooling Occupied and Unoccupied Setpoints For VDT Expert enter the desired Cooling Discharge Air Setpoints Energy Savings Mode Energy Savings Mode 4 can disable the cooling NOTE The cooling outputs are protected by an anti cycle ti
32. an alternative it can also be mounted with the terminals on either side IMPORTANT Do not mount with terminals facing up kha pim Simin PL M I IT Fig 1 Incorrect Mounting Model S8600M shown Fasten securely with four No 6 32 machine or No 8 sheet metal screws 69 1954 Mount the System Controls Mount any required controls such as the gas control spark igniter flame sensor thermostat limit and transformer according to manufacturer s instructions Wire the System N CAUTION Equipment Damage Hazard Disconnect power supply before beginning wiring or making wiring connections to prevent electrical shock or equipment damage All wiring must comply with local codes and ordinances See Fig 2 and Table 4 for proper wiring connections IMPORTANT 1 As shown in the wiring diagrams a common ground is required on a The pilot burner mounting bracket and b The GND BURNER terminal on the ignition module Failure to use the GND BURNER terminal may result in intermittent loss of spark and or loss of flame current sensitivity 2 Make sure the transformer has adequate VA The ignition module requires at least 0 1 A at 24 Vac Add the current draws of all other devices in the control circuit including the pilot and main valves in the gas control and multiply by 24 to determine the total VA requirement of these components Add this total to 2 4 VA for the igni tion modu
33. and Drill can be chucked up in a vari 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 P001117C Mestek Line Burners GAS MANIFOLD 65 0910 28 FLAME ROD 71 0201 06 PIN VISE PLAN VIEW BURNER PLATES REMOVED TD NA GASKET FLAME PILOT TIP 94 1 09506 PILOT TUBING WHEN REQUIRED MANIFOLD END CAP ASSEMBLY 94 0 09543 Nw GAS MANIFOLD 45 SECTION XI CIRCUIT ANALYSIS SEQUENCE AND BURNER SETUP AND HIGH FIRE MANIFOLD ADJUSTMENT CIRCUIT ANALYSIS MODULATING GAS VALVE MOTOR Connect a DC voltmeter capable of reading 0 10 VDC on the input terminals on Modulating Gas Valve Motor 11 The operation of the modulating gas valve motor with regard to voltage is as follows For a furnace size 160 it is 2 65 to 10 VDC For a furnace size 320 it is 2 65 to 10 VDC For a furnace size 480 it is 0 to 10 VDC With these voltages present the motor 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 At approximately 10 volts DC the motor should be delivering full flow to the heater and the burner should be in high fire If the DC voltage is obtained on the motor terminals but the heater does not respond as described the problem can be isolated to the motor itself
34. ater collection box Be sure drip leg is made so water will not fall on heater controls when drain plug is removed Pitch horizontal pipes upward 1 4 inch per foot toward outlet for condensate drainage Support horizontal runs as required to prevent sagging Vents should terminate that will not cause a down draft to occur This could affect the over fire draft pressure in the heat exchanger Do not install dampers or other restrictive devices in the flue vent pipe The stack should not be installed in such a manner that access to the components is obstructed Guy wires may be required to brace the stack above rooflines Outdoor units are supplied with an integral vent pipe and vent terminal and no additional material is required Provide a minimum of 36 clearance from combustible materials to the vent terminal F Field Piping Gas Piping All gas piping must be in accordance with the requirements 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 where required by local code 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 t
35. cation of LEDs Flame LED Yellow Indicates flame presence and strength See Table 6 Status LED Green ndicates system operation status and error condi tions See Table 7 and Table 8 for status specific to each model Table 6 Yellow LED Flame Codes Recommended Indicates Service Action Heartbeat Normal Flame Signal Not applicable 2 Weak Flame Signal Perform routine System will operate maintenance to reliably but flame signal is assure optimum less than desired flame signal NOTE This indication may flash temporarily during or shortly after lightoff on some applications Check gas supply pilot burner flame sense wiring contamination of flame rod burner ground connection reliably over time Service call recommended NOTE This indication may flash temporarily during or shortly after lightoff on some applications 1 OFF No Flame or Flame Signal Not applicable below minimum threshold for system operation a Flash Code Descriptions Heartbeat Constant gt gt second bright 7 second dim cycles The flash code number signifies that the LED flashes X times at 2Hz remains off for two seconds and then repeats the sequence Marginal Flame Signal less than 1 15A System may not operate 2f S8600B C H M S8610B C H M S8670D E J K INTERMITTENT PILOT GAS IGNITION CONTROL Table 7 Continuous Retry Models C M E and K Only Green LED Status Codes
36. ccomplished with the tach monitor TM 01 When voltage is applied the green power light will be illuminated The green tach light will blink and a contact will close when the burner motor feedback signal indicates the motor is running at an acceptable speed If the red fault light is illuminated with the burner motor running greater than 600 RPM the problem can be isolated to the control itself or the burner motor feedback signal If the proper voltages are not obtained and the wiring is correct the problem can be isolated to the electronics See the Troubleshooting section and the Digital Control User Manual SEQUENCE AND BURNER SETUP 1 0 Zone 583 Controller UC 01 must be calling for the burner to be enabled The DO 2 light will be on and Burner Enable Relay RE 28 needs to be energized With the safeties burner motor and tach monitor circuits made power will be applied to Burner Helay RE 02 If the outside air is above the Heating Economizer Setpoint 65 F the burner will be disabled You will need to disconnect the plug where the Outside Air Temperature Sensor TS 01 and Discharge Air Temperature Sensor TS 03 are wired to the I O Zone 583 Controller UC 01 see High Fire Adjustment in following section Reconnect the plug if you are getting close to the Freezestat lockout time which is approximately 3 minutes To reset the Freezestat alarm simply turn the power off and back on at the disconnect switch NOT
37. chnicians should service intermittent pilot systems 6 After troubleshooting check out the system again to be sure it is operating normally General troubleshooting process is as follows 1 Refer to LED Status and Troubleshooting on page 12 for LED status codes 2 Perform the Checkout on page 7 as the first step in troubleshooting 3 Check the troubleshooting guide Fig 13 to pin point the cause of the problem 4 If troubleshooting indicates an ignition problem see Ignition System Checks below to isolate and correct the problem 5 Following troubleshooting perform the Checkout on page again to be sure system is operating nor mally Ignition System Checks Step 1 Check ignition cable Make sure Ignition cable does not run in contact with any metal surfaces Ignition cable is no more than 36 in 0 9 m long Connections to the ignition module and to the igniter or igniter sensor are clean and tight Ignition cable provides good electrical continuity STEP 2 Check ignition system grounding Nuisance shutdowns are often caused by a poor or erratic ground A common ground is required for the module and the pilot burner bracket e Check the ground circuit from the GND BURNER terminal on the module to the pilot burner Make sure connections are clean and tight If the wire is damaged or deteriorated replace it with 14 to 18 gauge moisture resistant thermoplastic insulate
38. ction Contact Factory Replace 11 if proper voltage is measured See troubleshooting guide and Section XI Replace Outside Air Temperature Sensor TS 01 or Discharge Air Temperature Sensor 5 03 Contact factory Clean seat Clean valve or replace if necessary Increase inlet pressure if possible See valve adjustments in Section Change to correct setpoint setting If readings are not correct replace Discharge Air Temperature Sensor TS 03 or repair wiring Change to correct setpoint See Digital Control System User Manual Refer to Digital Control System User Manual for additional troublehooting suggestions 35 SECTION VII TROUBLE SHOOTING continued Modulating Room Temperature MRT MRT PRO or MRT EXPERT ControlS Portions reproduced with permission from Maxitrol Company Symptom Possible Cause Field Test A No Gas Flow with DO 2 on UC 01 energized B No Gas Flow or Continuous Low Fire on MT 11 Electronics OK C Continuous Low Fire Electronics Problem D Continuous Minimum Discharge Air Temperature Incorrect Maximum or Minimum Discharge Air Temperature Continuous High Fire Electronics OK Continuous High Fire Electronics Problem Main gas valve improperly installed Defective main gas valve Open or short circuit in modulating motor MT 11 No voltage
39. d completely assembled where shipping limitations allow Optional accessories are assembled and shipped mounted and wired whenever possible within limitations of shipping and handling Some optional accessories shipped separately may require field assembly 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 If the unit and or accessories cannot be installed immediately they should be stored in a clean dry environment If this is not possible and the unit must be stored outdoors it should be protected from the weather with tarpaulins or plastic coverings Do not assume that simply covering a unit will keep insects dust and condensation out of the unit and critical components Rotate the fan monthly Prior to beginning installation of a unit that has been in storage for weeks or months the unit and all components should be closely inspected Shipments are made F O B Dallas Texas by 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 un mounted are noted on the bill of lading These parts where feasible are packaged and shipped with the unit Upon receipt of shipment all units should be checked against the bill of lading to insure all items have bee
40. d ficiente de m me qu un mauvais reglage 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 UBHBEHH Applied AIT 4830 Transport Drive Dallas TX 75247 Phone 214 638 6010 Fax 214 905 0806 IOMIFL 2 SECTION I FOREWORD As is the case with any fine piece of equipment care Table of Contents must be taken to provide the proper attention to the Section 1 Foreword and Table of Contents 2 operation and maintenance detail of this machine Section Il General Information 3 Section Ill Installation
41. d wire with 221 F 105 C minimum rating If the flame rod or bracket is bent out of position restore to correct position STEP 3 Check spark ignition circuit You will need a short jumper wire made from ignition cable or other heavily insulated wire Close the manual gas valve e Disconnect the ignition cable at the SPARK terminal on the module A WARNING Electrical Shock Hazard Can cause severe injury death or property damage When performing the following steps do not touch stripped end of jumper or SPARK terminal The ignition circuit generates over 10 000 volts and electrical shock can result Energize the module and immediately touch one end of the jumper firmly to the GND terminal on the module Move the free end of the jumper slowly toward the SPARK terminal until a spark is established Pullthe jumper slowly away from the terminal and note the length of the gap when sparking stops Check Table 5 below Table 5 Arc Troubleshooting Arc Length No arc or arc less than 1 8 in 3 mm Action Check external fuse if provided Verify power at the module s input terminal Replace control if fuse and power are okay Voltage output is okay STEP 4 Check pilot and main burner lightoff Setthe thermostat to call for heat e Watch the pilot burner during the ignition sequence See if Ignition spark continues after the pilot is lit e The pilot lights and the spark stops but main bu
42. e and voltage is present at ignition control RE 02 output terminals See burner motor does not operate Cause 1 2 3 4 5 6 7 8 9 and 10 Check for 24 VAC at TR 08 terminals The red light is illuminated on the tach monitor 01 See technical data sheets on ignition control Manual pilot gas shut off valve closed Inlet gas pressure lower than minimum gas pressure required No gas through pilot regulator with sufficient inlet gas pressure if applicable No gas flow through gas valve Type of gas supplied natural gas or propane different than shown on unit rating plate Flame detection system not sensing pilot burner flame See section for servicing burner No voltage to spark rod See technical data sheets on ignition control Manual gas shut off valve closed on VG 02 No gas on outlet side of gas valve VG 02 regulator with proper inlet pressure No gas on outlet side of modulating motor MT 11 with proper inlet pressure and 0 10 VDC signal is correct Burner does not modulate and 0 10 VDC signal is not present See burner motor does not operate Remedy 1 2 3 4 5 6 7 8 9 and 10 Prove the power source Check wiring See Section XI for circuit analysis of burner motor Determine the cause of lockout Reset the ignition control Slowly open valve Increase gas pressure Clear obs
43. e toxic when exposed to heat i e refrigerant aerosols etc Field Assembly Drawing GASKET TYPICAL DETAIL B DETAIL B LIFTING LUG P a DETAIL A Locate the unit exactly level Special attention should be given to the duct electrical and fuel connection points Install ductwork with adequate flexible connection to isolate vibration from the ductwork All ductwork should have taped or caulked seams Ductwork should be properly sized so as not to inhibit airflow This information should be crossed checked with the position of support beams and stand pipes to insure that clearance dimensions coincide with those of the unit Make a visual inspection to insure no damage has occured to the unit during installation NOTE Return air units must be ducted The minimum clearance to combustible material must be maintained as listed in Table 1 Table 1 Minimum clearance to combustible material also consult local codes and regulations Clearances to Combustible Material Horizontal Units Front 48 Inches Hear 18 Inches Right 18 Inches Left 18 Inches Top 18 Inches Floor 6 Inches Consider control side as front of unit In addition to the combustible clearances listed above access for service should be allowed around the unit The recommended minimum access is 36 on front and rear sides for service access Optimum clearance for coil removal for units with cooling coil section would be equivalent to cabinet w
44. ected Fan is disabled Time clock night setback thermostat or field installed controls open Freeze protection tripped low discharge temperature Damper motor not operating its end switch not making or dampers binding Overload protection on motor starter tripped Belts loose or broken Motor may be burned or incorrectly wired Firestat and or smoke detector contacts not closed Bearing seized on shaft DO 1 on UC 01 not energized Auxiliary switch on starter ST 01 not closed Heat mode is disabled Fan starter relay not closed Outside air temperature higher than heating economizer setpoint Safety and limit circuits open Safety circuit status relay not closed Burner motor may be defective or incorrectly wired Burner blower motor control BC 01 open Burner status relay not closed DO 2 on UC 01 not energized Burner motor staying in high speed Check power source 2 Check and or replace Close or connect customer interlock Enable fan Check time clock night setback thermostat and field installed controls for proper settings Reset freeze stat by interrupting power Check for proper setting and burner operation Check for power at damper motor and that end switch has been wired correctly End switch should be wired N O normally open Check that linkage is free and not binding Reset
45. ection Check for pilot flame Replace gas valve if pilot flame present If no pilot flame cycle Call for Heat If error repeats replace control Reset by cycling Call for Heat If error repeats replace the control X Y flash codes signify that the LED flashes X times at 2Hz remains off for two seconds flashes Y times at 2Hz remains off for three seconds and then repeats the sequence 28 69 1954 S8600B C H M S8610B C H M S8670D E J K INTERMITTENT PILOT GAS IGNITION CONTROL Troubleshooting Guide Refer to the following guide for troubleshooting Fig 13 START BEFORE TROUBLESHOOTING FAMILIARIZE YOURSELF WITH THE STARTUP AND CHECKOUT PROCEDURES NOTE CALL FOR HEAT 24 VAC SUPPLY IS CONNECTED TO THE 24 V TERMINAL ON THE CONTROL TURN GAS SUPPLY OFF TURN THERMOSTAT CONTROLLER TO CALL FOR HEAT POWER TO MODULE 24 V NOMINAL CHECK LINE VOLTAGE POWER LOW VOLTAGE TRANSFORMER LIMIT CONTROLLER THERMOSTAT CONTROLLER AND WIRING ALSO CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM IF USED AND THAT THE END SWITCH IF USED IS MADE YES 30 SECOND PREPURGE DELAY S8670 ONLY NO REPLACE S8670 PULL IGNITION LEAD AND CHECK SPARK AT MODULE CHECK IGNITION CABLE GROUND WIRING CERAMIC INSULATOR AND GAP AND CORRECT CHECK BOOT OF THE IGNITION CABLE FOR SIGNS OF MELTING OR BUCKLING TAKE PROTECTIVE ACTION TO SHIELD CABLE AND BOOT FROM EXCESSIVE TE
46. elow On initial startup it may be necessary to fill the trap manually or after unit has operated sufficiently for a small amount of condensate to collect in the drain pan turn off the unit and the trap will automatically fill During the winter months when the cooling system is turned off and the unit is exposed to freezing conditions an antifreeze solution should be poured into the condensate pan trap to prevent freezing and possible damage The condensate drain trap may also be drained and capped but be sure to remove the cap when starting the cooling for the next season DRAIN PAN 1 1 2 MPT PVC FEMALE ADAPTER FITTING 1 1 2 NPT PIPE NIPPLE RETURN BEND 06 16 08 C000659A DRAIN PLUG 10 SECTION IV PRE START UP Do not attempt start up without completely reading and understanding this manual along with the Digital Control System user manual A Pre Start Up The owner s representative or equipment operator should be present during start up to receive instructions on care and adjustment of the equipment All equipment has been factory tested adjusted metered and inspected to meet conditions set at the time 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 CAUTION Line side of disconnect may be energized Follow proper lockout tagout procedures NOTE All servicing and adjustm
47. ents of this piece of equipment should be preformed by a qualified service engineer Perform a visual inspection internally and externally of the unit to make sure no damage has occurred and everything is secure 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 exte rior is acceptable 2 Check that any insulation inside of unit is properly secured 3 Remove all shipping blocks brackets and bolts from supply fan base with optional isolation base 4 Check all wiring for loose connections and tighten if necessary 5 Inspect all fan and motor bearings and lubricate if necessary CAUTION DO NOT RUPTURE GREASE SEALS 6 Inspect pulleys and belts for tightness tension and alignment Do not overtighten belts 7 Check set screws on all bearings pulleys fans and couplings for tightness 8 Check voltage supplied to disconnect switch the maximum voltage variation should not exceed 10 Phase voltage unbalance must not exceed 2 9 Check the thermostat s for normal operation 10 Check that system duct work is installed and free from obstructions 11 Check that fans turn freely in housing 12 Check that the area around the unit is clear of flam mable vapors or containers of flammable liquids 13 Check
48. es the loss of signal and de energizes the pilot and or gas valve Flow of gas to the burner stops as the valve closes 5 Once heating setpoint is satisfied the pilot and or gas valve and burner motor will be de energized Main supply air blower will continue to run 12 SECTION V UNIT START UP FAN AND HEAT Before attempting to start the heater read and understand the sequence of operations electrical schematic gas train burner ignition control and the Digital Control System user manual WARNING During installation testing servicing and troubleshooting of this product it may be necessary to work with live electrical components Have a licensed electrician or other individual who has been properly trained in handling live electrical components to perform these tasks Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury Make sure all manual gas valves are closed Make sure all doors and service panels have been closed or replaced Turn main disconnect switch off Check the incoming line voltage to match unit rating plate If voltage is over 10 of nameplate rating or phase voltage unbalance is over 2 notify contractor or power company Fan is Enabled And Disabled By The Following MDT And MRT Standard Rotate the remote Temperature Setpoint knob MP 15 Clockwise will enable the fan Counterclockwise will dis
49. f the unit will occur Packaged Unit Rigging ALL LIFTING LUGS PROVIDED MUST BE USED A Handling The Equiment The Packaged Comfort System has been designed for rigging and handling through the use of special lifting lugs installed on the base 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 During lifting operations slings or chains with hooks and l beam spreader are recommended see figure below Lifting must be equal to all lugs furnished The spreader bar I beam or equal must be equal in length to the longest span between lifting points Depending on sling length one or more spreaders are recommended In no case should the lift be less than 80 degrees from horizontal or more than 30 degrees from threaded shank direction When unloading and setting the unit use the lifting points 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 section It is recommended that all nuts and setscrews be tightened Turn fan shaft by hand to make certain that wheel does not rub against venturi and that bearing setscrews are tight Open the cover on the elect
50. f valves in the gas line to the appliance d Perform Gas Leak Test ahead of gas control if piping has been disturbed GAS LEAK TEST Paint the gas control gasket edges and all pipe connections upstream of the gas control with a rich soap and water solution Bubbles indicate gas leaks Tighten the joints and screws or replace component to stop gas leak Recheck with soap and water solution Step 2 Verify control system ground The igniter flame sensor and ignition module must share a common ground with the main burner Use thermoplastic insulated wire with a minimum rating of 221 F 105 C for the ground wire asbestos insulation is not acceptable If the temperature at the wire could exceed 221 F 105 C use a shield to protect the wire from radiant heat generated by the burner Connect the ground wire as follows a Fit one end of the ground wire with a female 1 4 in quick connect terminal and connect it to the male quick connect GND BURNER terminal on the ignition module b Strip the other end of the wire and fasten it under the igniter bracket mounting screw If nec essary use a shield to protect the ground wire from radiant heat c The burner serves as the common grounding area If there is not good metal to metal contact between the burner and ground run a lead from the burner to ground NOTE Earth ground is not required Step 3 Review Normal Operating Sequence and Module Specifications a See O
51. g Guide for your condensing unit or evaporative cooler Decrease Maximum Cooling Discharge Temperature Setpoint See Digital Control System User Manual Decrease Minimum Cooling Discharge Temperature Setpoint See Digital Control System User Manual Change to correct setpoints See Digital Control System User Manual Change to correct setpoints See Digital Control System User Manual If desired Space Temperature is not reached and cooling is at full capacity it may be undersized See Troubleshooting Guide for your condensing unit or evaporative cooler Refer to Digital Control System User Manual for additional troublehooting suggestions 38 SECTION VIII FLUE GAS ANALYSIS 92 RATIO CURVES FOR FUEL OILS amp GASES GAS 11 NAT GAS z ZZ TIMES ORSAT A i INDICATE INPROPER COM BU 3 TION POINTS ABOVE CURVE INDICATE INACCURATE ORSAT OR IMPROPER TECHNIQUE LAW PERCENT EXCESS AIR HL HL VAY j 1 1 l Lauf s e 1 z C CAC 15 ee ee ee PERCENT OXYGEN X02 39 SECTION IX MAINTENANCE SCHEDULE AND LUBRICATION REQUIREMENTS WARNING Failure to comply with the general safety information may result in extensive property damage severe personal injury or death Periodic maintenance is essential to the efficient operation and extended service life of this equipment
52. he pilot burner for the ignition trial time The spark lights the pilot flame when pilot gas is present A flame rectification circuit confirms the presence of the pilot flame shuts off the spark source and energizes the main valve relay The S8600 family uses a two level pilot flame proving sequence When a sufficient flame current is sensed the spark is turned OFF However the pilot flame must generate a higher level of flame current to energize the main valve This approach assures a stable pilot flame to support reliable burner lightoff If the pilot flame is weak or unstable the spark may turn back ON However the trial for pilot ignition will not exceed the stated ignition trial time Main Burner Operation When the main valve opens gas flows to the main burner where it is lit by the pilot flame There is a short flame stabilization period as the main valve opens to allow the pilot flame to stabilize as the main gas lights The system is now in the run mode with the presence of the pilot flame continuously monitored by the flame rectification circuit If the pilot flame goes out the control senses loss of pilot flame and shuts off both the pilot valve relay and the main valve relay Flow of gas to pilot and main burners stops as the valves close FAILED TRIAL FOR PILOT IGNITION Lockout Models S8600B H 58610 8670D J Lockout models provide a single trial for pilot ignition sequence If the pilot flame is not lit and
53. hey are the property of the transportation company when the claim is filed They will give you disposition instructions PACKING We comply with the packing requirements of the transportation companies and your bill of lading proved that everything was in good condition when shipped That bill of lading contract requires them to deliver in perfect condition SECTION II GENERAL INFORMATION A Purpose The purpose of this manual is to present a guide for proper installation maintenance and operation of the Packaged Comfort System and supplement but not to replace the services of qualified field service personnel to supervise the initial start up and adjustment of the unit Persons without previous experience with large commercial and industrial heating and cooling equip ment should not attempt the initial adjustment and checkout procedure which is essential before such installations may be considered ready for operation This manual should be made readily available to all operating personnel as an aid in troubleshooting and proper maintenance Due to the custom nature of this equip ment not all possibilities are addressed in this manual The customer or installer can obtain information from local sales representative or the factory Warning Failure to comply with general safety information may result in extensive property damage severe personal injury or death B Shipping The basic IFL Series Comfort System is shippe
54. idth DETAIL A ROOF CAP DIRECTIONS FOR FIELD ASSEMBLING AND WEATHERPROOFING SECTIONS 1 Apply tacky tape gasket to the end of the first section blower discharge heater etc See Fig 1 NOTE One roof cap is attached to a standing seam on each section for shipping purposes only It will be necessary to remove this PRIOR TO SLIDING SECTIONS TOGETHER Failure to do so may damage seams preventing proper seal 2 Slide adjoining section against the tacky taped first section If bolt holes are provided bolt the sections together tightly If bolt holes are not provided use furniture clamps to pull sections TIGHTLY together Sections whether bolted or not will be held together and sealed by the standing seams and hugger strips Fig 2 which will be attached later 3 Once the sections are connected apply caulking or silicone sealant along the standing roof seam Fig 3 and side seams where the sections come together Fig 1 It is mandatory to seal the roof and side seams along the entire outside of the unit and it is strongly suggested that the seams also be sealed along the inside of the unit if possible FIRST SECTION FIGURE 1 STANDING ROOF SEAM FIGURE 3 C000713 DETAIL B GASKET MATERIAL WITH FIELD APPLIED CAULK ROOF SEAM OR SEALANT 4 Apply caulking material along the top of both sides of the standing roof seam Fig 4 Place roof cap on top of the seam and secure it with two rows of TEK
55. ifferential pressure across them reaches the manufacturers recommended final value Dirty filter elements should be replaced with a clean element of the same type and size In addition the factory not only suggests but insists that air filters be checked every 30 days daily in icy weather and replaced with new filters throw away type or cleaned washable type as required Cleanable filters should be given new application of filter coating after washing to maintain optimum filter performance The frequency of cleaning and replacing air filters applies twelve months of the year where blowers are used for ventilation and heating D Belt Tensions and Adjustments Belt tension is adjusted during the initial run in and test periods at the factory However the belts are run as slack as possible to prevent excessive damage to the bearings yet tight enough to prevent slippage It is necessary therefore to tighten all belts during the first few months of operation and to check for proper tension weekly during the first 60 days after which 30 day check intervals are sufficient NOTE Turn off all power to the equipment before checking belt tensions CAUTION Do not attempt to tighten any belt or belts by changing the pitch of an adjustable pulley as this will change the speed of a driven pulley causing the unit to be rendered OUT OF AIR BALANCE Do not overtighten belts Suggested Belt Tension Method 1 Check tension frequen
56. ions or the unit manufacturer s instructions for proper bearing maintenance Note Drive side Sleevlock bearing installation SPB 2115 C2 1 Mount all the bearings and leave all the bolts and setscrews loose 2 Tighten setscrews on Sleevlock bearing to the tightening pattern as described in the installation sheet that comes with the bearing to a final 65 inch Ibs while rotating the shaft Check to make sure the insert of the bearing is centered in the bearing housing and then bolt bearing down 3 Tighten down the bolts and setscrews on the remaining bearings per installation sheet starting from the end bearing back toward s the Sleevlock while rotating the shaft 3 Dampers Dampers should be inspected monthly daily in icy weather for securely fastened linkages and smooth operation If dampers are binding or excessively noisy then lubrication may be required Place one drop of 20 wt machine oil silicone spray graphite or equal 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 4 Louvers Louvers should be inspected monthly daily in icy weather to make sure they are clear and open 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 d
57. it 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 ou un quelconque des cables livr s avec l unit devait tre remplac il doit tre remplac avec des cables pr vus pour r sister une chaleur d au moins 105 C E Venting All venting installations must conform to Part 7 Venting of Equipment in the current version of the National Fuel Gas Code ANSI Z223 1 or applicable provisions of local building codes All indoor units must be vented Each heater must have an individual vent pipe and vent terminal The heater used in this system is a Category appliance and all portions of the venting system must be designed and installed so as to prevent leakage of flue or vent gases into a building Hecommended vent pipe is 14 gauge Series 400 Stainless Steel The customer must provide a rain cap or weatherproof cap DO NOT support the weight of the stack and rain cap on the vent connection at the unit Insulate single wall vent pipe exposed to cold air or running through unheated areas Use as few elbows as possible and tape flue pipe joints with fireproof paper or approved material All vents must be able to maintain the pressure stated on the rating plate in high fire Warning CARBON M
58. l high limit gas pressure switches etc h Reset all operating controls back to proper setpoints for normal running conditions and make sure the burner modulates See the Digital Control user manual The following list covers general combustion problems and some of the possible cures Conditions may vary in the field Refer to combustion chart for efficiency CAUTION Check local codes for maximum allowable percentages and amounts of emissions Low Carbon Dioxide CO Fuel input too low Excess burner air Wrong draft setting Detectable Carbon Monoxide CO Fuel input too high Not enough burner air Restricted draft Flame impingement Excessive Stack Temperature Draft setting too high Incorrect burner air Fuel input too high Low Oxygen Oz e Oxygen reading must always be a positive percentage Check all dampers linkages and locking quadrants to make sure they are secure and operating correctly SAFETY AND CONTROLS CHECKOUT Ignition Control Close manual gas valve before burner Operate unit in heat mode After pilot flame has been established close manual pilot gas valve if applicable The ignition control must trip out within 10 30 seconds Gas Pressure Switches The low pas pressure switch will trip out and must be reset before resuming operation when the inlet gas shut off valve is turned off or inlet gas pressure is lower than the trip point The high gas pressure switch can
59. ld be unnecessary to remove the blower wheel from the blower housing 8 Slide the new shaft through the first blower wheel hub 9 Once the shaft is completely through the first blower wheel slide a bearing onto this end of the shaft 10 Slide the shaft through the next blower wheel hub 11 and add another bearing Continue this procedure until the shaft is through all of the blower wheels Place a bearing on each end of the shaft 12 Replace the old shims with new 13 Bolt the bearings in place and reattach the grease lines When installing a Sleevlock bearing see note at bottom of page 14 Adjust the shaft so the blower hub keyways are in the middle of the shaft keyways 15 Adjust the shaft so it protrudes past the non drive end bearing the blower sheave keyway mates with the shaft keyway and the drive side sheave can be aligned with the motor sheave Ideally the blower sheave should be as close to the drive side bearing as possible the motor sheave should be as close to the motor housing as possible and the belts should be straight Be sure the shaft does not rub on or interfere with the closing of the access door Align all bearing setscrews so that the same set screw on each bearing is pointed in the same direction as the other bearings setscrews Place a drop of BLUE Loctite on the bearing setscrews and tighten all of the setscrews Follow the mounting instruction s procedure
60. le The result is the minimum trans former VA rating Use a Class ll transformer if replacement is required CONNECT IGNITION CABLE Use Honeywell ignition cable or construct an ignition cable that conforms to suitable national standards such as Underwriters Laboratories Inc See Table 2 and Table 3 Table 2 Honeywell Pre assembled Ignition Cables UL Style 3257 CABLE PART MODULE LENGTH END PILOT BURNER NUMBER Rajah connector receptacle 90 degree rubber boot 394800 30 30 inches 1 4 inch quick connect insulated 394801 30 30 inches 1 4 inch Rajah connector quick receptacle connect straight rubber insulated boot Table 3 Recommended Ignition Cable for Field Assembly VOLTAGE TEMPERATURE CABLE TYPE RATING rms RATING UL Style 3217 10 000 302 F 150 C UL Style 3257 10 000 484 F 250 C 21 S8600B C H M S8610B C H M S8670D E J K INTERMITTENT PILOT GAS IGNITION CONTROL Cable must be no longer than 36 in 0 9 m To construct a cable fit one end of ignition cable with 1 4 in diameter Rajah connector receptacle and the other with a 1 4 in female quick connect Protect both ends with insulated boots NOTE The cable must not run in continuous contact with a metal surface or spark voltage will be greatly reduced Use ceramic or plastic standoff insulators as required To install 1 Connect one end of the cable to the male quick connect SPARK terminal on the igni tion module
61. lief openings by interlocking a powered exhaust system or by a combination of these methods D 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 voltage and amperage 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 appropriate terminals All leads are tagged to facilitate field connections See wiring diagram provided with equipment 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 unit the field provided disconnect must be of the proper size and voltage Refer to unit rating plate for minimum circuit ampacity and voltage The disconnect must be installed in accordance with Article 430 of the current edition of ANSI NFPA No 70 National Electrical Code Check the supply voltage before energizing the un
62. mer which has a 3 minute off 3 minute on delay A BACview or PC is required to change Setpoints For a more detailed control sequence see the Digital Control System user manual Turn main disconnect switch on and Enable fan When DC 01 fan relay is energized on UC 01 the damper opens if applicable After end switch has proven the damper is open blower fan starts See operating modes in Digital Control System user manual If trying to start or checkout cooling in a low ambient condition you will need to install a jumper in place of the outdoor air sensor TS 01 and the discharge air sensor TS 03 This will drive the unit to call for full cooling and energizes cooling relays DO 3 and DO 4 on 01 16 SECTION VI UNIT SHUTDOWN A Extended Shutdown Disable the heating and cooling circuits Close the Manual Firing Valve in the heater gas piping manifold 3 If the furnace was firing at the time of shutdown allow the main supply blower to run for a sufficient period to cool off the heat exchanger The furnace may have an automatic blower override that will perform this function automatically running the blower until the air reaches a fan cut off temperature N 4 Disable the fan 5 Turn the unit main power disconnect to the off position 6 Close all the manual gas shut off valves 7 Ifthe unit is to remain idle for an extended period the blower and motor shafts should be rotated by ha
63. minute delay a new trial for ignition is initiated This sequence continues until lightoff or Call for Heat is removed 58610 Separate 1 0 A Pilot 15 or 90 Lockout Spark and pilot gas ON until lightoff or trial for ignition and seconds as ends If pilot fails to light pilot gas and spark OFF 2 0 A Main ordered 100 shutoff and lockout Cycle Call for Heat to restart ignition sequence 58610 Separate 1 0 A Pilot 150r90 Continuous Spark and pilot gas ON until lightoff or trial for ignition and seconds as Retry ends If pilot fails to light pilot gas and spark OFF 2 0 A Main ordered 10096 shutoff After 5 minute delay a new trial for ignition is initiated This sequence continues until lightoff or Call for Heat is removed 58610 Combination 1 0 A Pilot 15 or 90 Lockout Spark and pilot gas ON until lightoff or trial for ignition and seconds as ends If pilot fails to light pilot gas and spark OFF 2 0 A Main ordered 100 shutoff and lockout Cycle Call for Heat to restart ignition sequence Automatic Ignition Systems ANSI 221 20 69 1954 _ 18 S8600B C H M S8610B C H M S8670D E J K INTERMITTENT PILOT GAS IGNITION CONTROL Table 1 Intermittent Pilot Ignition Models Continued Valve Igniter Current Trial for Ignition Sensor Rating Prepurge Pilot Sequence Type 24 Timing Ignition Type Ignition Sequence Description S8610M Separate 1 0 A Pilot None 150
64. n See following note Fractional HP Century G E Bronze sleeve single phase or equal bearings ODP or TEFC Recommendation See following note Fan shaft Fafnir Self aligning bearings or equal single row or double row ball bearings resilient mounted Recommendation See following note Dampers Factory Sleeve or equal Recommendation See following note 1 Blower Motors Some motors require lubrication while others do not Those that require lubrication can be identified by the presence of grease plugs in the motor casing at each end Motors that do not have grease plugs cannot be greased and are lubricated for the life of the motor bearing Lubrication of motors should be done while the mo tor is warm and at a standstill Remove and clean all grease plugs and insert a grease fitting in the upper hole in the motor casing at each end Viewed as if motor were sitting horizontally on its base There may be one or two plugs in each end casing of the motor Add a small amount of a clean good grade ball bear ing grease such as Exxon Polyrex EM or equal with a low pressure grease gun Run the motor 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 sup
65. n 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 you should request an inspection and a claim should be filed immediately with the carrier All IFL Series Comfort Systems are given a complete operations test and control circuit checkout before shipment 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 equipment 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 The factory also offers start up service 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 maintenance personnel in proper operations and maintenance Consult factory for quotations on periodic or start up service D 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
66. nch High voltage sparking electrode 69 1954 22 S8600B C H M S8610B C H M S8670D E J K INTERMITTENT PILOT GAS IGNITION CONTROL S8600 B C S8610 B C S8670 J K GND 24V Envira mv Pv Pv BRN GND 24V COM SENSE SPARK L A MAIN AIR THERMOSTAT 1 VALVE PROVING J switch 0 1ST 2ND OPERATOR OPERATOR DUAL VALVE COMBINATION GAS CONTROL A COMBUSTION 7 BLOWER a RE RELAY A O mmm O O O LIMIT L1 L2 L 1 CONTROLLER L HOT A COMBUSTION L2 L1 HOT PILOT BURNER IGNITER AIR BLOWER GROUND MOTOR LD 1 PILOT GAS SUPPLY N POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED ALTERNATE LIMIT CONTROLLER LOCATION MAXIMUM CABLE LENGTH FT 0 9 A CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO TRANSFORMER M23435 Fig 7 S8600 58610 B C 88670 J K connections with remote flame sensing in a heating system with power assisted combustion S8600 B C S8610 B C S8670 J K GND 24V i MV MV PV PV BRN GND 24V SENSOR AIR SWITCH PILOT BURNER IGNITER PILOT 1ST 2ND OPERATOR OPERATOR TWO STAGE DUAL VALVE COMBINATION GAS CONTROL M o COMBUSTION rea GROUND PILOT GAS SUPPLY LIMIT CONTROLLER Z COMBUSTION AIR BLOWER Lt 12 VES HOD MOTOR HOT PO
67. nd to spread the grease over the bearings B Emergency Shutdown Only 1 Open the main electrical disconnect switch 2 Close the main manual gas valve SECTION VII TROUBLE SHOOTING Check Safety Shutdown Performace RE 02 WARNING Fire or explosion hazard Can cause property damage severe injury or death Perform the safety shutdown test any time work is done on a gas system NOTE Read steps 1 through 7 before starting and compare to the safety sutdown or safety lockout tests recommended for the intermittent pilot IP ignition module Where diffferent use the procedure recommended for the module 1 Turn off gas supply at valve 2 Set thermostat or controller above room temperature to call for heat 3 Watch for ignition spark following prepurge See ignition module specifications 4 Time the length of the spark operation See the ignition module specifications 5 After the module locks out open the manual gas cock and make sure no gas is flowing to the pilot or main burner 6 Reset the ignition module RE 02 7 Operate system through one complete cycle to make sure all controls operate properly This equipment has been electrically and fire tested prior to shipment However during transit control setpoints can change and wiring can come loose Do not assume controls are defective until all associated setpoints and wiring are checked If you do not have the optional BACview 6 KP 01 keypad displa
68. ntal start up during inspection must be located and repaired or replace the heat b Inspect the burner carefully including upstream exchanger 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 44 SECTION X MESTEK LINE BURNERS Inspection and Maintenance of Gas Ports Drill sizes that may be used in the field to clean out Conduct initial inspection within the first month after burner ports are shown below commissioning Visually check the gas ports of new burner assemblies for any piping scale or debris Use HeaterSize DrillSize Pin Vise with drill bit to remove 200 MBH Input 160 MBH Output 5 64 400 MBH Input 320 MBH Output Annualinspections are normally adequate once the initial piping debris is removed The operating conditions of the burner will determine how frequently NOTE When cleaning the two pilot orifices or maintenance is actually required removing the manifold end cap assembly be careful not to damage the flame pilot tip gasket Use of an electric drill motor is not suggested unless both Pin Vise
69. ntrol does not exceed the rating of the control If the appliance operates at very high temperatures use insulation shielding and air circulation as necessary to protect the controls Proper insulation or shielding should be provided by the appliance manufacturer verify proper air circulation is maintained when the appliance is installed INSTALLATION men Installing This Product Read these instructions carefully Failure to follow them could damage the product or cause a hazard ous condition 2 Check the ratings given in these instructions to make sure the control is suitable for your application 3 Installer must be a trained experienced service technician 4 After installation is complete check out operation as provided in these instructions A WARNING Fire or Explosion Hazard Can cause severe injury death or property damage 1 The module can malfunction if it gets wet leading to accumulation of explosive gas Never install where water can flood drip or condense on the module Never try to use a module that has been wet replace it 2 Liquefied petroleum LP gas is heavier than air and will not naturally vent upward Do not operate electric switches lights or appliances until you are sure the appliance area is free of gas A WARNING Electrical Shock Hazard Can cause severe injury death or property damage Disconnect power supply before beginning wiring or making wiring c
70. o the unit WARNING To avoid equipment damage or possible personal injury do not connect gas piping to this unit until a supply line pressure leak test has been completed Connecting the unit before completing the pressure leak test may damage the unit gas valve and result in a fire hazard DANGER Never use an open flame to detect gas leaks Explosive conditions may exist which would result in personal injury or death 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 not 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 Refer to the heater s rating plate for determining the maximum supply pressure to the heater The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 PSIG The appliance must be isolated from the gas supply piping system by closing it s individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressure equal to or less than 1 2 PSIG Correctly sized piping must be run to the unit Please note that gas line pressure must be as shown on specification plate when unit is operating at full input The high press
71. of 221 F 105 C for the ground wire asbestos insulation is not acceptable If necessary use a shield to protect the wire from radiant heat generated by the burner Connect the ground wire as follows 1 Fitone end of the ground wire with a female 1 4 in quick connect terminal and connect it to the male quick connect BRN GND terminal on the ignition module 2 Strip the other end of the wire and fasten it under the pilot burner bracket mounting screw If neces sary use a shield to protect the ground wire from radiant heat 3 The pilot burner serves as the common grounding area If there is not good metal to metal contact between the pilot burner and ground run a lead from the pilot burner to ground NOTE Earth ground is not required FA ii SENSE MV PV ENVIRACOM 1 ALARM2 24V GND o4y ALARM1 OPT M23430 Fig 2 Ignition Module wiring connection locations Model 58610 shown Table 4 Wiring Connection Descriptions Connector Label Description MV 1 4 inch Main Valve connection MV PV 1 4 inch Common terminal for gas valve Pilot Valve connection Valve connection 3 16 inch Alarm a optional for B H D and J models only ALARM2 3 16 inch Alarm connection optional for B H D and J models only EnviraCOM 3 pin EnviraCOM communications connector SENSE 3 16 inch Flame Sensor B C J and K models Only SPARK 1 4 i
72. on ends If pilot fails to light pilot gas and 2 0 A Main ordered spark OFF 10096 shutoff After 5 minute delay a new trial for ignition is initiated This sequence continues until lightoff or Call for Heat is removed If established flame is lost all models restart ignition trial b Separate two rod remote flame sensing e Combination one rod local flame sensing All models provide PLANNING THE INSTALLATION Natural or LP gas Pilot burner ignition using a high voltage spark Flame rectification circuit to monitor flame presence A WARN 5 Monitoring of 24 pilot main gas valve Two LED indicators for flame presence strength and ides 2021 property system status errors damage f EnviraCOM communication protocol for system 1 Plan fine installatienas uiliid below diagnostics 5 Alarm Output contacts Lockout models E Intermittent pilot systems used wide variety of SPECIFICATIONS central heating equipment and on heating appliances such as commercial cookers agricultural equipment industrial heating equipment and pool heaters Some of Control Voltage 24V 18 30 Vac 50 60 Hz these applications may make heavy demands on the Current Draw 0 1 A plus valve load 24Vac controls either because of frequent cycling or because of Trial for Ignition 15 or 90 seconds depends on model moisture corrosive chemicals dust or excessi
73. on the inside of the bearing box for the proper tightening and torque values 19 Align the blower hubs keyway with those in the installation instructions included with the bearing Typical Procedure For Changing The Shaft And Bearings 21 22 3 bearings any shims Remove protective shaft coating Remove the drive side sheave Disconnect the grease lines from the existing Identify the total shim thickness at each bearing and mark the bearing mount for future reference Remove mounting bolts for bearings and remove 22 23 Loosen bearing and blower wheel shaft setscrews 42 20 shaft sure the clearance between the blower wheel and blower housing is the same on each side Rotate the shaft by hand to insure free operation Correct any rubbing of the blowers on the housings Place a drop of BLUE Loctite on the blower set screws and tighten all of the setscrews Align the blower and motor sheaves using a laser or straight edge and tighten the blower sheave to the shaft Replace the belts and tighten the motor base adjustment for the proper belt tension Over tightening the belt tension will severely reduce belt and bearing life Belt deflection should be approximately 1 64 inch of the belt span 24 Monitor for excessive heat or vibration during operation 25 All bearings are pre lubricated and should not require greasing Refer to the bearing manufacturer s instruct
74. onnections to prevent electrical shock or equipment damage N CAUTION If a new gas control is to be installed turn off the gas supply before starting installation Conduct a Gas Leak Test according to the gas control manufacturer instructions after the gas control is installed 2 Wiring errors can cause improper appliance operation and dangerous conditions such as bypassing safety features N CAUTION Equipment Damage Hazard Water can cause equipment damage or malfunction If the module must be mounted near water or moisture provide suitable waterproof enclosure Maintenance Requirements in Severe Environments Regular preventive maintenance is important in any application A WARNING Fire or Explosion Hazard May cause severe injury death or property damage Do not attempt to take the module apart or to clean it Improper reassembly and cleaning may cause unreliable operation Maintenance frequency must be determined individually for each application Some considerations are Cycling frequency Appliances that may cycle more than 20 000 times annually should be checked monthly ntermittent use Appliances that are used seasonally should be checked before shutdown and again before the next use 69 1954 20 S8600B C H M S8610B C H M S8670D E J K INTERMITTENT PILOT GAS IGNITION CONTROL e Consequence of unexpected shutdown Where the cost of an unexpected shutdown would be high the
75. oper rotation NOTE To change rotation of the blower simply interchange any two 2 of the leads of the motor starter for three 3 phase motors On single phase motors refer to motor nameplate Enable the fan Check for proper blower rpm Check that all motor amp draws do not exceed rating plate ratings and overloads are set to motor rating plate amps Check all dampers for proper operation linkage does not bind see Sequence of Operation and Digital Control System user manual for damper control modes Disable the fan NOTE When setting up the burner for the first time or if the appliance has been shut down for an extended period of time these same start up procedures should be followed NOTE Before attempting to light the pilot and main burner you need to review Circuit Analysis Sequence and Burner Setup in Section XI for proper Manifold and Valve Adjustments A BACview 6 or PC will be required to change setpoints Open first manual gas valve and check the gas supply pressure by replacing the plug fitting on the gas valve or line with a pressure gauge with appropriate range Check that pressure reading is within the specified range on the rating plate NOTE To adjust gas pressure on supply lines where a regulator has been installed to reduce the inlet pressure to rating plate maximum pressure remove dust cap of main gas regulator and turn adjusting screw clockwise to increase pressure or counterclockwise
76. ors if reading is incorrect or correct wiring Change to correct setpoint Change to correct setpoint Change to correct setpoints Clean replace valve and or seat if necessary Replace Outside Air Temperature Sensor TS 01 or Discharge Air Temperature Sensor TS 03 Contact factory Refer to Digital Control System User Manual for additional troublehooting suggestions B SECTION VII TROUBLE SHOOTING continued Modulating Room Temperature MRT MRT PRO or MRT EXPERT Controls Portions reproduced with permission from Maxitrol Company Symptom Possible Cause Field Test H Incorrect High 1 Inlet Pressure too low Read pressure at inlet Increase inlet pressure Fire Continuous Maximum Discharge Air Temperature Incorrect Space Temperature Incorrect outlet pressure adjustment of Pressure Regulator Open circuit in Space Temperature Sensor TS 02 or Discharge Air Temperature Sensor TS 03 Incorrect Maximum Heating Discharge Temperature Setpoint Incorrect Minimum Heating Discharge Temperature Setpoint Incorrect space temperature setpoint Insufficient burner capacity 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 pressure stated on the
77. p reading When the pilot is adjusted shut the burner off by disabling heat Setting Main Flame Install one manometer at test port on the elbow of the burner manifold for setting high fire manifold pressure and one on the heat exchanger test port to insure proper overfire draft in high fire Slowly open all manual gas shut off valves Enable the heat After pilot proven if applicable main gas valve opens and burner lights If the burner does not light within a few seconds after prepurge shut the burner off and repeat the previous steps Burner will hold in low fire for approximately 10 seconds before modulating up Adjust high fire pressure reading from manometer to match Normal Manifold Pressure firing rate shown on unit rating plate Refer to Valve Adjustment instructions in Section XI for setting high gas manifold pressure setting Check microamp reading with burner cycling through full firing range Cycle pilot and burner several times to insure smooth light off There should be a continuous spark for fifteen 15 seconds with pilot gas supply turned off Check pilot and main gas lines for leaks Main flame is now set See Final Checks and Adjustments on following page 14 FINAL CHECKS AND ADJUSTMENTS HEATING With the gas input pressure established the flue gas analysis can now be preformed This is done at the stack after unit is up to temperature The following readings should be taken b
78. pect cabinet and add caulking as required The porcelain on the ignition electrode must be H Casing intact not cracked The spark gap should be 1 8 of Periodic cleaning of the casing is recommended to an inch on Mestek burners remove dirt grease and corrosive substances that may injure finish Rusted or corroded areas should be 3 Replace all access panels which have been removed cleaned and painted Put system back into operation and view burner while cycling through full firing range This will give a visual I Support check for blocked burner ports Check for normal Inspect the entire support structure to be sure every response and function of all controls thing is firmly in place 4 Checkall gas piping for possible leaks using a soap J Heater bubble solution 1 Atleast a yearly inspection is recommended for heating installations and more frequently for 5 Inspect the burner support means to be sure that process applications in year round operation Your everything is firmly anchored in place own experience is the best guide in determining frequency of inspection but as a minimum the 6 Checkthe CO level in the entering and leaving following procedure should be followed airstream of the furnace If the CO level is greater a Shut the system down totally disconnecting or in the leaving airstream it is possible that the heat locking out power supply so there can be no exchanger is leaking CO into the airstream The leak accide
79. peration on page 8 and Specifications on page 2 Step 4 Reset the Module a Turn the thermostat to its lowest setting b Wait one minute As you do the remaining steps watch for points where operation deviates from normal Refer to the Troubleshooting guide on page 15 to correct problems 69 1954 DG S8600B C H M S8610B C H M S8670D E J K INTERMITTENT PILOT GAS IGNITION CONTROL Step 5 Check Safety Shutoff Operation a Turn gas supply off b Setthermostat or controller above room temper ature to call for heat c Watch for spark at pilot burner either immedi ately or following prepurge See device label d Time spark from start to shutoff See device label e On all continuous retry models wait 5 minutes Ignition sequence should start again followed by shutoff after 90 seconds maximum f Open manual gas cock and make sure no gas is flowing to pilot or main burner g Setthermostat below room temperature and wait one minute before continuing Step 6 Check Normal Operation a Setthermostat or controller above room temper ature to call for heat b Make sure pilot lights smoothly when gas reaches the pilot burner c Make sure main burner lights smoothly without flashback d Make sure burner operates smoothly without floating lifting or flame rollout to the furnace vestibule or heat buildup in the vestibule e Perform a gas leak test in the appliance GAS LEAK TEST Paint the gas cont
80. ply blower s Bearings have been prelu bricated with a number 2 lithium base grease Relu brication should be done with a similar grease using a low pressure grease gun Wipe all grease fittings clean before adding grease Grease should be added slowly in small amounts at frequent intervals while the shaft is being manually rotated A slight showing of grease at the seals with accom panying normal bearing temperature indicates proper lubrication Normal temperature can range from cool to hot to the touch depending on size speed and surrounding conditions Excessive bearing temperature indicates faulty lubrication An insufficient amount of grease is suggested by a bearing showing no grease at the seals and a higher than normal temperature and noise level Excessive leakage of grease at the seals and high operating temperature suggest too much grease Frequency of Lubrication Frequency of lubrica tion depends upon operating conditions The bearing operating temperature is the best index for determin ing a relubrication schedule The following chart gives the frequency of relubrication based upon 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 Upto125 F Clean 6 months 500 RPM Upto150 F Clean 2 months 1000 RPM Upto210 F Clean 2 weeks 1500 RPM
81. r90 Continuous Spark and pilot gas ON until lightoff or trial for ignition and seconds as ends If pilot fails to light pilot gas and spark OFF 2 0 A Main ordered 100 shutoff After 5 minute delay a new trial for ignition is initiated This sequence continues until lightoff or Call for Heat is removed 586700 Combination 1 0 A Pilot 30 15 or 90 After prepurge spark and pilot gas ON until lightoff or and seconds seconds as trial for ignition ends If pilot fails to light pilot gas and 2 0 A Main ordered spark OFF 100 shutoff and lockout Cycle Call for Heat to restart ignition sequence 58670 Combination 1 0 A Pilot 30 150r90 Continuous After prepurge spark and pilot gas ON until lightoff or and seconds seconds as Retry trial for ignition ends If pilot fails to light pilot gas and 2 0 A Main ordered spark OFF 10096 shutoff After 5 minute delay a new trial for ignition is initiated This sequence continues until lightoff or Call for Heat is removed 58670 Separate 1 0 A Pilot 30 15 or 90 Lockout X After prepurge spark and pilot gas ON until lightoff or and seconds seconds as trial for ignition ends If pilot fails to light pilot gas and 2 0 A Main ordered spark OFF 10096 shutoff and lockout Cycle Call for Heat to restart ignition sequence 58670 Separate 1 0 A Pilot 30 150r90 Continuous After prepurge spark and pilot gas ON until lightoff or and seconds seconds as Retry trial for igniti
82. rating plate Measure resistance per Thermistor Curve in Section XII Use a BACview 6 to read the space temperature TS 02 Check to see if heater is delivering at Maximum Discharge Setpoint Check to see if heater is delivering at Minimum Discharge Setpoint Check Unit Enable Potentiometer MP 15 Setpoint Check heating Occupied and or Unoccupied setpoint Check to see if heater is operating at high fire if possible or change to larger valve Consult factory about possibility of using special spring to reduce pressure drop on selected installations See valve adjustments in Section If readings are incorrect replace Space Temperature Sensor TS 02 or Discharge Air Temperature Sensor TS 03 or repair wiring If desired temperature is not reached increase Maximum Heating Discharge Temperature Setpoint If desired Space Temperature is not reached increase Minimum Heating Discharge Setpoint Change to correct setpoint Change to correct setpoint If desired Space Temperature is not reached with heater at high fire it may be undersized Consult Factory Refer to Digital Control System User Manual for additional troublehooting suggestions Control circuits external to MRT Controls can cause burner malfunction Always check manual valve to be certain gas is on and check limit controls for normal operation 67 SECTIO
83. rect VDC output voltage on UC 01 Foreign object holding ball valve open Inlet pressure too low Incorrect outlet pressure adjustment of Pressure Regulator Unit Enable Potentiometer MP 15 not set correctly Discharge Air Temperature Sensor TS 03 not reading correctly The Heating Discharge Air Setpoint on VDT EXPERT Control System is not set correctly 1 Arrow on side of valve should point in direction of gas flow Check for 24 VAC Check for 24V AC at TR 08 terminals Check DC Voltage on AO 1 Measure VDC across valve terminals Check Outside Air Temperature Sensor TS 01 or Discharge Air Temperature Sensor TS 03 for open internal circuit See Section XII for Thermistor curve Check DC voltage on AO 1 Remove and inspect valve and valve seat 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 pressure stated on the rating plate Enable Potentiometer MP 15 2 Check Discharge Air Temperature Sensor TS 03 and wiring See Section XII for Thermistor curve 3 Check setpoint with BACview or PC Check setpoint on Unit 1 Install properly Replace valve if Necessary Prove the power source See Se
84. rical control box located on the unit and ensure that all connections are tight Rotate fans monthly A USE WHEN LIFTING OVER 3 000 LBS B USE WHEN LIFTING UNDER 3 000 LBS 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 For indoor application combustion air shall be pro vided at a rate of at least 10 CFM or 1 square inch of free opening per 1000 BTU per hour of rated input If a separate mechanical means provides this air an interlock with the combustion blower shall be provided The rated output of gas burning appliances decreases with higher altitudes Above 2 000 feet the furnace shall be de rated 4 for each additional 1 000 feet of altitude Factory testing rating plate information is recorded on sea level conditions High altitude ratings may be obtained by a change in manifold pressure Appliances must be suitably marked to indicate their altitude adjusted input rating Under no circumstances should this equipment be installed in a negatively pressurized space Consult jurisdictional authority for proper ventilation requirements Combustion air containing or recirculation of room air may be hazardous in the presence of a Flammable solids liquids and gases b Explosive materials i e grain dust coal dust gunpowder etc c Substances which may becom
85. rmed to accept wood nailing strip and insulation provided by others 28 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 All electrical connections must be in accordance with Canadian Electrical Code Part 1 CSA Standard C22 1 All electrical connections must conform to the current edition of ANSI NFPA No 70 National Electrical Code and applicable local codes in Canada to the Canadian Electrical Code Part 1 CSA Standard C22 1 The following recommendations are not intended to supplant any requirements of federal state or local codes having jurisdiction Authorities having jurisdiction should be consulted before installations are made Local codes may require additional safety controls and or interlocks All installations in airplane hangers must be in accordance with current ANSI NFPA No 409 All installations 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 o
86. rner does not light e 8600 B H 58610 B H S8670 D J only The pilot lights the spark stops and main burner lights but the system shuts down e f so ensure adequate flame current as follows Turn off furnace at circuit breaker or fuse box Clean the flame rod with emery cloth Make sure electrical connections are clean and tight Replace damaged wire with moisture resistant No 18 wire rated for continuous duty up to 221 F 105 C e Check for cracked ceramic insulator which cause short to ground and replace igniter sensor if necessary Atthe gas control disconnect main valve wire from the MV terminal Arc 1 8 in 3 mm or longer 69 1954 26 S8600B C H M S8610B C H M S8670D E J K INTERMITTENT PILOT GAS IGNITION CONTROL Turn on power and set thermostat to call for heat The pilot should light but the main burner will remain off because the main valve actuator is disconnected Check the pilot flame Make sure it is blue steady and envelops 3 8 to 1 2 in 10 to 13 mm of the flame rod See Fig 11 for possible flame problems and their causes e If necessary adjust pilot flame by turning the pilot adjustment screw on the gas control clockwise to decrease or counterclockwise to increase pilot flame Following adjustment always replace pilot adjustment cover screw and tighten firmly to assure proper gas control operation Set thermostat below room temperature to end call for
87. rol gasket edges and all pipe connections downstream of the gas control including the pilot tubing connections with a rich soap and water solution Bubbles indicate gas leaks Tighten the joints and screws or replace component to stop gas leak Recheck with soap and water solution f Turnthe thermostat or controller below the room temperature Make sure the main burner and pilot flames go out OPERATION Module operation can be conveniently divided into two phases for the 58600 and 58610 and three phases for the 58670 phases Prepurge 58670 models only See Fig 10 Trial for ignition all models Main burner operation all models Fig 9 10 summarize the normal operating sequences of all the models Prepurge S8670 models Only When an S8670 model is used in a fan assisted combustion system the combustion air blower starts on a call for heat On proof of airflow the air proving switch 69 1954 closes and energizes the S8670 When this model is used in an atmospheric system the Call for Heat energizes the module In either case the module first initiates a 30 second delay to allow system prepurge After prepurge the module starts the trial for pilot ignition sequence Trial for Pilot Ignition On a Call for Heat and after prepurge on S8670 models the module energizes the spark source and the pilot valve relay simultaneously The pilot valve opens allowing gas to flow to t
88. sensed before the end of the ignition trial time the control shuts off the pilot valve 100 shutoff and goes to lockout The control remains in lockout until power to the control is cycled by the system thermostat or by removing and restoring system power Continuous Retry Models S8600C M 8610C M S8670E J Continuous retry models provide multiple trials for ignition If the pilot is not lit or sensed before the end of the trial for ignition time the control shuts off the spark and pilot gas 10096 shutoff There is a 5 minute delay before another ignition sequence is initiated The pattern of ignition sequence followed by a 5 minute delay continues until the pilot lights and is proved or the Call for Heat ends The 5 minute delay time can be bypassed by cycling the system thermostat or removing and restoring system power 24 S8600B C H M S8610B C H M S8670D E J K INTERMITTENT PILOT GAS IGNITION CONTROL OPERATING SEQUENCE PREPURGE MODELS S8760 E K RETRY S8670 D J LOCKOUT IDLE NOT POWERED CALL FOR HEAT WAIT FOR RECEIVED FROM CALL FOR HEAT THERMOSTAT TO BE REMOVED POWER TO ACTIVATE ALARM MODULE AND CONTACT S SELF CHECK OPTIONAL RETRY DELAY 5 MINUTES PREPURGE 30 SECONDS TRIAL FOR IGNITION SPARK ON GAS TIMER STARTED EN TRETE BEFORE TRIAL FOR IGNITION TIMER EXPIRES RETRY OR LOCKOUT MODEL FLAME PROVED LOCKOUT NO YES SPARK OFF OPEN
89. system should be checked more often Dusty wet or corrosive environment Since these environments can cause the modules to deteriorate more rapidly the system should be checked more often Any module should be replaced if it does not perform properly on checkout or troubleshooting In addition replace any module if it is wet or looks like it has ever been wet Protective enclosures as outlined under Planning the Installation are recommended regardless of checkout frequency Location The mounting location must provide Good clear access to the field wiring terminals Operating ambient temperatures between 40 F and 175 F 40 C and 79 C 165 F 74 C for S8610 and 58670 models Relative humidity below 95 noncondensing Protection from water steam or corrosive chemicals that are used to clean the appliance Protection from dripping water such as from an overfilled humidifier or from condensation Protection from dust or grease accumulation Mount the Ignition Module Select a location close enough to the burner to allow a short 3 ft 0 9 m max direct cable route to the pilot burner Ambient temperature at the module must be within the range listed under Operating Temperature on page 2 The module must be protected from water moisture corrosive chemicals and excessive dust and grease Mount the module with the terminals down to protect them from dripping water and dust As
90. 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 the thermostats especially those with mercury bulb contacts be mounted on a vibration free surface The sides 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 I Drains and Traps Heat Exchanger Furnaces are supplied with condensation removal pipe connections Condensate from the heat exchanger is acidic and may contain chemical compounds requiring special drainage The drain must be installed in accordance with all plumbing codes The condensate is to be drained via PVC or steel pipe with an indirect connection to the plumbing wastes Where a condensate neutralizer is used an overflow shall be provided such that condensate will be directed to the drain in the event that the neutralizer becomes plugged Indoor units typically require a condensate trap to be installed to prevent combustion gasses from entering the space Outdoor units may req
91. the starter by pushing red button on starter check amp draw Turn power off and check belts Turn power off and check motor and wiring Check firestat and smoke detector for correct settings and operation Turn power off and check See Digital Control System User Manual Check auxiliary switch circuit wiring and contact Enable the heat mode Check for power or replace Check setpoint Close safety and limit circuits Check for power or replace Turn power off and check motor and wiring Check wiring and or replace control See Section XI for circuit analysis of burner motor Check for power or replace See Digital Control System User Manual Check VDC at AO 3 output and replace UC 01 if defective See Section XI for circuit analysis of burner motor Refer to Digital Control System User Manual for additional troublehooting suggestions 5 SECTION VII TROUBLE SHOOTING continued Fan and Heat Mode No voltage at ignition control RE 02 input terminals Ignition control RE 02 goes into safety shutdown Lockout Pilot and or burner does not light after prepurge has timed out and voltage is present on ignition control RE 02 input terminals If pilot and or burner does not light after pre purge has timed out and there is no voltage at ignition control RE 02 output terminals If there is no heat with pilot OK if applicabl
92. tically affected Coils should be inspected on a regular basis and cleaned as required If any mixing plates are loose or missing fasteners tighten replace as necessary Always use zinc CAUTION Solutions used to clean coils must plated or stainless fasteners The mixing plates not be corrosive to metals or materials used in on the burner may display hairline cracks the manufacture of this equipment If cleaning These cracks are normal and caused by solutions are applied through means of high thermal stresses occurring during combustion pressure spray care must be taken to avoid The presence of these hairline cracks in no damaging the coil fins significant way affects the combustion efficiency or performance of the heater Should a large 2 Condensate Drain Pan Periodically flush the opening develop it may cause difficulties in cross condensate pan and drain system with a water ignition of flame across the face of the burner If hose this does occur the specific mixing plate or plates involved must be replaced F Gaskets Gaskets are used on doors inspection covers some 2 Inspect the flame rod and ignition electrode for dirt filter racks and some outdoor air dampers Inspect and moisture Wipe off if necessary Examine for gaskets periodically and repair or replace as required any evidence of premature arcing If in doubt check continuity of flame rod to be sure it is not grounding G Caulking out Replace if required Ins
93. tly 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 o properly tension a conventional V belt drive use the following procedure a Measure the span length b At the center of the span apply a force perpen dicular to the span to deflect the belt 1 64 inch for every inch of span length For example for a 40 inch span apply a force that will deflect the belt 40 64 or 5 8 of an inch c Compare the force you have applied with the values given in the table below If the force is between the values for normal tension and 1 1 2 times normal tension the belt tension should be satisfactory If the belt tension is not within this range it can be adjusted by loosening the motor mounting bolts and adjusting the position of the motor along its base B Section small Pounds pulley Pounds _ Force for diameter Belt Force for 1 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 7 4 5 8 8 6 Gates Hi Power 5 8 8 7 Note For recommendation of other types of belts consult respective manufacturers 43 E Coils And Related Items 1 Coils Coil surfaces must be kept clean of dirt WARNING Do not enlarge burner ports or and lint in order to operate at rated efficiency performance may be dras
94. to decrease pressure 43 Heat Is Enabled By The Following MDT And MRT Standard To enable the heat rotate the Temperature Setpoint knob MP 15 clockwise to the desired setpoint above the actual air temperature The allowable temperature range is 55 F to 90 F MRT PRO With Smart Room Sensor To enable the heat press the Warmer or Cooler button on the face of the remote TS 02 MRT PRO room sensor to the desired room setpoint Each push of the button changes the temperature setpoint by 1 F The setpoint can be changed a maximum of 10 F from the default of 65 F Changing the heating setpoint also changes the cooling setpoint MRT or VDT Expert With A KP 01 BACview To enable the heat for MRT Expert scroll thru the SETPOINTS menu in the BACview and enter the desired room Heating Occupied and Unoccupied Setpoints For VDT Expert enter the desired Heating Discharge Air Setpoints Energy Savings Modes There are 3 Energy Savings Modes that could disable the burner NOTE A BACview or PC is required to change Setpoints For a more detailed control sequence see the Digital Control System user manual CAUTION Do not attempt to start the burner when furnace is full of vapor or combustion chamber is very hot Connect a DC microammeter between the Sense terminal and flame rod sensing wire on the flame safeguard relay RE 02 A minimum of 1 2 microamps is required See Troubleshooting Guide for Honey
95. truction in vent orifice or line replace if defective Check for proper installation and voltage Correct or replace if defective Connect to proper fuel supply or contact factory for field conversion parts Flame Rod Assure rod is in pilot ourner flame check wiring and flame rod Check wiring Replace RE 02 if defective Check wiring and replace if defective Turn heat off on switch to the off position Slowly open all manual gas shut off valves Check for correct wiring and power Replace if defective Check wiring voltage and adjustment Correct wiring or replace if defective See troubleshooting guide and Section Check wiring at AO 01 and replace UC 01 if defective Refer to Digital Control System User Manual for additional troublehooting suggestions 139 SECTION VII TROUBLE SHOOTING continued Fan and Heat Mode For DDC Control Systems See Digital Control System User Manual and Section XI Circuit H Burner will not respond Analysis for gas and burner to temperature motor Building Pressure Transducer Check and or replace PT 13 or Damper Control components See section on Return air and outside Potentiometer defective or not trouble shooting PT 13 air damper operation not calibrated functioning properly see Buidling Pressure Transducer Check wiring sequence of operation PT 13 or Damper Control for damper control
96. try delay then initiate new trial for ignition Control waits until flame is no longer sensed and then goes to soft lockout Flash code continues Control auto resets from soft lockout after one hour Control auto resets from soft lockout after one hour Heartbeat Constant 1 2 second bright 72 second dim cycles A single flash code number signifies that the LED flashes X times at 2Hz remains off for two seconds and then repeats the sequence If system fails to light on next trial for ignition check gas supply pilot burner spark and flame sense wiring flame rod contaminated or out of position burner ground connection If system fails to light on next trial for ignition check gas supply pilot burner flame sense wiring contamination of flame rod burner ground connection Check for pilot flame Replace gas valve if pilot flame present If no pilot flame cycle Call for Heat If error repeats replace control Check flame sense lead wire for damage or shorting Check that flame rod is in proper position Check flame rod ceramic for cracks damage or tracking Check transformer and AC line for proper input voltage to the control Check with full system load on the transformer Check gas supply pilot burner spark and flame sense wiring flame rod contaminated or out of position burner ground connection Check gas supply pilot burner flame sense wiring contamination of flame rod burner ground conn
97. ubes from switches and transducers before using compressed air to blow through tubing Test ignition spark There should be a continuous spark for 15 seconds with pilot gas turned off 5 Quarterly a Complete the monthly maintenance schedule b Inspect all drives for proper belt tension and wear c Check the alignment of the sheaves and adjust if necessary d Inspect all bearings set screws for tightness and lubricate bearings if necessary e Check the flame and spark rod wiring and connection f Check the flame and spark rod Clean and adjust if nec essary g Inspect the burner carefully Clean adjust and replace if necessary h Check voltages and amp draw on all motor s i Checkthe operation of all gas 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 Inspect combustion chamber for flame impingment If there is evidence of flame impingement a complete burner adjustment must be made 6 Off Season or Yearly a Complete the monthly and quarterly maintenance schedule b Inspect all fan s wheels housings and motors Clean if necessary c Check that all fan blades fan wheels sheaves and couplings are securely set on the shaft d Inspect all bearings and alignment Adjust if necessary e Inspect all V belts sheaves and coupling inserts Replace if necessary f Inspect all electrical
98. uire installing a heat trace or special attention to drains to prevent freezing and clogging of the drain line Since the condensate is drained by gravity avoid long runs of drain piping If a long run of trapping cannot be avoided or the piping has water flow restrictions such as several elbows add extra height to provide enough hydrostatic head to overcome the frictional losses Always slope piping down a minimum of 1 8 per foot in the direction of the flow Condensate Drain Drawing 90 LONG RADIUS ELBOWS NOTE H TO BE MINIMUM OF 1 2 PLUS TOTAL SYSTEM STATIC PRESSURE K TO EXCEED THE NEGATIVE STATIC PRESSURE IN INCHES W C OF THIS SECTION OF UNIT WHERE APPLICABLE AND DOUBLE WHEN SPACE PERMITS Cooling Coil The cooling coil section is located in the unit so that supply air is drawn through the cooling coil s This results in the condensate being induced to the area of low static pressure Unless some means of pressure equalization is provided in the condensate drain the air rushing through the drain will cause the condensate to accumulate in the drain pan As the unit continues to operate the accumulated water will be picked up by the in rushing air and carried with the air over the side of the drain pan causing possible water leaks into the supply duct and or through the bottom of the unit causing water damage in the building A trap should be installed to prevent this condensate water buildup See drawing b
99. ure regulator and relief valve should be if possible mounted at least 5 to 10 feet upstream from the appliance regulator on the unit if applicable Building Pressure Transducer Piping PT 13 Pipe the high side to location inside the building that will not be affected by air movement Pipe the low side to the atmosphere positioned so it will not be affected by the wind and not exposed to the elements Be sure that all tubing is clean and clear of any debris before installing tubes on the transducer G Field Wiring and Remote Control Installation 1 Connect the power lines to the line side of the power distribution block or optional main disconnect switch 2 Field wiring is indicated on the wiring diagram typically as dashed lines Where field wiring to the control circuit is required take care to size the wires for a maximum 10 voltage drop The VA rating of the transformer should be the maximum load 3 Mount and wire remote control panel thermostats temperature sensors and any other field installed controls as indicated on the unit control wiring diagram 4 Connect all wiring to the appropriate field wiring terminal and any shielded or twisted wires as indicated on the unit control wiring diagram 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 a maximum ampacity of the heater L installation l ctrique d utilisateur aura une
100. ut not limited to CO Net Stack Temperature O2 Combustion Efficiency CO Check the combustion setting The furnace has been test fired in the factory for firing rate and combustion Field conditions may require adjustments to be made These checks should be done by a qualified service man a When the main flame is established and the burner motor MT 08 running at full speed check the gas manifold pressure at the test point nearest the burner downstream of the fully open modulating gas valve motor MT 11 Check the nameplate for the correct pressure and adjust the appliance regulator if necessary b Ensure proper overfire draft in high fire at test port in heat exchanger is set per rating plate c Check the CO and O reading at maximum input as shown on the rating plate O readings typically range from 4 6 CO readings should not exceed 400 PPM at any time Adjust the VG 02 gas regulator with the modulating gas valve motor fully open making fine adjustments before measuring again d Cycle burner several times to ensure smooth light off and proper operation Visually observe the flame pattern There must be no flame Impingement or hot spots on the combustion chamber that could cause scaling e Check all gas piping again for leaks using a soap bubble solution f When the unit installation is complete recheck the voltage and amp draw of each motor g Insure all safety controls are operative i e ignition contro
101. ve heat in Prepurge See Table 1 the environment In these situations special steps may be Ignition Sequence See Table 1 required to prevent nuisance shutdowns and premature Retry Delay 5 minutes C M E and K models only control failure These applications require special Flame Failure Response Time 2 seconds maximum Honeywell review contact your Honeywell Sales LEDs Two LEDs provide the following Representative for assistance The Status LED green provides system status and error codes Review the following conditions that can apply to your The Flame LED yellow indicates flame presence specific installation and take the precautionary steps and flame strength suggested Gas Control Honeywell models VR8204 and VR8304 Operating Temperature Frequent Cycling Minimum ambient temperature rating is 40 F 40 C Maximum ambient rating for S8600 used with 1 0A main valve is 175 F 79 C Maximum ambient rating for S8610 and S8670 used with 2 0A main valve is 165 F 74 C Relative humidity 0 to 95 noncondensing These controls are designed for use on appliances that typically cycle three to four times an hour only during the heating season In year round applications with greater cycling rates the control can wear out more quickly perform a monthly checkout 69 1954 _ 19 S8600B C H M S8610B C H M S8670D E J K INTERMITTENT PILOT GAS IGNITION CONTROL Water or Steam Cleaning If the control gets wet
102. well ignition control Connect the test instruments meters and thermometers on the heater and controls to measure and record the appropriate data SAFETY CHECKOUT With power supplied to the ignition control RE 02 and all safety devices are satisfied the burner motor MT 08 will run in pre purge mode for 30 seconds The pilot valve VG 01 if applicable or main gas valve VG 02 is energized and a 15 second trial for ignition begins If the flame sensing probe fails to prove the pilot or main flame it de energizes the spark igniter and the control will lockout on flame failure 10 30 seconds This safety step is performed to establish the flame sensing and test any of the safety circuits before main flame light off Open pilot if applicable and first main gas shut off valves slowly Reset high low gas pressure switches if applicable Check pilot and main gas lines for leaks using soap solution CAUTION You will have approximately three 3 minutes before the unit shuts down on Freezestat Low Discharge Temperature if you have disconnected plug wires TS 01 and TS 03 referred to in Section XI Enable the fan and burner adjust the setpoint to the highest setting to energize the heating relay DO 02 on UC 01 NOTE 3 OR 4 TRIALS MAY BE NEEDED TO PURGE AIR FROM GAS LINE Setting The Pilot Flame if applicable NOTE Pilot regulator if applicable adjustment may be needed to obtain the required microam
103. y it will be difficult to troubleshoot any alarm that may occur on the unit To reset most alarms on the I O Zone 583 Controller UC 01 without a BACview 6 keypad display simply turn the power off and back on at the unit disconnect If you have a BACview 6 keypad display the alarm can be reset remotely or at the I O Zone 583 Controller The following is a simplified list of possible problems and typical causes and remedies However it does not cover all possibilities and is intended as a guide only You might also need to reference the Digital Control System User Manual for additional trouble shooting and diagnostics WARNING Many of the steps listed on the following pages require electrical 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 Refer to manufacturer s for additional troubleshooting information t7 Honeywell 58600 58610 S8670D E J K Intermittent Pilot Gas Ignition Control INSTALLATION INSTRUCTIONS APPLICATION The 8600 family of ignition controls provide ignition Table 1 describes the main features of each available sequence flame monitoring and safety shutoff for model intermittent pilot gas fired heating appliances

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