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installation, operation and maintenance manual for indirect gas

1. PVC ELBOW 7 90 LONG RADIU PVC ELBOW 2 TO K DRAIN PAN DRAIN PVC ADAPTER FITTING FPT x SLIP PVC PIPE NIPPLE PVC PIPE NOTE NIPPLE H H TO BE A MINIMUM OF 1 2 PLUS THE TOTAL SYSTEM STATIC PRESSURE W C K TO EXCEED THE NEGATIVE STATIC PRESSURE IN W C OF 1 c THE SECTION OF THE UNIT WHERE THE DRAIN IS INSTALLED PVC RETURN BEND AND DOUBLE WHEN SPACE V PERMITS DRAIN PLUG 10 30 09 000659 SUGGESTED DESIGN FOR CONDENSATE DRAIN PANS UNDER A POSITIVE PRESSURE 90 LONG RADIUS PVC ELBOW 909 LONG RADIU PVC ELBOW ki TO J DRAIN PAN DRAIN PVC ADAPTER FITTING FPT x SLIP PVC PIPE NOTE NIPPLE G TO BE A MINIMUM OF PVC PIPE 112 PLUS THE TOTAL SYSTEM NIPPLE STATIC PRESSURE W C J TO EXCEED THE POSITIVE STATIC PRESSURE IN W C OF THE SECTION OF THE UNIT WHERE THE DRAIN IS INSTALLED PVC RETURN BEND 10 30 09 C000659B DRAIN PLUG 10 30 09 C000659B 18 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 if applicable Pre Start Up The owners representative or equipment operator should be present during start up to receive instructions on care
2. Honeywell Flame Safeguard Control RE 02 A keyboard display module Honeywell S7800A1 142 is recommended to read the flame signal and is a good troubleshooting device A V O M can also be used on the D C voltage test jacks marked and on flame amplifier Connect manometer to pilot test tee if applicable 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 Enable the fan and heat as described earlier in this section Check rotation of burner and induced draft fans amps and overload settings Make sure the damper on the induced draft fan is approximately 7596 open If limits and all safety controls are closed the burner and induced draft fan will run for 90 seconds before ignition trial as a pre purge cycle NOTE Do not leave the Run Test switch on the flame safeguard relay RE 02 in the TEST position during P F E P for more than 60 seconds This could cause the control program to go into a burner status alarm You can recycle the power to the unit to reset the burner status alarm NOTE Pilot regulator adjustment may be needed if the adjustment of the needle valve does not yield the required reading Typical adjustment of the needle valve is 1 1 2 to 2 turns open NOTE Frequently the cause of pilot problems relates to gas pressures that are too high and or air dampers that a
3. Temprite assumes no responsibility for loss or dam age 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 Re member claims are outlawed after nine months LOSS IN TRANSIT Before you sign for this shipment check against the bill of lading also the transportation company s delivery ticket Make sure that you get the exact total of articles listed Should the delivery ticket show more or less items than 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 ship ment In such cases save the packages and packing material then notify the transportation company at once and request an inspection When the inspector calls have him make out and leave a concealed bad order report He is obliged to give one to you Insist on it DISPOSITION OF D
4. RIGHT INNER SHOWN AUXILIARY SWITCH SW 12 SWITCH IN MT 11 FOLLOWER LOW FIRE START INNER BL RED BL YL AUXILIARY HIGH FIRE ADJUSTMENT SCREW THRU 13 VALVE LEFT OUTER d AUXILIARY 2 THRU 3 di n RN 1 jer GP 39 LOW FIRE SWITCH APPROX OVERRUNNING ADJUSTMENT FOLLOWER OUTER 10 DIFF CRANK ARM SCREW AUXILIARY i BUTTERFLY VALVE ASSEMBLY APPROX MOTOR IN SHUT POSITION 1 DIFF TERMINALS R amp W SHORTED CLOCKWISE OPENING 58 13 IN MT 11 MOTOR MOTOR BURNER CYCLING OPEN power 7 CLOSE RED BLUE 9 END 000710 24 TYPICAL SEQUENCE FOR MODULATING THERMOSTAT WITH 4 20 mA CONTROLS 4 20 mA CONTROL 115 VAC NOTES 1 THE 27 AND 120 OHM RESISTORS ARE SIZED TO HOLD MODULATING MOTOR AT APPROXIMATELY 25 OF MOTOR TRAVEL FOR LOW FIRE START 2 SW 11 BURNER CYCLING SWITCH IS MADE 20 TO 90 OF MOTOR TRAVEL 3 54 10 LOW FIRE START SWITCH MADE 0 TO 30 OF MOTOR TRAVEL OPERATION 1 STAT CALLS FOR HEAT DRIVING MTR 4 OPEN 2 WHEN MTR 4 REACHES 20 OPEN SW 11 CLOSES 3 SW 11 POWERS S2 AND WITH SW 21 CLOSED IT POWERS RE 6 AND PLACES MTR 4 UNDER RESISTOR CONTROL 4 MTR 4 MOVES TO 25 OPEN AND REMAINS THERE DURING TRAIL FOR IGNITION 52 Cp arm MTR 4 l 0 I IN SERIES WITH 5 UPON PROOF OF FLAME SW 21 DE ENERGIZES Lo ME SAFETY INTERLOCK BURNER CYCLING a 6 MTR 4 IS TRANSFERRED BACK TO CONTROL SW 21
5. 1 32 1 5 16 1 No 18 Air Hole Pilot 3 8 2 No 36 Air Hole Back No 18 L qum 180 Apart Plate Air Hole LI 5 i 41 FIX i 9 Orifice Drilled zl 844 for Natural Gas Diffuser Plate 2111 Flame Rod Porcelain Flame Rod0 Pilot Head r Ignition Electrode Pilot Assembly J Burner with Scanner Natural or LP Gas Pilot Assembly Scanner Type Natural or LP Gas 11 11 18 J RDIS SOA 44 144 18 1227 JIFISDA 1 4 eb The from the electrode tip should jump from tip to the body of the pilot housing and should be with the hole in the backside of pilot housing so that the blower air passing throught this hole will cause the arc to FLAG or move around Normal spark gap should be 1 16 3 32 The electrode should not be moved so far forward that the pilot flame will impinge on the porcelain insulator This may cause damage to the porcelain See the drawings for the pilot assembly for the C Burner Pilot Assembly C Burner For C1 amp C2 Burner 1 16 3 32 Spark Gap between 2 15 16 Primary Air Holes 2 Electrode Tip and Pilot Case Housing Air Hole iew Pilot Orifice Pilot Ass
6. CAUTION Solutions used to clean 5 must not be corrosive to metals or materials used in the manufacture of this equipment When using any type of coil cleaner always read the manufacturer s warnings and directions to properly use their product If cleaning solutions are applied through means of high pressure spray care must be taken to avoid damaging coil fins 2 Condensate Drain Pan Periodically flush the condensate pan and drain system F Gaskets Gaskets are used on doors inspection covers some filter racks and some outdoor air dampers Inspect gaskets periodically and repair or replace as required G Caulking Inspect cabinet and add caulking as required H Casing Periodic cleaning of the casing is recommended to remove dirt grease and any corrosive substances that may harm the finish Rusted or corroded spots should be cleaned and repainted I Support Means Inspect the entire unit and burner support means to be sure everything is firmly in place J Burner Refer to burner manufacturer IOM for recommended burner maintenance 61 SECTION X THERMISTOR OUTPUT CURVE FOR UNITS WITH DDC CONTROLS Resistance Ohms Typical 10 000 Ohm Thermistor Output Curve 30000 25000 20000 15000 10000 5000 0 32 41 50 59 68 77 86 95 Temperature in Degrees F 104 62 SECTION XI REPLACEMENT PARTS Replacement parts may be order
7. eee ae INDUSTRIES INSTALLATION OPERATION AND MAINTENANCE MANUAL FOR INDIRECT GAS FIRED HEATERS INCLUDING UNITS WITH DDC CONTROLS IOMTIF 4 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 liguids in open contain ers in the vicinity of this appliance is hazardous POUR VOTRE S CURIT L utilisation et l entreposage d essence ou d autres liquides ou produits mettant des vapeurs inflammables dans des r cipients ouverts proximit de cet appareil est dangereux FOR YOUR SAFETY POUR VOTRE S CURIT If you smell gas Si vous sentez une odeur de gaz 2 1 Open Windows 1 Ouvrez les fen tres 2 Don t touch electrical switches 2 Ne pas actionner d interrupteur 3 Extinguish any open flame 3 teindre toute flamme ouverte 4 Immediately call your gas supplier 4 Appelez imm diatement votre ire fournisseur de gaz WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or death Read the installation operating and maintenance i
8. Change to correct setpoint Sensor TS 02 and or Unit Enable Potentiometer MP 15 setpoint 1c Check Heating Occupied 1c Change to correct setpoint and or Unoccupied setpoint Incorrect Maximum or minimum 1 Install a BACview 6 or PC 1 Change to correct setpoints Maximum heating discharge or Minimum temperature setpoint Discharge Air not set correctly Temperature Refer to Digital Control System User Manual for additional troubleshooting suggestions Control circuits external to MRT Controls can cause burner malfunction Always check manual valve to be certain gas is on and check limit controls for normal operation 46 SECTION VII TROUBLESHOOTING WITH DDC CONTROLS continued Modulating Room Temperature MRT MRT PRO or MRT EXPERT Controls continued Symptom Possible Cause Field Test Remedy G Continuous High Fire Electronics OK Foreign object holding butterfly valve GP 39 open Inspect linkage valve 1 Readjust linkage on valve or replace if necessary H Continuous High Fire Electronics Problem Open circuit in Outside or Inlet Air Temperature Sensor TS 01 and Discharge Air Temperature Sensor TS 03 Measure resistance per Thermistor Curve If readings are incorrect replace Outside or Inlet Air Temperature Sensor TS 01 or Discharge Air Temperature Sensor TS 03 or repair wiring l Incorrect High Fire Inlet press
9. Internal Fault was on when it should Remove system power and turn off power supply be off 1 Remove system power and turn off fuel supply 2 Check wiring correct any errors 3 inspect Pilot Fuel Valve s both places and connections 4 Reset and sequence the relay module 5 If the fault persists replace the relay module Code 4 3 Flame not sensed or 1 Check wiring correct any errors Flame sensed when it should 2 Make sure the flame amplifier and flame detector are compatible Amplifier be on or off 3 Remove the flame amplifier and inspect the connections Reseat the amplifier Problem 4 Reset and sequence the relay module 5 If the code reappears replace the flame amplifier and or the flame detector 6 If the fault persists replace the relay module Code 4 4 The configuration 1 Inspect the jumper connections Make sure the clipped jumpers were completely Configuration jumpers differ from the removed Jumper sample taken at startup 2 Reset and sequence the relay module Problem 3 If the fault persists replace the relay module Code 5 1 Preignition Interlock 1 Check wiring and correct any errors Preignition fault 2 Check Preignition Interlock switches to assure proper functioning Interlock 3 Check fuel valve operation 4 Reset and sequence the relay module monitor the Preignition Interlock status 5 If the fault persists replace the relay module Code 5 2 Either High Fire Switch 1 Check wiring and correct any er
10. Shipping Base Indirect Gas Fired units are shipped completely assembled where shipping limitations allow Optional inlet hoods filter and or damper sections or other large accessories are assembled and shipped mounted and wired whenever possible within 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 heater and or accessories cannot be installed immediately they should be stored in a clean dry environment If this is not possible and the heater must be stored outdoors it should be protected from the weather with tarpaulins or plastic coverings Rotate the fans monthly Prior to beginning installation of a unit that has been in storage for weeks or months the unit and its components should be closely inspected Prior to beginning installation of a unit that has been in storage for weeks or months the unit and its 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
11. and shipped with the units Upon receipt of shipment all units should be checked against the bill of lading to insure all items have been received All equipment and any optional accessories should be checked carefully for physical damage in the presence of the carrier s representative If parts are missing or damage has occurred a claim should be filed immediately with the carrier All Indirect Gas Fired units 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 s maintenance personnel in proper operations and maintenance Consult factory for quotations on periodic or start up service SECTION III INSTALLATION FOR CANADIAN INSTALLATIONS ONLY 1 All installations must conform with local building codes or in the absence of
12. r CARD EE bust COVER SEQUENCE STATUS i LEDs N TEL RELAY MODULE RESET F FLAME PUSHBUTTON AMPLIFIER FEAME FLAME CURRENT SIMULATOR INPUT TEST JACKS M7552A WIRING SUBBASE Ma Figure 6 Selectable Site Configurable Jumpers SELECTABLE CONFIGURATION JUMPERS RUN TEST SWITCH EC7895C RM7895C D RM7896C D M7553A Table 7 Site Configurable Jumper Options Jumper Number Description Intact Clipped JR1 Pilot Flame Establishing Period PFEP 10 Seconds 4 Seconds JR2 Flame Failure Action Recycle Lockout JR3 Airflow Switch ILK Recycle Lockout Failure IMPORTANT Clipping and removing a jumper after 200 hours of operation causes a nonresettable Fault 110 The relay module must then be replaced RUN TEST C D ONLY SWITCH CONFIGURATION JUMPERS SEQUENCE STATUS LED PANEL RESET BUTTON KEYBOARD DISPLAY MODULE N CAPTIVE MOUNTING SCREW FLAME AMPLIFIER x 22827 Figure 4 RM7897A C Relay Module Exploded View Ads SECTION VII TROUBLE SHOOTING continued Figure 2 Wiring Subbase and Seguence Chart for RM7897A i TA 22222 FOR DIRECT SPARK IGNITION OIL OR GAS IGNITION TRANSFORMER 1 LINE VOLTAGE BURNER MOTOR BLOWER MAIN VALVE PREIGNITION INTERLOCK BURNER CONTROLLER LIMITS RUNNING INTERLOCK INCLUDING AIRFLOW SWITCH PILOTAGNITION
13. relates to gas pressures that are too high and or air dampers that are closed too far This causes a fuel rich mixture NOTE 3 or 4 trials may be needed to purge air from pilot line Watch D C voltmeter carefully The reading should be steady and between 2 0 and 5 0 Volts D C If the reading is too low slowly turn the needle valve in or out until satisfactory flame signal is obtained See separate literature for testing of flame safeguard Make sure that the combustion air and pilot gas pressure is sufficient to provide instant ignition a stable flame and flame signal Cycle pilot several times to insure reliability With pilot adjusted you can now shut down the burner by turning the Heat on off switch to the off position Setting the Main Flame IMPORTANT When the Flame Safeguard relay module is switched to the TEST mode it stops and holds at the next Run Test Switch point in the operating sequence Make sure that the Run Test Switch is in the Run position before starting the burner CAUTION Do not attempt to start the burner when furnace is full of vapor or combustion chamber is very hot CAUTION At no time should you stand in front of the relief door Connectthe test instruments meters and thermometers on the heater and controls to measure and record the appropriate data Install one manometer at test port on the last tee of the burner manifold and one at the relief door Set all thermostats to call f
14. 30 while the slow blinks identify the units portion of the fault code two slow blinks is 2 Three fast blinks followed by two slow blinks would be fault code 32 This identifies a running interlock on during STANDBY See following Table for Blinking Fault Code List The LED code repeats as long as the fault exists To clear the fault press the RESET button Blinking Fault Codes and Recommended Troubleshooting Fault Code System Failure Recommended Troubleshooting Code 1 1 Low AC Line detected 1 Check the relay module and display module connections Low AC Line 2 Reset and sequence the Relay Module Voltage 3 Check the 7800 power supply and make sure that frequency and voltage meet specifications Code 1 2 Excessive noise or 4 Check the backup power supply as appropriate AC Quality device running on slow Problem fast or AC line dropout detected Code 2 1 Flame sensed when no 1 Check that flame is not present in the combustion chamber correct any errors Unexpected flame is expected during 2 sure that the flame amplifier and flame detector are compatible Flame Signal STANDBY or PURGE 3 Check the wiring and correct any errors 4 Remove the flame amplifier and inspect its connections Reseat the amplifier 5 Reset and sequence the relay module 6 If the code reappears replace the flame amplifier and or the flame detector 7 If the fault persists replace the relay module Cod
15. Clogged Filter Switch Adjust to field condition SUGGESTED CONTROLS SETTINGS FOR OPTIONAL DDC CONTROLS Refer to Digital Control System user manual for default settings TS 02 Space Temperature Sensor Customer Discretion 15 Unit Enable Potentiometer Customer Discretion KP 01 Keypad Display Module Customer Discretion PT 13 Building Pressure Transducer Adjust to MP 05 Damper Control Potentiometer Customer Field Condition Discretion BEFORE ATTEMPTING TO START THE HEATER READ THE TYPICAL SEQUENCE OF OPERATION AS SHOWN BELOW Typical Sequence Of Operations Note This se quence is written for only the burner safety and oper ating portion of the heater Other control systems for dampers mixing boxes and temperature controls are 4 included in the unit typical sequence of operation and or wiring diagram 3 Ignition transformer is de energized and pilot valve remains on Main fuel valve s will open The main burner flame will be established 5 Pilot valve is de energized This is only on heaters 1 With main supply air fan s on thermostat setpoint calling for heat and all switches and operating con trols in their normal position the exauster motor and burner motor will run and pre purge the combustion chamber Pre purge timing is not adjustable and is approximately 90 seconds With pre purge timing complete the pilot solenoid valve and ignition transformer are energi
16. Indirect Gas Fired unit has been designed for rigging and handling through the use of special lifting lugs installed on the top and or sides of each unit When unloading and setting the unit use the lifting lugs provided as shown in Drawing 000539 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 set screws be tightened Turn fan shaft by hand to make certain that blower does not rub against blower housing and that bearing set screws are tight If units are not set immediately cover all openings that might be exposed to the weather Rotate fans monthly IMPORTANT Lift and install the modules or sections of a unit separately Flange connections provided between modules or sections are not structural and damage will occur if any attempt is made to lift modules that have flanged together See the specification sheet and submittal drawing for unit or section weight and to determine proper orientation for each section When unloading sections and or units or moving equipment to its final location exercise care to avoid distortion Lift sections and or units only by the lifting lugs provided and follow the procedures as outlined below R
17. OF PC 6 IN GAS VALVE VG 2 7 WHEN MTR 4 OPENS 30 SW 10 WILL LOW FIRE HOLDING OPEN 8 SW 21 SWITCH FORMS A BY PASS CIRCUIT AROUND SW 10 SCREWDRIVER AT ONLY TO ADJUST CAM 4 STRAIGHT BLADE SCREWDRIVER HONEYWELL CRANK ARM RIGHT INNER SHOWN AUXILIARY SWITCH SW 10 SWITCH IN MTR 4 FOLLOWER LOW FIRE START INNER BL RED BL YL AUXILIARY R oer O BLUE HIGH FIRE ADJUSTMENT SCREW i THRU 17 VALVE LEFT OUTER AUXILIARY 2 THRU 3 SWITCH VALVE SLOW RISE PORTION SWITCH APPROX OVERRUNNING ADJUSTMENT FOLLOWER OUTER 10 DIFF CRANK ARM SCREW AUXILIARY BUTTERFLY VALVE ASSEMBLY APPROX MOTOR IN SHUT POSITION 1 DIFF TERMINALS R amp W SHORTED CLOCKWISE OPENING SW 11 IN MTR 4 MOTOR MOTOR BURNER CYCLING OPEN power CLOSE RED 6 BLUE END C000714 25 SECTION V UNIT START UP WITH DDC CONTROLS Before attempting to start the heater read and understand the seguence of operations electrical schematic flame safeguard control control com ponents gas train burner and the Digital Control System user manual WARNING During installation testing servicing and trouble shooting of this product it may be necessarvtoworkwithliveelectricalcomponents 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 al
18. Setpoints menu in the BACview and enter the desired room Heating Occupied and Unoccupied Setpoints For VDT Expert enter the desired Heating Discharge Air Setpoint Energy Savings Modes There are three 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 Users Manual Sequence and Burner Setup with DDC The I O Zone 583 Controller UC 01 must be calling for the burner to be enabled The DO 2 light will be on and Burner Enable Relay RE 28 needs to be energized If the outside or inlet air temperature is above the Heating Economizer Setpoint 65 F the burner will be disabled You will need to disconnect the plug where the Outside or Inlet Air Temperature Sensor TS 01 and Discharge Air Temperature Sensor TS 03 are wired to the I O Zone 583 Controller UC 01 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 NOTE A BACview or PC is required to change settings See the Digital Control System User Manual for a more detailed sequence of operation Setting the Pilot Flame CAUTION Do not attempt to start the pilot when furnace is full of vapor or combustion chamber is very hot CAUTION At no time should you stand in front of the relief door
19. VDC at IN 4 8 GND will be 0 76 50 CHECKOUT PROCEDURE FOR INTERFACE MODULE 02 07230 Adjustments The Q7230A provides adjustable range zero and 5 Set the controller to output the signal required to span for two wire current or voltage control Separate drive the motor to the closed position Wait for the potentiometers are provided on the circuit module for motor to stop driving closed adjusting the zero point and the span It includes a cw 6 Turn the zero potentiometer slowly counterclockwise ccw switch for configuring the motor to rotate clockwise MA the motor starts to open or counterclockwise with an increase in control signal 7 Turn the zero potentiometer slowly clockwise w until motor is fully closed This is defined as the 1 Set Mod IV motor pots both CW or both CCW zero setting for your application Use the checkout procedure in 8 Set the controller to output the signal required to Table 3 to ensure proper motor function drive the motor to the fully open position Wait for 2 Verifythatthe zero potentiometer is fully clockwise and the motor to stop driving open that the span potentiometer is fully counterclockwise 9 Turn the span potentiometer slowly clockwise w Do not exceed the stop point of the potentiometer until motor starts to drive closed The difference 3 Select desired rotation direction cw electrically between the fully open position signal and the fully normally closed is the most co
20. application NOTE HOOD REQUIRES ADDITIONAL INSTALLER PROVIDED SUPPORT DETAIL A C ADJOINING ADJOINING APPLY GASKET MATERIAL PRIOR TO ATTACHING SECTIONS THEN CAULK OR SEAL ALONG EACH SEAM DETAIL A DETAIL B eoa Ae 28 7 mm AS AE s OC i il H c gt FIRST SECTION TACKY TAPE nae 2 2 DETAIL B CAULK ROOF CAP GASKET MATERIAL STANDING Sf WITH FIELD APPLIED CAULK ROOF SEAM STANDING ROOF SEAM 000713 FIGURE 4 ii D Location of Accessories Where applicable standard or optional accessories will be placed inside the fan section of the unit for shipment and must be removed and installed by the mechanical or electrical contractor Remotely located discharge or inlet dampers must be eguipped with an end switch and interlocked to insure maximum design opening before starting and running circuits may be energized Field constructed intake accessories should be properly designed to minimize the entry of rain and snow Adequate building relief must be provided so as to not over pressurize the building when the heater is operating at its rated capacity This can be accomplished by taking into account through standard engineering methods the structure s designed infiltration rate by providing properly sized relief openings by interlocking a powe
21. back thermostat not closed Bearing seized on shaft 39 Check power source Replace fuse s Close or connect customer interlock Switch to on position Close door check and or replace switch Check stat and settings reset by re cycling the power Check sensor and location Check for power at damper motor and that end switch has been wired correctly End switch should be wired N O normally open Clear linkage Reset 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 time clock and field installed controls for correct set tings and voltage Check night set back thermostat for correct settings Turn power off and check bearings SECTION VII TROUBLESHOOTING continued Symptom Cause Remedy B No voltage at flame safeguard relay input Fan and Heat off on switch in off position Place switch in on position terminals RE 02 SW 11 SW 13 in MT 11 MTR 4 2 Check modulating motor for if applicable not closed proper operation see sheet in manual Auxiliary switch on starter 3 Check auxiliary circuit wiring not closed and contacts Proof of closure switch open 4 Check and see if gas valve if applicable is closed check wiring on circuit Thermostat open 5 Check thermostat for proper set ting High temperature limit is
22. ge EL A 10 SECOND INTERRUPTED ILOT MASTER SWITCH INITIATE A PFEP INITIAL 00 10 SEC 00 POWERUP TIMED 004 sEc ip 10 20 ONLY STANDBY PREPURGE JR1 CLIPPED RUN POSTPURGE STANDBY Power POWER POWER POWER POWER POWER LED O O OPior Gruior JO O DISPLAY O O OFLAME FLAME GBrLAME FLAME JO O O O Oman G vau man JO OALARM QALARM QALARM QALARM JO Q BURNER BURNER BLOWER MOTOR 5 10 IGN INTERMITTENTPILOT 8 INTERRUPTED PILOT 21 MAINVALVE 9 OPERATING To CONTROLS LIMITS BURNER CONTROLLER CLOSED L1 6 AND INTERLOCKS RUNNING INTERLOCKS CLOSED 6 TO 7 CK CLOSED 570 PII FLAME SIGNAL SAFE START CHECK FLAME PROVING SSC A 120 VAC 50 60 HZ POWER SUPPLY PROVIDE DISCONNECT MEANS A SEE FLAME DETECTOR SPECIFICATIONS FOR CORRECT WIRING AND OVERLOAD PROTECTION AS REQUIRED A PROGRAMMED ON SETUP USING S7800A1142 DISPLAY A DO NOT CONNECT ANY WIRES TO UNUSED TERMINALS A PURGE TIME DEPENDS ON WHICH ST7800 IS INSTALLED M22728B 35 SECTION VII TROUBLE SHOOTING continued The POWER LED provides fault identification when the Relay Module locks out on an alarm Fault identification is a series of fast and slow blinking LED lights The fast blinks identify the tens portion of the fault code three fast blinks is
23. machine Section II General Information 3 Section III Installation 2 2222 4 Section IV Pre Start Up Lena 19 This manual of instructions along with Digital Control Section V Unit Start Up without DDC Controls 21 System User Manual for systems with optional DDC Section V Unit Start Up with DDC Controls 26 controls has been prepared in order for you to become Section VI Unit Shut Down 30 well acquainted with those details and in doing so Section VII Troubleshooting 31 will be able to give your Indirect Gas Fired System the Section VIII Servicing the Burner 52 care and attention which any piece of equipment needs Section IX Maintenance Schedule and and deserves Lubrication Requirements 57 Section X Thermistor Output Curve for It is the customer and installation personnel units with DDC Controls 62 responsibilty to determine if the unit is equipped Section XI Replacement Parts 63 with all of the safety devices required for the par ticular application Safety considerations include the accessibility of the unit to non service person nel the provision of electrical lockout switches maintenance procedures and automatic control sequences Clearly mark any shutoff devices IMPORTANT NOTICE
24. not required If vent lines are even partially plugged this will interfere with proper venting of pressure con trol devices Check that all manual gas shut off valves are closed When failure or malfunction of this heater creates a hazard to other fuel burning equipment e g when the heater provides make up air to a boiler room the heater is to be interlocked to open inlet air dampers or other such devices Motor overload relay setting should match the motor s nameplate full load amperage Check any dampers or mixing boxes if supplied Make sure all damper linkage is free to move and no binding will occur If dampers are of the modulating type check control capillary tubes to insure that the tubes and bulbs are in the proper location and will not rub against any other parts Check to ensure all manual reset safety devices have been reset and limits are in the normal operating posi tion Check to ensure the flue stack is installed properly and is free of obstructions Adjust the induced draft damper so it is approximately 75 open Remove shipping screw from rear relief door if ap plicable Check that all fuses are installed Check that inlet gas pressure is the same as shown on the rating plate Check that field wiring connections to the burner mo tor and draft inducer motor are connected to the cor rect starters Check to make sure the inlet gas pressure is the same as the rating plate SUGGESTED TOOLS AND INSTRU
25. off and check belts Turn power off and check motor and wiring Check time clock and field installed controls for correct set tings and voltage Close switch if applicable Turn power off and check bearings See multiplex voltage value chart 42 SECTION VII TROUBLESHOOTING WITH DDC CONTROLS continued Symptom Cause Remedy B No voltage at flame 1 Heat Mode is disabled 1 Enable the heating mode safeguard relay input 2 Incorrect setpoint 2 Check for proper setting terminals RE 02 3 DO 2 or RE 28 is not energized 3 See digital control system user manual 4 Auxiliary switch on starter 4 Check auxiliary circuit wiring not closed and contacts 5 Air flow switch open 5 Check for proper CFM Adjust and or replace switch 6 RE 27 RE 56 and or RE 65 6 See multiplexed voltage value contacts open chart 7 Proof of closure switch open 7 Check and see if gas valve if applicable is closed check wiring on circuit 8 High temperature limit is open 8 Check limit for proper settings 9 High Low gas pressure 9 Correct gas pressure and reset switches open switches 10 Outside air temperature 10 Check for proper setpoint higher than heating economizer setpoint C Flame safeguard relay 1 See technical data sheets on 1 Determine the cause of RE 02 goes into safety flame safeguard relay lockout Push reset button on shutdown Lockout flame sa
26. on the wiring diagram typically dashed lines Where field wiring of the control circuit is required take care to size the wires for a maximum 1096 voltage drop The VA rating of the transformer should be the maximum load 4 Mount and wire remote control panel thermostat temperature sensors and any other field installed controls as indicated on the unit control wiring diagram 5 Connect all wiring to the appropriate field wiring terminal and any shielded or twisted wires as indicated on the unit control wiring diagram 6 Field wiring shall have a temperature rating of at least 105 C The minimum size of the supply cable circuit shall be sufficient for the maximum ampacity of the heater NOTE Burner and exhauster motor wiring must be connected to the corresponding starter As each motor and starter are sized as a matched set incorrectly wired components may cause some motors to have nuisance shutdowns and others will not have proper overload protection 248 10 T SECOND STAGE COOLING T FIRST STAGE COOLING COIL A RP 16 Ass I LR 52 TO IA A TO SEE NOTE 12 Q O 12 TO SECOND STAGE SUCTION 4 FIRST 5 SUCTION A FRAME COIL ASSEMBLY END ELEVATION THE ABOVE PIPING SCHEMATIC SHOULD BE USED AS A GUIDE ONLY PROPER ENGINEERING DESIGN OF THE OVERALL REFRIGERATION SYSTEM DICTATE AN ALTERNATE PIPING SCHEMATIC BE USED TO THE ONE ILLUSTRATED ABOVE GENERAL
27. open 6 Check limit for proper settings High Low gas pressure 7 Correct gas pressure and reset Switches open switches Outside air temperature 8 Check ductstat for proper higher than on off inlet setting ductstat setting Time clock or field installed con 9 Check time clock and field con trols open trols for correct settings and voltage C Flame safeguard relay See technical data sheets on 1 Determine the cause of RE 02 goes into safety flame safeguard relay lockout Push reset button on shutdown Lockout flame safeguard relay D Pilot does not light after Manual pilot shut off valve 1 Slowly open valve 90 second pre purge closed has timed out and voltage Inlet gas pressure lower than 2 Increase gas pressure is present on flame minimum gas pressure safeguard output required terminals No gas through pilot regulator 3 Clear obstruction in vent with sufficient inlet gas orifice or line replace if pressure defective No gas flow through pilot 4 Check for proper installation solenoid valve and voltage Correct or replace if defective Type of gas supplied natural 5 Connect to proper fuel supply gas or propane different than of contact factory for field shown on unit rating plate conversion parts Flame detection system not 6a U V Sensor Clean lens sensing pilot flame See check wiring and spark rod section for servicing burner 6b Flame Rod Assure rod is in pilot flame check wiring and flame
28. 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 on next page Evaporator Coil Blow Through The cooling coil section can be located in the unit so that supply air is blown through the evaporative coil s A properly piped trap should be installed to control the condensate flow from the unit and also eliminate conditioned air from being blown out the condensate drain See drawing on next page On initial start up 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 Er SUGGESTED P TRAP DESIGN FOR CONDENSATE DRAIN PANS UNDER A NEGATIVE PRESSURE 90 LONG RADIUS
29. reached and cooling is at full capacity system may be undersized See Trouble Shooting Guide for your condensing section or evaporative cooler 41 SECTION VII TROUBLESHOOTING WITH DDC CONTROLS Symptom Cause Remedy A Supply fan s do not operate 10 11 12 13 14 15 16 Low or no voltage Fuse s blown Customer s interlock not closed or connected Fan is disabled Door switch open DO 1 on UC 01 not energized RE 57 contacts not closed Freeze protection tripped 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 Time clock or field installed controls not closed Auxiliary Unit Enable Switch SW 09 not closed Bearing seized on shaft Multiplexed voltage values not correct Check power source Replace fuse s Close or connect customer interlock Enable the fan s Close door check and or replace switch See digital control system user manual Check power source and or replace Check stat and settings reset by re cycling the power Check sensor and location Check for power at damper motor and that end switch has been wired correctly End switch should be wired N O normally open Clear linkage Reset the starter by pushing red button on starter check amp draw Turn power
30. remove dust cap of main gas regulator and turn adjusting screw clockwise to increase pressure or counterclockwise to decrease pressure Setting the Pilot Flame CAUTION Do notattemptto start the pilot when furnace is full of vapor or combustion chamber is very hot CAUTION At no time should you stand in front of the relief door Honeywell Flame Safeguard Control RE 02 A keyboard display module Honeywell S7800A1142 is recommended to read the flame signal and is a good troubleshooting device A V O M can also be used on the D C voltage test jacks marked and on flame amplifier Connect manometer to pilot test tee if applicable Set all thermostats to call for heat Set inlet ductstat if applicable above outside air temperature Turn Fan and Heat Off On switches to the On position and check rotation of burner and induced draft fans amps and overload settings Make sure the damper on the induced draft fan is approximately 75 open If limits and all safety controls are closed the burner and induced draft fan will run for 90 seconds before ignition trial as a pre purge cycle Place run test switch on the flame safeguard relay in the test position during P F E P b S NOTE Pilot regulator adjustment may be needed if the adjustment of the needle valve does not yield the required reading Typical adjustment of the needle valve is 1 1 2 to 2 turns open NOTE Frequently the cause of pilot problems
31. side Sleevlock bearing installation SPB 2115 C2 1 Mountall 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 3 Louvers Louvers should be inspected monthly daily in icy weather to insure they are clean and clear C Air Filters All filter banks should be equipped with a manometer or differential pressure switch to indicate when the filters are dirty Filters should be replaced when the differential pressure across them reaches the manufacturer s recommended final value Dirty filt
32. switch opens b Ignition pilot valve terminal is energized c Main valve terminal is energized d Delayed main valve terminal is energized RM7897C e Internal system fault occurred f Purge card is removed g Purge card is bad h Flame signal is detected for 30 seconds i Preignition interlocks open durning stand by 4 PILOT FLAME ESTABLISHING PERIOD PFEP a Airflow lockout feature is enabled and the airflow switch opens b No flame signal at end of PFEP c Ignition pilot valve intermittent pilot valve terminal is not energized d Main valve terminal is energized 7897 e Delayed second stage main valve terminal is energized 7897 f Internal system fault occurred g Purge card is removed h Purge card is bad 5 MAIN FLAME ESTABLISHING PERIOD MFEP RM7897A teminal 21 a Airflow lockout feature is enabled and the airflow Switch opens b Ignition terminal is energized c Ignition pilot valve terminal is not energized d Main valve terminal is not energized e Delayed main valve terminal is energized f Loss of flame signal g Internal system fault occurred h Purge card is removed i Purge card is bad 6 RUN PERIOD a No flame present JR2 removed b Airflow lockout feature is enabled and the airflow Switch opens c Interrupted pilot valve terminal is energized RM7897A terminal 21 d Main valve terminal is not energized e Delayed main valve terminal is not energ
33. terminals defective Burner will not respond 1 Forunits with DDC Controls 1 See Digital Control System User to temperature Manual Flame safeguard goes 1 Pilot gas pressure may be too 1 Adjust needle valve typically into alarm when main high 1 1 2 to 2 turns open from closed flame is trying to position establish on units with interrupted pilot Return air or outside air 1 Building Pressure Transducer 13 1 Check and or replace components damper not functioning Damper Control Potentiometer MP See section on trouble shooting properly see sequence 05 or Photohelic Controller PS 13 PT 13 of operations for damper defective or not calibrated control 2 Building Pressure Transducer 13 2 Check wiring and or replace bad Damper Control Potentiometer MP components 05 or Photohelic Controller PS 13 defective or not wired correctly 3 Building Pressure Transducer PT 13 3 Install correctly See section Damper Control Potentiometer MP on trouble shooting PT 13 and 05 or Photohelic Controller PS 13 manufacturer s cut sheet defective or not installed correctly 4 Unit Control Module UC 01 defective 4 Check and or replace Contact Factory 5 Unit Control Module UC 01 not 5 Check wiring wired correctly 6 Two position switch defective 6 Check and or replace 7 Damper motor defective 7 Check and or replace 8 Dampers binding and or loose 8 Check and repair 44 SECTION VI
34. 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 direc tion as the other bearings setscrews Place a drop of BLUE Loctite on the bearing set screws and tighten all of the setscrews Follow the mounting instruction s procedure on the inside of the bearing box for the proper tightening and torque values Align the blower hubs keyway with those in the shaft Be sure the clearance between the blower wheel and blower housing is the same on each side Rotate the shaft by hand to insure free operation Correct any rubbing of the blowers on the housings Place a drop of BLUE Loctite on the blower 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 vibration during operation 25 All bearings are pre lubricated and should not require greasing Refer to the bearing manufacturer s instructions or the unit manufacturer s instructions for proper bearing maintenance Note Drive
35. 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 a 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 100RPM Upto125 F Clean 6 months 500 RPM Upto150 F Clean 2 months 1000 RPM Upto210 F Clean 2 weeks 1500 RPM Over150 F Clean weekly Any Speed Upto150 F Dirty 1 we
36. 01 will send a 0 to 10 VDC signal to the Interface Module IM 02 located inside the Modulating Gas Valve Operator MT 11 See check out procedure for IM 02 At approximately O VDC the valve will be in low fire and 10 VDC is high fire Prior to setting low and high fire you should have your test equipment installed and be familiar with the Butterfly Valve GP 39 and its adjustment For the high fire setpoint refer to the unit rating plate for Normal Manifold Pressure in inches of W C With the Modulating Gas Valve Operator MT 11 in its high fire position set high fire using the Main Gas Pressure Regulator GP 05 and with the high fire adjusting screw on the Butterfly Valve GP 39 Remove the or wire from IM 02 and set low fire with the low fire adjusting screw on GP 39 See final checks and adjustments Cycle the pilot and burner several times to be sure it lights off reliably Enable the fans and heat as described earlier in this section Restart unit After the pilot proves the main automatic fuel valve s will be energized Slowly open the last gas shut off valve and the burner should light immediately CAUTION If main flame does not light within a few seconds after pilot flame is established shut the burner down and repeat steps You may have to eliminate air from the main gas line The main gas pressure and or burner air setting may also need to be adjusted If flame signal drops significantly when main gas v
37. 3 TS 03 circuit or wiring circuit See Thermistor curve F Continuous High 1 Foreign object holding 1 Inspect linkage and valve 1 Readjust linkage on valve or Fire Electronics butterfly valve GP 39 replace if necessary OK open G Incorrect 1 Inlet pressure too low 1 Read pressure at inlet to 1 Increase inlet pressure if High Fire modulating valve using a possible manometer with unit operating at full fire Pressure should be equal to the sum of outlet pressure setting plus pressure drop of the valve 2 Incorrect outlet pressure 2 Read manifold pressure using 2 See Sequence and Burner adjustment of Pressure manometer and compare with setup in Section X Regulator the pressure stated on the specification plate H Incorrect 1 Unit Enable Potentiometer 1 Check setpoint on Unit Enable 1 Change to correct setpoint Discharge Air MP 15 not set correctly Potentiometer MP 15 setting Temperature 2 Discharge Air 2 Check Discharge Air 2 If readings are not correct Temperature Sensor TS Temperature Sensor TS 03 replace Discharge Air 03 not reading correctly and wiring See Thermistor Temperature Sensor TS 03 3 The Heating Discharge curve or repair wiring Air Setpoint on 3 Check setpoint with BACview 3 Change to correct setpoint VDT EXPERT Control or PC See Digital Control System System is not set User Manual correctly Refer to Digital Control System User Manual for additional tr
38. AMAGED ARTICLES Never return damaged articles to us They are the prop erty of the transportation company when the claim is filled They will give you disposition instructions PACKING We comply with the packing requirements of the trans portation 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 Indirect Gas Fired System and supplement but not to replace the services of gualified field service personnel to supervise the initial start up and adjustment of the unit Persons without previous experience with large commercial and industrial heating equipment should not attempt the initial adjustment and checkout procedure which is essential before such installations may be considered ready for operation This manual should be made readily available to all operating personnel as an aid in troubleshooting and proper maintenance Due to the custom nature of Temprite equipment not all possibilities are addressed in this manual The customer or installer can obtain information from Temprite s sales representative or theTemprite factory WARNING Failure to comply with general safety information may result in extensive property damage severe personal injury or death B
39. ATE THERMAL EXPANSION VALVE TXV 11 SENSING BULB FROM THERMAL EXPANSION VALVE TXV TO BE LOCATED ON THE SIDE OF A HORIZONTAL PORTION OF THE DX COILS SUCTION LINE PIPING AT AN ANGLE OF APPROXIMATELY 120 FROM VERTICAL DO NOT LOCATE SENSING BULB ON ANY PIPING USED IN A TRAP OR DOWNSTREAM OF A TRAP 12 INSTALL TRAP IN SUCTION LINE AS ILLUSTRATED IF COMPRESSOR IS LOCATED BELOW THE THE DX COIL 13 ALL COIL SPECIALTIES AND REFRIGERANT PIPING SHOWN OTHER THAN THE REFRIGERANT DISTRIBUTOR AND ANY OTHER REQUIRED REFRIGERATION SYSTEM SPECIALTIES ARE TO BE PROVIDED BY AND INSTALLED IN THE FIELD BY OTHERS 16 I Locating Temperature Controls The room or outdoor thermostats should be mounted where they will not be subjected to direct impact of the heated air or radiant heat from the sun It is also recommended that thermostats especially those with mercury bulb contacts be mounted on a vibration free surface The 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 J Drains and Traps Some furnaces maybe 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 accordan
40. I TROUBLESHOOTING WITH DDC CONTROLS continued Modulating Discharge Temperature MDT or MDT EXPERT Controls Symptom Possible Cause Field Test Remedy A No Gas Flow 1 Gas valves improperly 1 Arrow on side or bottom of 1 Install properly with DO 2 installed valves should point in direction or UC 01 of gas flow energized UJ Continuous Low Fire Electronics Incorrect operation of Interface Module IM 02 Check for 2 10 VDC at IM 02 input terminals See checkout procedure if voltage is correct Problem 2 No output voltage on UC 01 2 Check 0 10 VDC Voltage on 1 2 Contact Factory C Continuous Low 1 Defective modulating 1 Inspect wiring see checkout 1 Replace modulating gas Fire Electronics gas valve operator MT procedure in section X valve operator MT 11 or OK 11 and or burned out transformer transformer D Incorrect 1 Incorrect low fire butterfly 1 See butterfly valve adjustment 1 Adjust to proper minimum fire Minimum Fire valve GP 39 adjustment E Continuous High 1 Open circuit in Outside or 1 Check Outside or Inlet Air 1 Replace Outside or Inlet Air Fire Electronics Inlet Air Temperature Sensor Temperature Sensor TS 01 Temperature Sensor TS 01 Problem TS 01 and or Discharge and or Discharge Air Temperature and or Discharge Air Air Temperature Sensor Sensor TS 03 for open internal Temperature Sensor TS 0
41. IGGING AND MOUNTING INDIRECT FIRED UNITS LIFTING LUGS PROVIDED IN ONE OF TWO LOCATIONS A USE WHEN LIFTING OVER 3 000 LBS B USE WHEN LIFTING UNDER 3 000 LBS C000539 Warning To insure that a proper unit lift is made lift unit approximately 24 inches and verify proper center of gravity lift point To avoid dropping of unit reposition lifting point if unit is not level Failure to properly lift unit could result in death or serious injury or possible eguipment or property only damage B Locating the Unit Prior to locating the unit authorities having jurisdiction should be consulted before installations are made Approval permits should be checked against the unit received Combustion air shall be provided at a rate of at least 0 20 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 96 for each additional 1 000 feet of altitude above sea level 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 in
42. MENTS Volt Ohm meter Tachometer Stack amp Temperature Thermometer Gas Pressure Gauge 0 35 Ibs Ammeter Amprobe or equal U Tube Manometer 0 10 W C Two Required Flue Gas Test Equipment Standard Hand Tools D C Volt Meter BAC View 6 for DDC Controls if applicable SUGGESTED CONTROLS SETTINGS FL 01 Fan 959 110 RE 21 Time Clock Customer Discretion FL 02 High Limit TDM Down Discharge 165 F 01 Room Thermostat Customer Discretion FL 02 High Limit All Other Units 200 F 02 Modulating Discharge Ductstat 709 F FL 04 Auxiliary High Limit TDM Down Discharge 175 F 03 On Off Inlet 65 F FL 04 Auxiliary High Limit All Other Units 210 F TC 06 High Limit Discharge Ductstat 100 F PS 01 Draft Proving Switch Adjust to field condition TC 07 Low Limit Discharge Ductstat 60 F PS 02 Burner Proving Switch Adjust to field condition TC 08 Freeze Thermostat 45 F amp 3 Minutes PS 04 Low Gas Pressure Switch 1 0 W C TC 55 Return Air Ductstat Customer Discretion PS 07 High Gas Pressure Switch 125 above 58 Night Setback Thermostat Customer Discretion burner firing rate PS 10 Main Air Proving Switch Adjust to field condition PS 12
43. ND ADJUSTMENTS After the burner has been in operation for at least 10 minutes this allows the combustion chamber and heat exchanger to reach aneguilibrium temperature a flue gas analysis can now be performed There is a test plug in the stand off box where the induced draft fan airflow switch tube is located The following readings should be taken but not limited to o Net Stack Temperature O 96 Combustion Efficiency 96 If necessary make adjustments on burner air shutter DO NOT change the fuel input rate 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 e 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 480 F Above Ambient Draft setting too high Excess burner air Fuel input too high Blocked and or restricted secondary tubes Low Oxygen e Oxygen reading must always be a positive percentage Make sure there is a minimum of 0 20 W C at relief door when burner is in high fire with a warm stack Cycle burner several times to ensure smooth light off and proper operation Visually observe the flame pattern Th
44. NED 3 DIRECTION DISCHARGE BOX 4 DIRECTION OPTIONAL GASKET PLENUM EXTENSION ALIGNMENT FLANGE CAP GASKET HEAT EXCHANGER SECTION ALIGNMENT FLANGE CAP GASKET FAN SECTION SCREENED INLET SECTION DISCHARGE BOX GASKET PLENUM EXTENSION SHEET METAL SCREW IN PLACE LIFTING LUG GRILLS 3 DIRECTION DISCHARGE BOX 4 DIRECTION OPTIONAL GASKET PLENUM EXTENSION ALIGNMENT FLANGE CAP GASKET COOLING SECTION OPTIONAL ALIGNMENT FLANGE CAP GASKET HEATER EXCHANGER SECTION ALIGNMENT FLANGE CAP GASKET FAN V BANK AND INLET SECTION P nu BOX GASKET PLENUM EXTENSION SHEET METAL SCREW IN PLACE LIFTING LUG GRILLS DIRECTION DISCHARGE BOX 4 DIRECTION OPTIONAL Pls GASKET PROP FAN SECTION ALIGNMENT FLANGE CAP T GASKET COOLING SECTION OPTIONAL ALIGNMENT FLANGE CAP 0 GASKET P a V BANK AND INLET SECTION DISCHARGE BOX GASKET 7 Du PLENUM EXTENSION SHEET METAL SCREW IN PLACE C000712 10 DIRECTIONS FOR FIELD ASSEMBLING AND WEATHERPFOOFING SECTIONS 1 Apply gasket material to the end of the first section blower discharge heater ets 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
45. NOTES COMPONENT IDENTIFICATION 1 RECOMMEND FIRST STAGE AND SECOND STAGE OF COOLING HOT GAS BYPASS TEE BE PROVIDED WITH HOT GAS BYPASS LIQUID LINE SOLENOID VALVE 2 ALL PIPING TO BE ACR TYPE 1 COPPER 1 HOT GAS BYPASS VALVE SECOND STAGE 3 ALL PIPING TO BE PITCHED IN THE DIRECTION OF HOT GAS BYPASS VALVE FIRST STAGE REFRIGERANT FLOW PITCH TO BE 1 INCH PER 10 FEET THERMAL EXPANSION VALVE 1 4 ALL SUCTION LINES TO BE INSULATED CIRCUIT 2 COIL A 5 LIQUID LINE FILTER DRIER SIGHT GLASS SUCTION LINE THERMAL EXPANSION VALVE TXV 2A FILTER DRIER ISOLATION VALVES FITTINGS DISCHARGE CIRCUIT 1 COIL A VIBRATION ABSORBER ACCUMULATORS AND OTHER 1 THERMAL EXPANSION VALVE TXV 1B AVAILABLE SYSTEM OPTIONS ARE NOT SHOWN CIRCUIT 2 COIL B 6 RECOMMEND LONG RADIUS ELBOWS BE USED TO MINIMIZE 1 THERMAL EXPANSION VALVE 2 SYSTEM PRESSURE DROP CIRCUIT 1 COIL B 7 RECOMMEND LIQUID LINES FOR R 410A BE SIZED FOR A OX EVAPORATOR COILA MAXIMUM PRESSURE DROP OF 6 PSIG DX EVAPORATOR COIL B INTERTWINED 8 RECOMMEND SUCTION LINES FOR R 410A BE SIZED FOR A RERBIGERANTIISTRIB UTOR MAXIMUM PRESSURE DROP 3 PSIG CONDENSATE PAN PROVIDED WITH DRAIN 9 RECOMMEND CONDENSER SUBCOOLING CIRCUIT FOR R 410A CONNECTIONS ON BOTH ENDE BE CAPABLE SUBCOOLING LIQUID BETWEEN 12 19 F 10 CONNECT 1 4 O D EXTERNAL EQUALIZING LINE GENERALLY LOCATED IN EACH SUCTION HEADER OF EACH DX COIL TO P000971R410 THE APPROPRI
46. NS UPWARD 1 INCH PER FOOT TOWARD OUTLET FOR CONDENSATE DRAINAGE SUPPORT HORIZONTAL RUNS AS REQUIRED TO PREVENT SAGGING 4 FORNONHIGH TURNDOWN BURNERS WHENEVER USING SIDE WALL VENTING A DRAIN LINE SHOULD BE ADDED TO THE BOTTOM OF THE EXHAUSTER HOUSING FOR CONDENSATE REMOVAL C000563A 14 Pitch horizontal pipes downward inch per foot toward outlet for condensate drainage Support horizontal runs as required to prevent sagging Vents should terminate that would not cause a down draft to occur This could affect the negative pressure required 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 a stack The stack shall have aminimum of at least 36 clearance to combustible materials WARNING CARBON MONOXIDE Your venting system must not be blocked by any snow snow drifts or any foreign matter Inspect your venting system to ensure adeguate ventilation exists at all times Failure to heed these warnings could result in carbon monoxide poisoning symptoms include grogginess lethargv inappropriate tiredness or flu like symptoms G Field Piping Gas Piping All gas piping must be in accordance with the requirements outlined in the National Fuel Gas Code A
47. NSI 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 PT plugged tapping accessible for test gauge connection must be installed immediately upstream of the gas supply connection to the unit WARNING To avoid equipment damage 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 liguid petroleum gases should be used on threaded joints Refer to the heater s rating plate to determine the minimum gas supply pressure for obtaining the maximum gas capacity for which this heater is specified Refer to the heater s rating plate to determine the maximum supply pressure to the heater The appliance and its individual shutoff valve must be disconnected from the gas supply piping system duri
48. O O O O NIN Co o o e 00 CLEANOUT COVER WITH DRAIN PLUG NOTES 1 WEIGHT OF STACK MUST BE SUPPORTED FROM FLOOR OR BUILDING STRUCTURE DO NOT SUPPORT STACK FROM INDUCED DRAFT FAN 2 RECOMMENDED STACK MATERIAL IS 14 GAGE SERIES 400 STAINLESS STEEL CONTINUOUSLY BUTT WELDED TYPE C EXHAUST STACK 0000541 eu APPROVED SIDE WALL VENT DEVICE SIDE WALL VENTING APPROVED SIDE WALL VENT DEVICE DIMENSIONS e SIZE 35 6 1 4 6 3 8 HXW 40 6 1 4 6 3 8 1 45 6 1 4 6 3 8 55 6 1 4 6 3 8 gt SEE NOTE 4 65 7 7 3 8 EXHAUSTER 75 7 7 3 8 85 7 7 3 8 100 7 7 3 8 BUILDING WALL 125 9 9 3 8 150 9 9 3 8 175 9 9 3 8 200 9 9 3 8 DIVERTER BUILDING WALL 250 10 5 8 11 1 8 275 10 5 8 11 1 8 1 300 10 5 8 11 1 8 325 10 5 8 11 1 8 lo 4 350 10 58 11 1 8 400 10 5 8 11 1 8 24 MIN 500 10 5 8 11 1 8 HXW e 5 600 10 5 8 11 1 8 SEE NOTE 4 Y EXHAUSTER NOTES 1 WEIGHT OF STACK MUST BE SUPPORTED FROM FLOOR ALTERNATE SIDE OR BUILDING STRUCTURE DO NOT SUPPORT STACK WALL DESIGN FROM INDUCED DRAFT FAN 2 RECOMMENDED STACK MATERIAL IS 14 GAGE SERIES 400 STAINLESS STEEL CONTINUOUSLY BUTT WELDED EXHAUST STACK 3 PITCH HORIZONTAL RU
49. PURGE sequence the Run Test Switch placed in the TEST position causes the PREPURGE timing to stop 2 In the Pilot Flame Establishing Period the Run Test Switch placed in the TEST position stops the timer during the first eight seconds of a ten second PFEP selection or during the first three seconds of a four second PFEP selection It allows for pilot turn down test and other burner adjustments This activates a fifteen second flameout timer that per mits pilot flame adjustment without nuisance safety shutdowns The Run Test Switch is ignored during PFEP for the C relay module if terminals 8 and 9 or 9 and 21 are jumpered IMPORTANT When the relay module is switched to the TEST mode it stops and holds at the next Run Test Switch point in the operating sequence Make sure that the Run Test Switch is in the RUN position before leaving the installation 33 SECTION VII TROUBLE SHOOTING continued SETTINGS AND ADJUSTMENTS Selectable Site Configurable Jumpers The relay module has three site configurable jumper options see Fig 6 and Table 7 If necessary clip the site configurable jumpers with side cutters and remove the resistors from the relay module SERVICE NOTE Clipping and removing a site con figurable jumper enhances the level of safety Figure 5 Sequence Status LEDs RUN TEST SWITCH s RM7895C D LL CAPTIVE 7895 sest MOUNTING RM7896C D 2 SCREW PLUG IN H T PURGE
50. alves open slightly increase or decrease pilot gas pressure to attain a steady flame signal After the burner lights adjust gas pressure regulator using a manometer and combustion air damper to match the normal manifold pressure shown on unit nameplate Make sure the setpoint and gas valves are in high fire These units have an induced draft fan a minimum of 0 20 W C must be maintained at the relief door simultaneously while setting the fuel to air pressure on the burner at full input This is done by changing the damper setting at the induced draft fan outlet with a warm stack Be sure to lock down the locking quadrant when you are done Observe flame as burner modulates when setpoints are adjusted Note Flame should modulate slowly and evenly throughout the entire travel although flame may become somewhat dirty during travel If stopped at any point proper combustion should resume Observe low fire it should be substantial enough to maintain proper combustion and be within the designed turndown range of the burner CAUTION Too low of an input setting will cause condensation of the flue gases this should be avoided unless condensate drains are provided Check all gas piping again for leaks using a soap bubble solution See final checks and adjustments 000723 BUTTERFLY VALVE ASSEMBLY MOTOR IN SHUT POSITION TERMINALS R amp W SHORTED CLOCKWISE OPENING 28 FINAL CHECKS A
51. and adjustments of the equipment All equipment has been factory tested adjusted metered and inspected to meet conditions set at the time the order was placed Only minimal adjustments should be required All information in this service manual is typical All prod ucts are semi custom and changes may occur CAUTION Line side of disconnect may be energized Follow proper lockout tagout procedures NOTE A qualified service engineer should perform all servicing and adjustments of the Indirect Gas Fired unit Perform a visual inspection internally and externally to make sure no damage has occurred and that everything is secure This inspection is very important and should be completed with great care given to detail A good pre start inspection will insure against possible unit damage on start up and will save valuable analysis time 1 Check that the physical condition of the unit exterior is acceptable 2 Check that any insulation inside the unit is properly secured 3 Remove all shipping blocks brackets and bolts from supply fan base with optional isolation base 4 Checkall terminals for loose connections and inspect all wiring terminations to insure that all crimped con nections are tight 5 Inspect all fan and motor bearings and lubricate if necessary CAUTION DO NOT RUTURE GREASE SEALS 6 Inspect pulleys and belts for tightness tension and alignment Do not overtighten belts 7 Check set screws on all
52. as shut off valves slowly Last main gas shut off valve before burner must remain closed at this time Reset high low gas pressure switches if applicable Check pilot and main gas lines for leaks using soap solution Check the gas supply pressure by replacing the plug fitting on the pilot gas 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 to decrease pressure 26 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 to 90 F MRT PRO With Smart Room Sensor To enable the heat press the Warmer or Cooler button on the face of the remote MRT Pro room sensor TS 02 to the desired room setpoint Each push of the button changes the temperature setpoint by 1 F The setpoint can be changed a maximum of 10 F from the default of 65 F Changing the heating setpoint also changes the cooling setpoint MRT Expert or MDT Expert With a BACview KP 01 To enable the heat for MRT Expert scroll through the
53. ation Ideal tension is the lowest tension at which the belt will not slip under peak load conditions Over tensioning shortens belt and bearing life Alternate Belt Tension Method 2 To properly tension a conventional V belt drive use the following procedure a Measure the span length b At the center of the span apply a force perpen dicular to the span to deflect the belt 1 64 inch for every inch of span length For example for a 40 inch span apply a force that will deflect the belt 40 64 or 5 8 of an inch c Compare the force you have applied with the values given in the table below If the force is between the values for normal tension and 1 1 2 times normal tension the belt tension should be satisfactory If the belt tension is not within this range it can be adjusted by loosening the motor mounting bolts and adjusting the position of the motor along its base B Section small Pounds pulley Pounds Force for diameter Belt Force for 17 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 E Optional Coils And Related Items 1 Coils Coil surfaces must be kept clean of dirt and lint in order to operate at rated efficiency Coils should be inspected on a regular basis and cleaned as required 60
54. b Inspect all drives for proper belt tension wear and alignment c Check that bearings fans props sheaves and coupling setscrews are securely locked to the shaft d Remove pilot assembly Clean and adjust if nec essary Refer to burner manufacturer IOM e Check the voltage and amps on all motors f Check the operation of all safety limits and con trols Clean and recalibrate or replace g Check the operation of the automatic gas shut off valves and check them for leakage at the pressure test ports provided h Inspect all electrical components connections and terminals Clean or replace and tighten as necessary i For DDC Controls Check that the battery in the UC 01 controller has 3 VDC CAUTION Do not remove the battery with the power to the unit turned off 6 Off Season or Yearly a Complete the monthly and quarterly mainte nance schedules b Inspect and if necessary clean all fan wheels props and housings c Check all nuts and bolts for tightness d Inspect all bearings and check condition and alignment e Check the condensation lines for any leaks or blockages if applicable f Inspect all burner components g Clean flame sensor ignition electrodes and check for cracks h Test the flame safeguard relay RE 02 and replace components if necessary i Inspect all regulators relief valves motorized valves solenoid valves vent valves manual shut off valves and safety shut of
55. bearings pulleys fans and couplings for tightness 8 Check voltage supplied to disconnect switch the maximum voltage variation should not exceed 1096 Phase voltage unbalance must not exceed 296 Check thermostat s for normal operation 10 Check that system duct work is installed and free of 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 that all piping connections particularly unions are tight Check all gas piping for leaks using a soap 14 15 16 18 19 20 21 22 23 24 25 26 27 28 29 bubble solution The most common types of problems found relative to the gas train itself is free of 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 Check that all accessories requiring field wiring have been properly installed Check burner for proper location and alignment Check that filters filter stops accessories and any ship loose items are installed properly Check that vent lines if applicable are run to atmo sphere on gas regulators and pressure switches for indoor units Vent lines should terminate outside the building with a turndown elbow and bug screen Note that some units will use vent limiters and vent lines are
56. belts are tight and sheaves are aligned The fan belts can be checked every 30 days after the first 60 days of new belt run in CAUTION Do not overtighten belts b Check set screws and bolts on the fan bearings cou plings 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 pilot and burner flame signal and safety lockout RE 02 c Check the fuel pressure in the fuel supply line to each heater d Check the burner manifold pressure and draft e Do a flue gas analysis f Inspect filters Clean or replace as necessary g Inspect main fan bearings lubricate if necessary See following section on bearing lubrication h Check all dampers damper actuators and link ages Adjust and tighten if necessary i Inspect area and make sure that no combustible or hazardous material has been stored within clearances as shown on the specification plate j Check for any vibration or unusual noise If any is observed locate the cause and correct k Ensure the supply discharge combustion air vents and stack remain clean and open I Check and clear air sensing tubes and fittings CAUTION Remove tubes from switches and transducers before using compressed air to blow through tubing 5 Quarterly a Complete the monthly maintenance schedule
57. ce 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 entering the space Outdoor units may require 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 and 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 Evaporator Coil Draw Through The cooling coil section can be located in the unit so that supply air is drawn through the evaporative 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
58. cedure Proper Motor Response Switch in Switch in Counterclockwise Clockwise Position Position 1 Open terminals F Motor closes fully ccw Motor closely fully cw 2 Jumper F to Motor opens fully cw Motor closes fully ccw 3 Remove either T terminal Spring return motors return to normal spring position fully ccw for mechanically normally closed motors fully cw for mechanically normally open motors and denotes terminals on the controller 51 SECTION VIII SERVICING THE BURNER This section is intended as a guide in making some repairs and adjustments to the power burner Many of the repairs will require the service of a skilled heating service technician For more information refer to the burner Power Flame Burners 1 GAS ELECTRIC IGNITION The gas electric pilots used on Power Flame burners are either flame rod or scanner design 2 POOR FLAME SIGNAL Try adjusting needle valve or pilot pressure regulator Should this not be successful check the primary pilot air If neither of these methods improve the reading inspect the flame rod position The spark is to arc against the outside radius of the pilot assembly case not the pilot head nozzle The normal spark gap should be 1 16 3 32 See the drawings for pilot assembly for the J Burner Pilot Assembly J Burner with Flame Rod Natural Gas Only 12 1 4 J R 15 30A 13 3 4 J R 50A r 1 16 to 3 32 Spark Gap r 3 8 2 31 32
59. e condensation of the flue gases this should be avoided unless condensate drains are provided See following drawings for operation of modulating thermostat and typical circuit SW 11 SW 13 should cycle the burner See final checks and adjustments toward the end of this section BA TYPICAL SEQUENCE FOR MODULATING THERMOSTAT WITH 135 CONTROLS 5 1 RESISTORS ARE SIZED TO HOLD MODULATING 4 MOTOR AT APPROXIMATELY 25 OF MOTOR TRAVEL FOR LOW FIRE START 2 SW 13 BURNER CYCLING SWITCH IS MADE 20 90 OF MOTOR TRAVEL 3 SW 12 LOW FIRE START SWITCH MADE 0 TO 30 OF MOTOR TRAVEL 06 120 OPERATION MOD MOTOR ROOM 1 STAT CALLS FOR HEAT DRIVING MT 11 OPEN THERMOSTAT 2 WHEN 11 REACHES 20 OPEN SW 13 CLOSES E 05 06 2 Ta LOW FIRE LOW FIRE HOLD 3 54 13 POWERS 06 AND PLACES 11 BURNER CYCLING UNDER RESISTOR CONTROL RED BLUE E 4 MT 11 MOVES TO 25 OPEN AND REMAINS CLOSED ON CALL FOR HEAT SAFEGUARD THERE DURING TRAIL FOR IGNITION INTERLOCKS 5 UPON PROOF OF FLAME RE 05 DE ENERGIZES 06 SW 12 6 MT 11 IS TRANSFERRED BACK TO CONTROL SIR 7 WHEN 11 OPENS TO 30 SW 12 WILL 46 BL RED BL YL ico OPEN 8 RE 05 CONTACTS FORM A BY PASS CIRCUIT ME DEAN AROUND SW 12 MOVE SCREWDRIVER AT TOP ONLY TO ADJUST CAM 4 STRAIGHT BLADE SCREWDRIVER HONEYWELL CRANK ARM
60. e 2 2 No flame time present 1 Measure the flame signal If one exists verify that it meets specifications Flame Signal at the end of the Pllot 2 Make sure that the flame amplifier and flame detector are compatible Absent Flame Establishing 3 Inspect the main fuel valve s and valve connection s Period lost during the 4 Verify that the fuel pressure is sufficient to supply fuel to the combustion chamber Main Flame Establishing Inspect the connections to the fuel pressure switches Make sure they are Period or during RUN functioning properly 5 Inspect the Airflow Switch and make sure that it is functioning properly 6 Check the flame detector sighting position reset and recycle Measure the flame signal strength Verify that it meets specifications If not refer to the flame detector and or flame amplifier checkout procedures in the installation instructions 7 Replace the flame amplifier and or the flame detector if necessary 8 If the fault persists replace the relay module Code 2 3 Flame signal value is 1 Make sure the flame detector and flame amplifier are compatible Flame Signal too high to be valid 2 Remove the flame amplifier and inspect its connections Reset the flame amplifier Overrange 3 Reset and sequence the relay module 4 Check the flame detector sighting position reset and recycle Measure flame strength Verify that it meets specifications If not refer to the flame detector and or flame amplifier chec
61. e is no voltage at 2 Burner or draft motor not 2 Check wiring fuses and amp flame safeguard relay running draw on motors output terminals 3 Burner or draft air 3 Check for correct rotation of proving switch is open motors and or adjust switch If there is no heat with 1 Manual gas shut off valve 1 Disable the heat Slowly open all pilot on and voltage closed manual gas shut off valves is present at flame 2 No gas on outlet side of 2 Clear obstruction in vent orifice safeguard relay output regulator with proper inlet or line Check for correct size terminals pressure spring Replace if defective 3 No gas on outlet side of valve 3 Check wiring voltage and or actuator with proper inlet adjustment Correct wiring or pressure replace if defective 4 Low fire start switch SW 10 SW 12 4 Check for proper operation see in MT 11 MTR 4 is open sheet in manual for proper settings 5 Inlet gas pressure lower than 5 ncrease gas pressure the required gas pressure 6 Normally open vent valve if 6 Check for correct installation applicable not closing and voltage Correct or replace 7 Gas nozzles obstructed or 7 Clear obstruction or blockage plugged see burner IOM If there is no heat with pilot 1 Flame safeguard relay run test 1 Place switch in run position on and novoltage is present switch in test position or is see technical cut sheet on flame at flame safeguard relay defective safeguard relay or replace if output
62. e total shim thickness at each bearing and mark the bearing mount for future reference Remove mounting bolts for bearings and remove any shims Loosen bearing and blower wheel shaft setscrews 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2 22 23 59 Remove the shaft from the unit by sliding the bearings and blower wheels along the shaft as the shaft is extracted Unless a blower wheel is damaged it should be unnecessary to remove the blower wheel from the blower housing Slide the new shaft through the first blower wheel hub Once the shaft is completely through the first blower wheel slide a bearing onto this end of the shaft Slide the shaft through the next blower wheel hub and add another bearing Continue this procedure until the shaft is through all of the blower wheels Place a bearing on each end of the shaft Replace the old shims with new Bolt the bearings in place and reattach the grease lines When installing a Sleevlock bearing see note at bottom of page Adjust the shaft so the blower hub keyways are in the middle of the shaft keyways Adjust the shaft so it protrudes past the non drive end bearing the blower sheave keyway mates with the shaft keyway and the drive side sheave can be aligned with the motor sheave Ideally the blower sheave should be as close to the drive side bearing as possible the motor sheave should be as close to
63. ect is not furnished with heater the field provided disconnect must be of the proper size and voltage Refer to unit nameplate 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 and applicable local codes in Canada to the Canadian Electrical Code Part 1 CSA Standard C22 1 Check the supply voltage before energizing the unit The maximum voltage variation should not exceed 10 Phase voltage unbalance must not exceed 296 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 F 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 The National Fuel Gas Code is subject to change questions regarding venting requirements should be directed to the local authority having jurisdiction All Indirect Fired Units are Category III appliances and must be vented Each unit must have an individual vent pipe and vent terminal Recommended vent pipe is 14 Gauge Series Stainless Steel Type vent 15 not acceptable DO NOT support the weight of the stack on the induced draft fan housing of the unit Insulate single wall vent pipe exposed to cold air or running through un
64. ed from the factory All warranty parts will be shipped freight allowed from the factory via standard ground service Warranty parts must be returned within 30 days Credit will be issued if part is complete defective and returned on time Dealer Contractor Name City When parts are ordered MODEL NUMBER SERIAL NUMBER FACTORY ORDER F O AND PART NUM BERS are required Belts filters and fuses are not cov ered under warranty Address State Zip Ph E INDUSTRIES 4830 Transport Drive Dallas TX 75247 Phone 214 638 6010 Fax 214 905 0806 www tempriteheating com
65. ek to 1 month Any Speed Over 150 F Dirty daily to 1 week Any Speed Any Temp Very Dirty daily to 1 week Any Speed Any Temp Extreme daily to Conditions 1 week 58 Browning Bearing Set Screw Torgue Values Model Shaft Size Torgue in Ibs Set Screw VPS 212 3 4 66 85 VPS 214 7 8 66 85 VPS 116 1 66 85 VF2S 116 1 66 85 VPS 219 13 16 66 85 VF4S 219 13 16 66 85 VPS 220 11 4 126 164 VPS 223 17 16 126 164 VPS 323 17 16 126 164 VF4S 227 111 16 126 164 VPS 327 111 16 228 296 VPS 231 1 15 16 228 296 VF4S 231 1 15 16 228 296 VPS 331 1 15 16 228 296 VPS 235 2 3 16 228 296 VF4S 235 2 3 16 228 296 VPS 236 2 1 4 228 296 VPS 239 2 7 16 228 296 VF4S 243 211 16 348 452 VPS 343 211 16 348 452 VPS 347 2 15 16 348 452 BOA Concentric VPB 231 1 15 16 220 240 VPB 331 1 15 16 220 240 Spherical Roller SPB 1000 NE 13 16 290 380 SPB 1000 NE 17 16 290 380 SPB 1000 NE 111 16 290 380 SPB 1000 NE 115 16 290 380 SPB 1000 NE 23 16 290 380 SPB 1000 NE 2 7 16 620 930 SPB 1000 NE 211 16 620 930 SPB 1000 NE 215 16 620 930 Sealmaster Sleevloc SPB 2115 C2 1 15 16 65 When replacing bearings refer to the manufacturers installation instructions included with the bearing Typical Procedure For Changing The Shaft And Bearings Remove protective shaft coating 2 3 Remove the drive side sheave Disconnect the grease lines from the existing bearings Identify th
66. embly C Burner For C3 CA amp C5 Burner 1 16 3 32 31 16 Primary Air Holes 2 Spark Gap between Electrode Tip and Pilot Case Housing Air Hole Pilot Orifice Pilot Case to Gas Manifold Adjustment Pilot case to gas manifold adjustment is very important As depicted the inside radius of the pilot body must be tight against the outside radius of the gas Boffle manifold rifice Ring Inner Tube The bottom of the pilot body must also be tight against the notched portion l of the baffle ring just slightly above Pilot Body the scanner pipe If there is an air gap between the pilot body and the gas Scanner Pipe manifold and or the baffle ring the resulting air flow may prevent the pilot Intermediate Tube flame from being swept downward across the scanner pipe C88834 sb Gas Oil Gas Oil Burner Diffuser Adjustment Gas Air Premix Adjustment Knob Blast Tube Diffuser Position Adjustment G P Burners 1 GAS ELECTRIC IGNITION DIFFUSER POSITION ADJUSTMENT Moving the blast tube diffuser assembly fore or aft on gas or oil firing will move the flame front point of re tention in order to attain the best quietest smoothest combustion for specific job conditions If the initial mid way point factory setting does not provide satisfactory results move fore or aft in small increments to achieve the best combustion results If unit is oil o
67. er 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 WARNING 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 is with the use of a Belt Tension Checker 1 Check tension frequently during the first 24 48 hours of run in oper
68. ere must be no flame impingement or hot spots on the combustion chamber that could cause scaling Check voltage and amperage on all motors Check all dampers linkages and locking quadrants to make sure they are secure and operating correctly Check all gas piping for leaks SAFETY AND CONTROLS CHECKOUT Flame Safeguard Close the last manual gas valve before burner Operate unit in heat mode After pilot flame has been established quickly close manual pilot gas valve The flame safeguard must trip out in approximately 15 seconds Gas Pressure Switches The low gas 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 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 Air Pressure Switches The air pressure switches can be checked by turning the adjusting screw to call for a higher pressure than is normally used on the system Recycle is automatic when t
69. f valves Check their operation and clean or replace as necessary j Inspect and clean all drip legs in fuel lines and in the flue k Remove the rear panel and the rear header box cover Inspect the header box and tubes Look for carbon deposits soot scale or rust Clean if necessary 1 Inspect the combustion chamber for carbon deposits soot scale or signs of flame impinge ment Clean if necessary If there is evidence of flame impingement a complete burner adjust ment must be made m Lubricate fan motors as directed by motor manu facturer Inspect motors for loose connections n Lightly oil all door latches Check that the cabinet is weather tight Replace door gaskets and re caulk as needed p Check the CO level in the entering and leaving airstream of the furnace If the CO is greater in the leaving airstream it is possible that the heat exchanger is leaking CO into the airstream The leak must be located and repaired or replace the heat exchanger NOTE Keep screened air intakes clear of obstruc tions at all times 57 B Lubrication Instructions Item Manufacturer Bearing Type All 3 phase US Baldor Single row ball fan motors or equal bearings 1 HP to 100 HP TEFC Recommendation See following note All 1 phase Century G E Bronze sleeve motors or equal bearings Fractional HP ODP TEFC or TEAO Recommendation See following note Fractional HP Century Bron
70. feguard relay D Pilot does not light after 1 Manual pilot shut off valve 1 Slowly open valve 90 second pre purge closed has timed out and voltage 2 Inlet gas pressure lower than 2 Increase gas pressure is present on flame minimum gas pressure safeguard output required terminals 3 No gas through pilot regulator 3 Clear obstruction in vent with sufficient inlet gas orifice or line replace if pressure defective 4 No gas flow through pilot 4 Check for proper installation solenoid valve and voltage Correct or replace if defective 5 Type of gas supplied natural 5 Connect to proper fuel supply gas or propane different than of contact factory for field shown on unit rating plate conversion parts 6 Flame detection system not 6a U V Sensor Clean lens sensing pilot flame See check wiring and spark rod section for servicing burner 6b Flame Rod Assure rod is in pilot flame check wiring and flame rod 7 No voltage on secondary side 7 Check wiring Replace of ignition transformer transformer if defective cd SECTION VII TROUBLESHOOTING WITH DDC CONTROLS continued Symptom Cause Remedy If pilot does not light after 90 second pre purge has timed out Flame safeguard relay run test switch in test position or is defective Place switch in run position see technical cut sheet on flame safe guard relay or replace if defective and ther
71. ghtout the trial for ignition state 2 Main Flame Establishing Period MFEP a After PFEP and with the presence of flame the main fuel valve terminal 9 is powered If a flame out occurs the relay module locks out or recycles depending on status of jumper JR2 within 0 8 or 3 seconds depending on the Flame Failure Response Time FFRT of the amplifier b The RM7897A terminal 21 has a ten second MFEP After the Ignition Trials the interupted pilot valve terminal 8 is de energized If a flameout occurs the relay module locks out or recycles depending on status of jumper JR2 within 0 8 or 3 seconds depending on the amplifier FFRT Run 1 The RM7897C has a delayed main valve that is en ergized once the RUN period is entered 2 The relay module is now in RUN and remains in RUN until the controller input terminal 6 opens indicating that the demand is satisfied or a limit has opened Post Purge After demand is satisfied or a limit opens de energizing terminal 6 the Ignition Pilot valve main valve and delayed main valve terminals 8 9 and 21 are de energized The blower motor terminal 4 remains powered during the specified programmed time The Pre Ignition Interlock closes within the first five seconds of Post Purge Run Test Switch The Run Test Switch is located on the top side of the relay module see Fig 4 The Run Test Switch allows the burner sequence to be altered as follows 1 In the measured PRE
72. h one bar and Disconnect the tubes from the transducer ending with four When the Auto Zero process Make sure the Low and High fittings are clean is complete the display will show done for and clear do not insert any sharp objects into the approximately 4 seconds then Auto pressure fittings Make sure the tubing is also clean 8 Return the rotary switch to the R1 position and clear of any debris 9 Reinstall the tubes on the transducer It is very 3 Connect the High and Low ports on the transducer important that the High tube be placed inside the together with a short length of tubing Do not allow building and positioned so that air movement does any kinks in the tubing The voltage at Voltage Out not affect it The Low side should be to atmosphere and Gnd 4 20mA Out should be 2 5 VDC If not and positioned so it is not exposed to the weather continue to the next step 10 With the use of a BACview 6 KP 01 place the 4 Place the rotary switch into the position The unit in the Building Pressure mode See the Digital current directional mode will show on the display Control System User Manual Press the NEXT button until bl shows on the 11 The voltage at Voltage Out and Gnd 4 20mA Out display will vary between 0 to 5 VDC 0 VDC means the 5 Place the rotary switch in the OUT position Press building is in a negative pressure and should open the NEXT button until 0 5 shows on the display the Outside Air Prof
73. he cooling NOTE The cooling outputs are protected by an anti cycle timer which has a 3 minute off 3 minute on delay A BACview or PC is required to change Setpoints For a more detailed control sequence see the Digital System User Manual SECTION VI UNIT SHUTDOWN A Extended Shutdown 1 Disable the heat for 3 minutes or a sufficient amount of time to allow the heat exchanger to cool down Then disable the fans Close all the manual gas shut off valves Open the main electrical disconnect switch If the unit is to remain idle for an extended pe riod the fan and motor shafts should be rotated by hand to spread the grease over the bearings BON B Emergency Shutdown Only 1 Open the main electrical disconnect switch 2 Close the main manual gas valve 30 SECTION VII TROUBLE SHOOTING Check Safety Shutdown Performance 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 shutdown or safety lockout tests recommended for the intermittent or interrupted pilot flame safeguard relay module Where different use the procedure recommended for the module 1 Turn off gas supply Adjust setpoint above room temperature to call for heat 3 Watch for ignition spark following prepurge See flame safeguard relay module specificat
74. he switch returned to its original setting If the burner or draft proving switches open this could cause the flame safeguard to go into standby mode 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 29 Cooling is Enabled By The Following amp MRT Standard To enable the cooling rotate the remote Temperature Setpoint knob MP 15 clockwise to the desired setpoint 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 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 MDT Expert With a KP 01 BACview To enable the cooling for MRT Expert scroll through 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 t
75. heated areas The venting system for these heaters 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 All vents must be able to maintain a minimum of 0 20 W C in high fire 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 or regulators relief valves or other equipment The vent pipe diameter must be as shown in specification chart on following page An adaptor from induced draft fan housing to vent pipe must be field supplied 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 into the induced draft fan housing Be sure drip leg is made so water will not fall on heater controls when drain plug is removed 12 DIMENSIONS SIZE AC p gr HEIGHT TO BE IN ACCORDANCE WITH LOCAL CODES B it ff gt m A e EN o Co 10 10 A ROOF LINE CONDENSATE DRIP LEDGE 64 10 5 8 64 64 10 5 8 10 5 8 64 64 10 5 8 10 5 8 64 10 5 8 72 110 5 8 72 110 5 8 11 1 8 gt N N N N N N a 00 O
76. ile Damper and close the 6 Place the rotary switch into the 0 position The Return Air Damper 5 VDC means the building is in display will show Auto a positive pressure and should open the Return Air Damper and close the Outside Air Profile Damper PT 13 Bapi P N Mestex P N Range Rotary Switch Position ZPS LR EZ NT IN 68 0330 82 0 1 IN WC R1 www 4 17 gc MULTIPLEXED VOLTAGE RESISTOR SWITCH OHMS IN VALUE RESISTOR ID CLOSED CIRCUIT VOLTS DC RS1 2 3 4 RS2 3 4 RS1 3 4 RS3 4 RS1 2 4 RS2 4 RS1 4 RS4 RS1 2 3 MULTIPLEXED VOLTAGE VALUES pets RS3 RS1 2 RS2 RS1 NONE UNPLUGGED IN 3 JUMPER RS 04 MIXED AIR TEMP 1 36 TO RE 56 RS 03 SAFETY CKT STATUS 1 73 GND RE 09 RS 02 FLAME FAILURE 1 87 SW 72 RS 01 100 OA or 100 OUTPUT 1 92 IN 4 RE 27 RS 04 BURNER STATUS 1 36 TO RE 65 RS 03 FAN STATUS 1 73 GND RE 12 RS 02 CLOGGED FILTER 1 87 SW 09 RS 01 AUXILIARY UNIT ENABLE 1 92 CHECK ALL TERMINAL CONNECTIONS FOR TIGHTNESS The DC voltage is to be checked at the UC 01 board With the Fan and Burner Enabled With the Fan Enabled When the safety circuit relay RE 56 is energized When the fan status relay RE 65 is energized the the contacts will close and the VDC at IN 3 amp GND contacts will close and the VDC at IN 4 amp GND will be will be 1 73 When the burner status relay RE 27 is 1 73 energized the contacts will close and the
77. ions 4 Time the length of the spark operation See the flame safeguard relay module specifications 5 Afterthe module locks out open the manual gas cock and make sure no gas is flowing to the pilot or main burner 6 Resetthe flame safeguard relay 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 con trols are defective until all associated setpoints and wiring are checked You also need to reference the Digital Control System User Manual for additional trouble shooting and diag nostics for units with DDC controls If you do not have the optional BACview 6 KP 01 keypad display it will be difficult to troubleshoot any alarm that may occur on units with DDC controls To reset most alarms on the 1 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 re set remotely or at the I O Zone 583 UC 01 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 Refer to the burner manufacturer for additional instructions WARNING Many of the steps listed on the fol
78. ized RM7897C f Internal system fault occurred g Purge card is removed h Purge card is bad i Ignition terminal is energized OPERATION Seguence of Operation The RM7897A has the operating seguences listed be low see Fig 5 and 6 The RM7897A LED provide posi tive visual indication of the program seguence POWER PILOT FLAME MAIN and Initiate The RM7897A Relay Module enters the INITIATE seguence when the relay module is powered The RM7897A can also enter the INITIATE sequence if the relay module verifies voltage fluctuations of 10 15 or frequency fluctuations of 10 during any part of the operating sequence The INITIATE sequence lasts for ten seconds unless the voltage or frequency tolerances are not met When not met a hold condition is initiated and displayed on the optional KDM for at least five seconds when met the INITIATE sequence restarts If the condition is not corrected and the hold condition exists for four minutes the RM7897A locks out d SECTION VII TROUBLE SHOOTING continued Causes for hold conditions in the INITIATE seguence 1 AC line dropout detection 2 ACline noise that can prevent a sufficient reading of the line voltage inputs 3 Low line voltage brownouts The INITIATE sequence also delays the burner motor starter from being energized and de energized from an intermittent AC line input or control input Standby The RM7897A is ready to start an operating
79. kout procedures in the installation instructions 5 If the code reappears replace the flame amplifier and or the flame detector 6 Ifthe fault persists replace the relay module Code 3 1 Running or Lockout 1 Check wiring correct any errors Running Interlock fault during 2 Inspect the fan make sure there is no air intake blockage and that it is supplying air Interlock Switch Prepurge 3 Make sure the Lockout Interlock switches are functioning properly and the contacts Problem are free from contaminants 4 Reset and sequence the relay module to Prepurge place the TEST RUN Switch in the TEST position if available Measure the voltage between terminal 7 and G ground 120 Vac should be present Switch TEST RUN back to RUN 5 If steps 1 through 4 are correct and the fault persists replace the relay module 36 Blinking Fault Codes and Recommended Troubleshooting Fault Code System Failure Recommended Troubleshooting Code 3 2 Lockout Interlock 1 Check wiring to make sure that the Lockout Interlocks are connected properly Running powered at improper between terminals 6 and 7 Correct any errors Interlock On point in sequence or On 2 Reset and sequence the relay module During in Standby 3 If the fault persists measure the voltage between terminal 6 and G ground then Standby between terminal 7 and G If there is 120 Vac at terminal 6 when the controller is off the controller switch ma
80. l electrical safetv precautions when exposed to live electrical components could result in death or serious injurv 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 nameplate rating If voltage is over 10 of nameplate rating or phase voltage unbalance is over 296 notify contractor or power company Fans Are Enabled And Disabled By The Following MDT And MRT Standard By rotating the remote Temperature Setpoint knob MP 15 Clockwise will enable the fans Counterclockwise will disable the fans MRT PRO With Smart Room Sensor To enable the fans and place the unit in the Occupied Mode press the Manual On button on the face of the TS 02 MRT PRO room sensor Pressing the Warmer button will add 30 minute increments of time for a total of 9 hours of operating time To disable the fans and place unit in the Unoccupied Mode press and hold down the Manual On button Alternately pressing the Manual On button will also decrease the amount of operating time until it reaches zero and turns the fans off MRT Expert or MDT Expert With A BACview KP 01 To enable the fans go to Unit Modes and enter MANUAL this mode will enable the fans To also enable the fans go to Unit Modes and enter AUTO this mode has four different functions that control the fans and unit o
81. local codes with current CAN CGA B149 Installation Codes for Gas Burning Appliances and Equipment 2 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 requirement 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 AII 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 f located in such an environment premature failure of the unit will occur A Handling the Equipment As explained previously the basic unit is designed for shipping in one piece where shipping limitations allow Some optional accessories may require field mounting The
82. low ing pages reguire electrical cabinet and blower ac cess 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 rest were at fault this is an indication of a problem with the system that should be investigated exi SECTION VII TROUBLE SHOOTING continued HONEYWELL RM7897A1002 RM7897C1000 7800 SERIES RELAY MODULES PRINCIPAL TECHNICAL FEATURES The RM7897 provides all customary flame safeguard functions as well as significant advancements in safety annunciation and system diagnostics Safety Shutdown Lockout Occurs if 1 INITIATE PERIOD a Purge card is not installed or removed b Purge card is bad c Configuration jumpers have been changed after 200 hours Fault Code 110 d AC line power errors occurred see Operation e Four minute INITIATE period has been exceeded 2 STANDBY PERIOD a Airflow lockout feature is enabled and the airflow switch does not close after ten seconds or within the specified purge card timing b Flame signal is detected after 240 seconds c Ignition pilot valve terminal is energized d Main valve terminal is energized e Delayed main valve terminal is energized RM7897C f Internal system fault occurred g Purge card is removed h Purge card is bad i Preignition Interlock open 3 PREPURGE PERIOD a Airflow lockout feature is enabled and the airflow
83. mmon The following closed position signal is defined as the operating directions apply for the clockwise setting For span counterclockwise setting reverse open and closed 10 Recheck the fully closed position and readjust the and reverse clockwise counterclockwise zero potentiometer if necessary Turn the zero Remove film on switch before use Default switch potentiometer clockwise A to close the motor position is CW and counterclockwise Mo open the motor 4 For current control connect the current input signal 11 Recheck the fully open position and readjust to 1 screw terminal 3 and COM screw terminal the span potentiometer if necessary Turn the 5 For voltage control connect the voltage input span potentiometer clockwise to close the motor signal to V screw terminal 1 and COM screw counterclockwise to open the motor Verify the mid terminal 5 point of your stroke 2 10 Vdc CONTROLLER o 9 0l sS 1 T2 F COM 1 V o SPAN ERO N POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED O O O O 9 8 A CONNECTING TO EITHER OR WILL DRIVE THE MOTOR TO FULLY OPEN A oN RPLY Fig 5 Q7230A terminals and adjustments Fig 8 Typical wiring diagram for Q7230A Interface g 000719 Module and 91 Modutrol IV Motor with 2 10 Vdc controller C000720 Table 3 7230 91 Checkout Pro
84. nces listed above access for service should be allowed around the unit The recommended minimum access clearance is shown in Table 2 Table 2 Unit Minimum Unit Minimum Size Access Size Access Up to 1750 36 inches 2000 MBH 50 inches MBH Output Output and Larger Optimum clearance for shaft removal would be equivalent to cabinet width Make a visual inspection to insure no damage has occured to the unit during installation C Curb Mounted Units Outdoor units can be supplied with an optional roof curb The curb greatly facilitates installation thereby reducing installation costs All connections to the unit duct piping electrical power and control wiring can be made through the roof opening The curb may be shipped prior to unit shipment All curbs are shipped un assembled from the factory Use extreme caution in handling the curb Proper handling and positioning will assure a water tight curb unit installation Re check approval prints prior to installation Be sure that there are no obstructions to ducting and that proper planning has been exercised in connection of piping and or electrical services The curb assembly may be bolted or welded to either trusses or roof decking however connection to roof trusses is recommended The curb is designed to carry the weight of the unit Additional support is required for certain applications Placement of the curb is critical in squareness and leveli
85. ng Shims for leveling must be applied to the curb application of shims to the unit will tend to destroy the sealing effect after installation Make sure sealing tape is in place before unit is set Be careful not to allow gaps where two pieces of sealing tape meet A bubble level must be used in the leveling process Measure across diagonals to check for squareness Allowable tolerance is 1 4 difference between diaganol measurements Double check approval prints before setting the unit Upon completion of setting the curb apply roofing material and flashing as required DISCHARGE 221 5 OPTIONAL PLENUM EXTENSION OPTIONAL UNIT LOCATION OF SCREEN IF NO OPTIONS ARE USED GASKET FILTER BOX OPTIONAL GASKET INLET DAMPER OPTIONAL SCREEN OPTIONAL ON INLET DAMPER UNIT TAPPING SCREW INLET DAMPER DA GASKET 5 50002 LINI LaySVO L3ySV9 831114 431114 MO LINA MO LINN COOH 11770 LINN 394vHOSIQ NOISN31X3 WnN3 1d SNISVO WOLLOG dol ONISVO SMINOS SMINOS WOLLOG ONiddvL 4135 9NISVO 401 ONiddWL 4135 MO dOl 1VNOLLdo IVNOILdO L37NI GOOH IVNOILdO XIL 9nm 3405012 JOOHAHIHLVIM IVNOILdO NOISN3LX3 WANNITA eb lt D IVNOILdO 1 219 1 SJIZZON 510 907 Laysv9 SCREENED ACCESS DOOR SCREE
86. ng any pressure testing of that system at test pressures in excess of 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 gt PSIG Correctly sized piping must be run to the unit Please note that gas line pressure must be as shown on specification plate when unit is operating at full input The high pressure regulator and relief valve should be if possible mounted at least 5 to 10 feet upstream from the appliance regulator on the unit if 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 Refrigerant Piping Refer to drawing on following page H Field Wiring and Remote Control Installation 1 If the optional low temperature was not an integral part of the heater the factory recommends that a low temperature limit control be installed in areas where freeze protection is needed in the event of burner shut down 2 Connect the power lines to the line side of the power distribution block or optional main disconnect switch 3 Field wiring is indicated
87. nstructions thoroughly before installing or servicing this eguipment AVERTISSEMENT Une installation d ficiente de m me qu un mauvais r glage modification entretien ou maintenance peuvent occasionner des dommages mat ri els corporels voire causer la mort Lire attentivement les instructions d installation d utilisation et d entretien avant d installer ou d intervenir sur cet appareil WARNING Install operate and maintain unit in accordance with manufacturer s instructions to avoid exposure to fuel substances or substances from incomplete combustion which can cause death or serious illness The state of California has determined that these substances may cause cancer birth defects or other reproductive harm INSTALLER S RESPONSIBILITY Installer Please Note This equipment has been test fired and inspected It has been shipped free from defects from our factory However during shipment and installation problems such as loose wires leaks or loose fasteners may occur It is the installer s responsibility to inspect and correct any problems that may be found TEMPRI TK 4830 Transport Drive Dallas TX 75247 Phone 214 638 6010 Fax 214 905 0806 www tempriteheating com SECTION I FOREWORD As is the case with any fine piece of eguipment care Table of Contents must be taken to provide the proper attention to the op Section I Foreword and Table of Contents 2 eration and maintenance detail of this
88. or heat Set inlet ductstat if applicable above outside air temperature Restart unit After the pilot proves the main automatic fuel valves will be energized Slowly open the last gas shut off valve and the burner should light immediately CAUTION If main flame does not light within a few seconds after pilot flame is established shut the burner down and repeat steps You may have to eliminate air from the main gas line The main gas pressure and or burner air setting may also need to be readjusted If flame signal drops significantly when main gas valves open slightly increase or decrease pilot gas pressure to attain a steady flame signal After the burner lights adjust gas pressure regulator using a manometer and combustion air damper to match normal manifold pressure shown on unit nameplate Make sure the thermostat and gas valves are in high fire These units have an induced draft fan a minimum of 0 20 W C must be maintained at the relief door simultaneously while setting the fuel to air pressure on the burner at full input This is done by changing the damper setting at the induced draft fan outlet with a warm stack Be sure to lock down the locking quadrant when you are done Check all gas piping again for leaks using a soap bubble solution On Off Operation Check to make sure operating thermostat cycles burner and induced draft fan See final checks and adjustments High Low Off Operation Turn the two
89. otentiometer MP 15 Setpoint 2b Check Heating Occupied 2b Change to correct setpoint and or Unoccupied setpoint Insufficient burner capacity 3 Check to see if heater is 3 If desired Space Temper ature is not reached with heater at high fire it may be undersized Consult Factory Refer to Digital Control System User Manual for additional troubleshooting suggestions Control circuits external to MRT Controls can cause burner malfunction Always check manual valve to be certain gas is on and check limit controls for normal operation edi SECTION VII TROUBLESHOOTING WITH DDC CONTROLS continued Cooling Mode Symptom Cause Remedy A There is no voltage at cooling relays Cooling mode is disabled Enable the cooling mode cooler is not operating correctiv RE 34 RE 35 and or RE 33 and 2 Auxiliarv switch on starter ST 01 2 Check auxiliarv circuit wiring and the fan is enabled is not closed contact 3 Air flow switch open 3 Check for proper CFM Adjust and or replace switch 4 Cooling Changeover and or 4 Change to correct setpoints See Economizer Setpoints not set Digital Control User Manual correctly 5 DO 3 and or DO 4 are not 5 See Digital Control System User energized Manual B Cooling relays RE 34 RE 35 1 Cooling relays RE 34 RE 35 1 Check and or replace and or RE 33 are energized and and or RE 33 contacts are not conden
90. oubleshooting suggestions 45 SECTION VII TROUBLESHOOTING WITH DDC CONTROLS continued Modulating Room Temperature MRT MRT PRO MRT EXPERT Controls Symptom Possible Cause Field Test Remedy A No Gas Flow with DO 2 on UC 01 energized Gas valves improperly installed Arrow on side or bottom of valves should point in direction of gas flow Install properly B Continuous Low Fire Electronics OK Defective modulating gas valve operator MT 11 and or burned out transformer Inspect wiring see check out procedure in Section X Replace modulating gas valve operator MT 11 or transformer C Continuous Low Incorrect operation of Check for 2 10 VDC at input See checkout procedure if Fire Electronics interface module IM 02 terminals voltage is correct Problem No output voltage on 2 Check 0 10 VDC voltage on 2 Consult factory UC 01 AO 1 D Incorrect Incorrect low fire butterfly 1 See Butterfly Valve Adjustment 1 Adjustto proper minimum Minimum Fire valve GP 39 adjustment fire E Continuous Incorrect room 1a Check Space Temperature 1a Replace Sensors if reading is Minimum temperature Sensor TS 02 use a incorrect or correct wiring Discharge Air BACview 6 to read TS 02 Temperature and Discharge Air Sensor TS 03 for correct readings See Thermistor curve 1b Check Space Temperature 1b
91. pen the blowers or props run Turn Fan on off switch to position Check supply fans for proper rotation The burner and induced draft fan rotation can be checked when the heat section is started NOTE To change rotation of the fans simply interchange any two 2 of the line leads of the motor starter for 3 phase motors On single phase motors refer to motor nameplate Turn Fan on off switch to on position Check for proper fan RPM Check that all amp draws do not exceed nameplate ratings and overloads are set to nameplate amps Check to make sure all dampers and controls are working properly Turn Fan on off switch to off position 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 Open pilot and first main gas shut off valves slowly Last main gas shut off valve before the burner must remain closed at this time Reset high low gas pressure switches if applicable Check pilot and main gas lines for leaks using soap solution Check the gas supply pressure by replacing the plug fitting on the pilot gas line with a pressure gauge with appropriate range Check that pressure reading is within the specified range on the raring plate NOTE adjust gas pressure on supply lines where a regulator has been installed to set inlet pressure to rating plate maximum pressure
92. peration They are a Time Clock Heating and Cooling Night Setbacks and signal from an external source to an auxiliary digital input To disable the fans go to Unit Modes and enter OFF NOTE A BACview or PC is required to change Unit Modes For a more detailed control sequence see the Digital Control User Manual If power supply meets requirements turn main disconnect switch on and Enable fans Damper opens if applicable After end switch has proven damper is open the blower fan turns on See operating modes in Digital Control System user manual Disable the fans Check supply blower for proper rotation The burner and induced draft fan rotation will be checked when the heat section is started NOTE To change rotation of the blower simply interchange any two 2 of the line leads of the motor starter for three 3 phase motors On single phase motors refer to motor nameplate Enable the fans Check for proper blower rpm Check that all motor amp draws do not exceed motor nameplate ratings and overloads are set to motor rating plate amps Check all dampers for proper operation and linkage does not bind see Sequence of Operation and Digital Control System user manual for damper control modes Disable the fans NOTE When setting up the burner for the first time of if appliance has been shut down for an extended period of time these same start up procedures should be followed Open pilot and first main g
93. put 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 become toxic when exposed to heat i e refrigerant aerosols etc 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 The minimum clearance to combustible material must be maintained as listed in Table 1 Table 1 Minimum clearance to combustible material also consult local codes and regulations Clearances to Combustible Material Vertical Units Horizontal Units Front 48 inches 48 inches Rear 18 inches 18 inches Right 18 inches 18 inches Left 18 inches 18 inches Top 18 inches 18 inches Floor Zero 6 inches Consider control side as front of unit In addition to the combustible cleara
94. r combination gas oil the attached flexible copper oil nozzle line will move fore or aft with the assembly When firing on oil moving the assembly forward will tend to broaden the flame pattern and moving it back will narrow the flame pattern Similar results are obtained on gas but ob servation of sound and combustion tests are the best determinants of results on either gas or oil The gas electric pilots used on G P burners are either flame rod or scanner design 2 POOR FLAME SIGNAL Try adjusting needle valve or pilot pressure regulator Should this not be successful check the primary pilot air If neither of these methods improve the reading inspect the flame rod position Ignition Electrode For Straight G P Gas Burners Using A Flat Diffuser Plate l D Ei Selll 1 16 to 1 8 Gap 000564 3 IGNITION ELECTRODE The igniion electrode is positioned as shown with the horizontal part of the electrode flush with the diffuser plate Leaving a of 1 16 to 1 8 wide The pointing direction of the electrode is as shown but is not critical 4 FLAME SENSOR a flame sensor shown is a rectification or a flame rod A UV scanner can be used instead In that case the scanner tube is positioned in the same holder as the flame rod 54 MODEL 400 Burners 1 GAS ELECTRIC IGNITION The gas electric pilot
95. re closed too far This causes a fuel rich mixture NOTE 3 or 4 TRIALS MAY BE NEEDED TO PURGE AIR FROM PILOT LINE Watch D C voltmeter carefully The reading should be steady and between 2 0 and 5 0 Volts D C If the reading is too low slowly turn the needle valve in or out until satisfactory flame signal is obtained see separate literature for testing of flame safeguard Make sure that the combustion air and pilot gas pressure is sufficient to provide instant ignition a stable flame and flame signal Cycle pilot several times to insure reliability With pilot now adjusted you can now shut down the burner by disabling the heat D Setting the Main Flame IMPORTANT When the Flame Safeguard relay module is switched to the TEST mode it stops and holds at the next Run Test Switch point in the operating seguence Make sure that the Run Test Switch is in the RUN position before starting the burner CAUTION Do not attempt to start the burner when furnace is full of vapor or combustion chamber is very hot CAUTION At no time should you stand in front of the relief door Connectthe test instruments meters and thermometers on the heater and controls to measure and record the appropriate data Install one manometer at test port on the last tee of the burner manifold and one at the relief door With all the safeties made this will energize Burner Relay RE 02 and burner will light The 1 Zone 583 Controller UC
96. red exhaust System or by a combination of these methods E Electrical Connections Warning Open all disconnect switches and secure in that position before wiring unit Failure to do so may result in personal injury or death from electrical shock Warning Controls must be protected from wa ter Do not allow water to drip on the electrical controls Note Before installing any wiring check the unit rating plate for power supply voltage and minimum amperage All electrical connections must conform to the current edition of ANSI NFPA No 70 National Electrical Code and applicable state and local codes in Canada to the Canadian Electrical Code Part 1 CSA Standard C22 1 andapplicable provincial and local codes Since shipment of unit may require disassembly after factory check and test reconnection of some electrical devices will be required in the field Connect electrical wires supplied in factory furnished conduit to 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 If damper actuators require field wiring be sure the gasket and cover are securely mounted and assembly is watertight Entry location for all field installed and control wiring is through the control panel If optional disconn
97. rod No voltage on secondary side 7 Check wiring Replace of ignition transformer transformer if defective SECTION VII TROUBLESHOOTING continued properly 4 Condensing section or evaporative correctly or defective Setpoint is lower than design conditions Insufficient cooling cooler is not operating properly Symptom Cause Remedy E If pilot does not light Flame safeguard relay Place switch in run position see after 90 second pre run test switch in test technical cut sheet on flame safe purge has timed out position or is defective guard relay or replace if defective and there is no voltage at Burner or draft motor not Check wiring fuses and amp flame safeguard relay running draw on motors output terminals Burner or draft air Check for correct rotation of proving switch is open motors and or adjust switch F If there is no heat with Last manual gas shut off valve Turn Heat off on switch to the pilot on and voltage closed off position Slowly open all is present at flame manual gas shut off valves safeguard relay output No gas on outlet side of Clear obstruction in vent orifice terminals regulator with proper inlet or line Check for correct size pressure spring Replace if defective No gas on outlet side of valve Check wiring voltage and or actuator with proper inlet adjustment Correct wiring or pressure replace if defective Low fire start
98. rors High Fire Sw or Low Fire Switch 2 Reset and sequence the relay module or Low Fire failure 3 Use manual motor potentiometer to drive the motor open and closed Verify at Sw motor switch that the end switches are operating properly Use RUN TEST switch if manual potentiometer is not available 4 Reset and sequence the relay module 5 If the fault persists replace the relay module 37 Blinking Fault Codes and Recommended Troubleshooting Fault Code System Failure Recommended Troubleshooting Code 5 3 Man Open Switch Start 1 Check wiring and correct any errors Man Open Switch or Control On in 2 Make sure that the Manual Open Valve Switch Start Switch and Control are Sw Start Sw the wrong operational operating properly or Control On state 3 Stat Switch held iOni too long 4 Reset and sequence the relay module 5 Reset and sequence the relay module If the fault persists replace the relay module RM7838A1014 RM7838B1013 or RM7838C1004 only Code 6 1 Relay Module self test 1 Reset and sequence the relay module Internal Faults failure 2 If fault reappears remove power from the device reapply power then reset and sequence the relay module 3 Ifthe fault persists replace the relay module Code 6 2 Relay Module Self Test 1 Reset and sequence the relay module Internal Faults failure 2 If fault reappears remove power from the device reapply power then reset and seq
99. s used on MAXON burners are either flame rod or scanner design 2 POOR FLAME SIGNAL Try adjusting needle valve or pilot pressure regulator Should this not be successful check the primary pilot air If neither of these methods improve the reading inspect the flame rod position MAXON Electrode amp Flame Rod Locking 1 2 Collar Bushing Insulator Spark Ignitor Flame Rod Burner Model Dimensions Dimensions px EY x z 4 4 2 9 ikel 55 1 1 1 3 5 2 3 FLUE GAS ANALYSIS This curve correlates the relative values of O and CO for the fuels listed as well as the percentage of excess air at given O and CO values Example Following the dotted line on the vertical axis from 496 O to curve H and the dotted line on the hori zontal axis to the left the 96 excess air column shows that 4 O equals 2596 excess air Following the vertical dotted line axis again from curve H to fuel A Natural Gas and the horizontal axis to the left the 96 CO column shows that 496 O and 2596 ex cess air correlate to 9 1 2 CO for Natural Gas Table 13 Again following the 496 O vertical axis fo fuel line E 2 Fuel Oil and to the left to the CO column shows that 4 O and 25 excess air correlate to 12 1 2 CO on 2 Fuel Oil This chart can be used to determine required CO or O values and therefore equivalent BTU input values for the
100. secondary fuel when the burner has been properly adjusted for the primary fuel inputs O Ratio Curves for Fuel Oils and Gases 170 17 HI 160 16 gt 4 150 15 B 7 140 14 D 130 13 y 221112 UE 120 12 z 5 i 7 110 11 V 100 10 7 oso it 3 80 8 b 70 7 1 7 60 B 6 E 650 8 5 5 5405 4 22 5 5 ad 30 3 1 271 o OQ rn 9 20 2 24 a a 22 10 1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 20 93 PERCENT OXYGEN CURVE FUEL MAXIMUM 0 CURVE FUEL MAXIMUM A Nautral Gas 11 7 E 2 Fuel Oil 15 2 B Natural Gas 12 1 F 5 Fuel Oil 16 0 12 1 G 6 Fuel Oil 16 9 D Butane 14 0 H Excess Air vs 56 SECTION IX MAINTENANCE SCHEDULE AND LUBRICATION REGUIREMENTS WARNING Failure to comply with the general safety information may result in extensive property damage severe personal injury or death Periodic maintenance is essential to the efficient operation and extended service life of this equipment Failure to provide maintenance as recommended may void the equipment warranty A Maintenance Schedule 1 Daily a Check gauges monitors instruments and equipment settings 2 After 8 hours of operation a Check that fan
101. sequence when the operating control input determines a call for heat is present The burner switch limits operating limit control and all microcomputer monitored circuits must be in the correct state for the relay module to continue into the PREPURGE sequence Normal Start Up Prepurge The RM7897A Relay Module provides PREPURGE timing selectable from two seconds to thirty minutes with power applied and the operating control indicating a call for heat 1 The Airflow Interlock burner switch Run Test switch and all microcomputer monitored circuits must also be in the correct operating state 2 The motor output terminal 4 is powered to start the PREPURGE sequence 3 The Airflow Interlock input closes ten seconds into PREPURGE or within the specified purge card timing otherwise a recycle to the beginning of PREPURGE or lockout occurs depending on how the Airflow Switch selectable jumper JR3 is config ured Ignition Trials 1 Pilot Flame Establishing Period PFEP a When the PFEP begins 1 The pilot valve and ignition transformer terminal 21 is energized The RM7897A has an intermittent pilot valve terminal 8 and inter rupted pilot valve terminal 21 2 Flame must be proven by the end of the ten second PFEP four seconds if Configuration Jumper JR1 is clipped to allow the sequence to continue If a flame is not proven by the end of PFEP a safety shutdown occurs 3 The pre ignition interlock is ignored throu
102. sing unit or evaporative closed cooler is not on 2 Cooling relays RE 34 RE 35 2 Correct wiring and or RE 33 contacts are not wired correctly 3 Compressors or evaporative pump 3 See Troubleshooting Guide for your not running condensing unit or evaporative cooler C Incorrect Space Temperature 1 Incorrect Maximum Cooling 1 Decrease Maximum Cooling Discharge Temperature Setpoint Discharge Temperature Setpoint See Digital Control System User Manual 2 Incorrect Minimum Cooling 2 Decrease Minimum Cooling Discharge Temperature Setpoint Discharge Temperature Setpoint See Digital Control System User Manual 3 Unit Enable Potentiometer MP 15 3 Change to correct setpoints not set correctly See Digital Control System User Manual 4 Cooling Occupied and or 4 Change to correct setpoint settings Unoccupied setpoints not set See Digital Control System User correctly Manual 5 Insufficient cooling 5 If desired Space Temperature is not reached and cooling is at full capacity it may be undersized 6 Condensing section or evaporative 6 See Troubleshooting Guide for your condensing unit or evaporative cooler Refer to Digital Control System User Manual for additional troubleshooting suggestions 48 SECTION VII TROUBLESHOOTING WITH DDC CONTROLS continued To Calibrate the Building Pressure Transducer 7 Press the NEXT button The display will show a LE series of progress bars starting wit
103. stage thermostat down slowly until main gas valve begins to drive closed low fire or the power on the second stage may be disconnected NOTE Low fire rate should be set at approximately 5096 of high fire CAUTION Too low of an input setting will cause condensation of the flue gases To reset low fire remove the cover from the Two Stage gas valve actuator and using the wrench provided readjust the internal cam setting Check to make sure Two Stage thermostat cycles burner and induced draft fan See final checks and adjustments 22 Modulating Operation Set high fire by adjusting main gas regulator and by the high fire adjusting screw on the butterfly valve Observe flame as burner modulates when thermostats are adjusted NOTE Flame should modulate slowly and evenly throughout the entire travel although flame may become somewhat dirty during travel If stopped at any point proper combustion should resume Turn all modulating thermostats to their lowest setting without turning the burner off or with power off remove the coil wire on low fire hold relay and restart burner Set low fire with the low fire adjusting screw on the butterfly valve BUTTERFLY VALVE ASSEMBLY MOTOR IN SHUT POSITION Observe low fire it should be substantial enough to TERMINALS RAW SHORTE maintain proper combustion and be within the designed turndown range of the burner CAUTION Too low of an input setting will caus
104. switch SW 10 SW Check for proper operation see 12 in MT 11 MTR 4 is open if sheet in manual for proper settings applicable Inlet gas pressure lower than Increase gas pressure the required gas pressure Normally open vent valve if Check for correct installation applicable not closing and voltage Correct or replace Gas nozzles obstructed or Clear obstruction or blockage plugged see burner IOM G Ifthere is no heat with Flame safeguard relay run test Place switch in run position pilot on and no switch in test position or is see technical cut sheet on flame voltage is present at defective safeguard relay or replace if flame safeguard relay defective output terminals H Flame safeguard Pilot gas pressure may be too Adjust needle valve typically goes into alarm when high 1 1 2 to 2 turns open from closed main flame is trying to position establish on units with interrupted pilot Return air or outside air Damper motor and or end switch Check wiring and or replace damper not functioning not wired correctly or defective end switch properly see sequence Thermostat relays and or poten Check wiring and or replace of operations tiometer not wired correctly or bad components defective Dampers binding and or loose Check and or replace J Cooling not functioning Thermostat and or relays not wired Check wiring and or replace bad components Adjust thermostat to correct setpoint If desired space temperature is not
105. to do so may dam age 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 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 4 Apply caulking material along the top of both sides of the standing roof seam Fig 4 Place roof cap Fig 4 on top of the seam and secure it with two rows of TEK screws one down each side spaced approximately 8 10 inches apart down the entire length of the seam Apply two strips of tacky tape one down each side to the back side of each hugger strip Fig 2 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 After hugger strips are installed caulk around the edges to complete the seal Repeat this process for each section as it is attached The number of sections varies by
106. uence the relay module 3 If fault does not repeat on the next cycle check for electrical noise being copied into the relay module through the external loads or possibly an electrical grounding issue 4 If the fault persists replace the relay module Code 6 3 Fault with special OEM 1 Check wiring and operation of special OEM inputs Device input circuits 2 Reset and sequence the relay module Specific 3 If fault reappears remove power from the device reapply power then reset and sequence the relay module 4 If the fault does not repeat on the next cycle check for electrical noise being copied into the relay module through the external loads or possibly an electrical grounding issue 5 If the fault persists replace the relay module Code 6 4 Unused at this time Accessory Fault Code 7 7 Unused at this time Unused 38 SECTION VII TROUBLESHOOTING continued Sympiom Cause Remedy A Supply fan s do not operate 10 11 12 13 Low or no voltage Fuse s blown Customer s interlock not closed or connected Fan on off switch in off position Door switch open Freeze protection tripped 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 Time clock or field installed controls not closed Night set
107. ure too low Read inlet pressure at valve using a manometer with heater operating at full fire Pressure should be at least equal to the sum of outlet pressure setting and pressure drop of the valve Increase inlet pressure if possible or change to larger valve Consult factory about possibility of using special spring to reduce pressure drop on selected installations operating at high fire Incorrect outlet 2 Read outlet pressure using 2 See Sequence and Burner pressure adjustment manometer and compare Setup in Section X with the pressure stated on the specification plate J Continuous Open circuit in Discharge 1 Measure resistance per 1 If readings are incorrect Maximum Air Temperature Sensor Thermistor Curve replace Discharge Air Discharge Air 15 03 Temperature Sensor Temperature TS 03 or repair wiring Incorrect Maximum 2 Check to see if heater is 2 If desired temperature is Heating Discharge delivering at Maximum not reached increase Temperature Setpoint Heating Temperature Maximum Heating Discharge Discharge Setpoint Temperature Setpoint K Incorrect Space 1 Incorrect Minimum Heating 1 Check to see if heater 1 If desired Space Temperature Discharge Temperature is delivering at Minimum Temperature is not reached Setpoint Discharge Setpoint increase Minimum Heating Discharge Setpoint Incorrect space setpoint 2 Check Unit Enable 2a Change to correct setpoint P
108. y be bad or is jumpered 4 If steps 1 through are correct and there is 120 Vac at terminal 7 when the controller is closed and the fault persists check for a welded or jumpered Running Interlock or Airflow Switch Correct any errors 5 If steps 1 through 4 are correct and the fault persists replace the relay module Code 3 3 VPS Valve Proving 1 Check wiring making sure upstream valve is connected to terminal 9 and VPS in Switch in wrong state downstream valve is connected to terminal 17 Improper State during VPS Test 2 Conduct Valve Seat leakage test using a manometer 3 Reset and sequence the relay module if fault repeats test VPS connected to terminal 16 is functioning properly replace if necessary 4 Reset and sequence the relay module 5 If fault persists replace the relay module Code 4 1 No purge card or the 1 Make sure the purge card is seated properly Purge Card purge card timing has 2 Inspect the purge card and the connector on the relay module for any damage or Problem changed from the contaminants original configuration 3 Reset and sequence the relay module 4 If the fault code reappears replace the purge card 5 Reset and sequence the relay module 6 If the fault code persists replace the relay module Code 4 2 Pilot ignition valve A WARNING Wiring terminal main valve Electrical Shock Hazard Fire or Explosion Hazard Problem ignition or Main Valve 2 Can cause severe injury death or property damage
109. ze 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 mo tor casing at each end Motors that do not have grease plugs cannot be greased and are lubricated for the life of the motor bearing Lubrication of motors should be done while the motor is warm and at a standstill Remove and clean all grease plugs and insert a grease fitting in the upper hole in the motor casing at each end Viewed as if motor were sitting horizontally on its base There may be one or two plugs in each end casing of the motor Add a small amount of a clean good grade ball bearing grease such as Exxon Polyrex EM or equal with a low pressure grease gun Run the motor five minutes before remov ing the grease fittings and replacing the plugs CAUTION An excess of grease will overheat the bearings NOTE On totally enclosed fan cooled TEFC motors the rear end fan housing must be removed to expose the grease plugs 2 Pillow Block Bearings Pillow block bearings are used on supply blower s Bearings have been prelu bricated
110. zed The pi lot flame will be established and sensed by the flame sensor with interrupted pilots 6 Once thermostat setpoint is satisfied the main fuel valve s burner motor and exhauster motor will be de energized Main supply air fan s will continue to run 20 SECTION V UNIT START UP WITHOUT DDC CONTROLS Before attempting to start the heater read and understand the sequence of operations electrical schematic gas train burner and flame safeguard control WARNING During installation testing servicing and trouble shooting of this product it may necessary to work with live electrical components Have a gualified 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 nameplate rating If voltage is over 10 of nameplate rating or phase voltage unbalance is over 2 notify contractor or power company If power supply meets requirements turn main disconnect switch on Turn Fan on off switch to on position Inlet shut off damper s if applicable opens after end switch has proven damper is o

installation, operation and maintenance manual for indirect gas

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