Installation/Operation Manual for IFL
Contents
1. 3 Section Ill Installation asias 5 This manual of instructions has been prepared in order Section IV Pre Start 11 for you to become well acquainted with those details Section V Unit Start 13 and in doing so you will be able to give your IFL Section VI Unit Shut Down 15 Indirect Fired Comfort System the care and attention Section VII Troubleshooting 16 which any piece of equipment needs and deserves Section VIII Flue Gas Analysis 19 Section IX Maintenance Schedule and Lubrication Requirements 20 Section X Replacement Parts 23 Section XI Typical Wiring Diagram 23 IMPORTANT NOTICE Applied Air assumes no responsibility for loss or damage in transit therefore you should protect yourself by following these instructions Failure to do so is your responsibility BILL OF LADING Save your bill of lading It is a contract and you will need it provided you have to file a loss or damage claim Remember claims are outlawed after nine months LOSS 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 get2. THE ABOVE PIPING SCHEMATIC SHOULD BE USED AS A GUIDE ONLY PROPER ENGINEERING DESIGN OF THE OVERALL REFRIGERATION SYSTEM MAY DICTATE AN ALTERNATE PIPING SCHEMATIC BE USED TO THE ONE ILLUSTRATED ABOVE GENERAL NOTES T TT 12 13 p wm xo RECOMMEND FIRST STAGE OF COOLING BE PROVIDED WITH HOT GAS BYPASS ALL PIPING TO BE ACR TYPE L COPPER ALL PIPING TO BE PITCHED IN THE DIRECTION OF REFRIGERANT FLOW PITCH TO BE 1 INCH PER 10 FEET ALL SUCTION LINES TO BE INSULATED LIQUID LINE FILTER DRIER SIGHT GLASS SUCTION LINE FILTER DRIER ISOLATION VALVES FITTINGS DISCHARGE VIBRATION ABSORBER ACCUMULATORS AND OTHER AVAILABLE SYSTEM OPTIONS ARE NOT SHOWN RECOMMEND LONG RADIUS ELBOWS BE USED TO MINIMIZE SYSTEM PRESSURE DROP RECOMMEND LIQUID LINES FOR R 22 BE SIZED FOR A MAXIMUM PRESSURE DROP OF 6 PSIG RECOMMEND SUCTION LINES FOR R 22 BE SIZED FOR A MAXIMUM PRESSURE DROP OF 3 PSIG RECOMMEND CONDENSOR SUBCOOLING CIRCUIT FOR R 22 BE CAPABLE OF SUBCOOLING LIQUID BETWEEN 12 F TO 19 F CONNECT 1 4 O D EXTERNAL EQUALIZING LINE GENERALLY LOCATED IN EACH SUCTION HEADER OF EACH DX COIL TO THE APPROPRIATE THERMAL EXPANSION VALVE TXV 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 INSTALL TRAP
3. by providing properly sized relief openings by interlocking a powered exhaust system or by a combination of these methods F Electrical Connections WARNING Open all disconnect switches and secure in that position before wiring unit Failure to do so may result in personal injury or death from electrical shock WARNING Controls must be protected from water Do not allow water to drip on the ignition system NOTE Before installing any wiring check the unit rating plate for supply power rating All electrical connections must conform to the current edition of ANSI NFPA No 70 National Electrical Code and applicable state and local codes in Canada to the Canadian Electrical Code Part 1 CSA Standard C22 1 and applicable provincial and local codes Since shipment of unit may require disassembly after factory check and test reconnection of some electrical devices will be required in the field Connect electrical wires supplied in factory furnished conduit to appro priate terminals All leads are tagged to facilitate field connections See wiring diagram provided with equip ment Complete all wiring to any optional accessories as shown on unit bill of material and electrical wiring diagram as required before applying voltage to the unit Entry location for all field installed and control wiring is through the control panel If optional disconnect is not furnished with heater the field provided disconnect must be of th
4. established if applicable the main manual valve is turned on Reset the controller and the ignition sequence will recycle Once the main automatic gas valve is energized the burner will light and the control valve will modulate to thermostat setpoint Check to make sure the main flame signal is steady If the burner does not light within a few seconds after pre purge shut the burner off and repeat the previous steps a Check the combustion air setting The duct furnace has been test fired in the factory for firing rate and combustion Field conditions may require adjustments to be made These checks should be done by a qualified service man a When the main flame is established check the gas manifold pressure at the test points nearest the burner downstream of the gas control valve Check the nameplate for the correct pressure and adjust the appliance regulator if necessary b Check the CO and O reading at maximum and minimum inputs shown on the rating label readings typically range from 4 10 CO readings should not exceed 400 PPM at any time Adjust the air gas ratios with the control linkages making fine adjustments before measuring again Ensure proper overfire draft at test port in burner section is set per nameplate d Visually observe the flame and insure that the flame does not impinge on the heat exchanger surface and that there are no hot spots on the com bustion chamber e Check all gas piping agai
5. hazard Can cause property damage severe injury or death Perform the safety shutdown test any time work is done a gas system NOTE Read steps 1 through 7 before starting and compare to the safety shutdown or safety lockout tests recommended for the Flame Safeguard Where different use the procedure recommended for the Flame Safeguard Turn off gas supply 2 Set thermostat or controller above room temperature to call for heat Watch for ignition spark either immediately or following prepurge cycle See Flame Safeguard module specifications Time the length of the spark operation See Flame Safeguard module specifications After the Flame Safeguard module locks out open the manual gas valve and make sure no gas is flowing to the pilot or main burner Reset the Flame Safeguard module 7 Operate system through one complete cycle Refer to manufacturer s IOM for additional troubleshooting information Symptom Cause Remedy A Blower does not operate 1 Low or no voltage 1 Check power source 2 Fuse s blown 2 Replace fuse s 3 Customer s interlock not closed 3 Close or connect customer or connected interlock 4 Fan on off switch in off 4 Switch to on position position 5 Door switch open 5 Close door 6 Freeze protection tripped 6 Check stat and settings reset by re cycling the power Check sensor and location 7 Damper motor not operating 7 Ch
6. indicated on the wiring diagram typically as dashed lines Where field wiring of the control circuit is required take care to size the wires for a maximum 10 voltage drop The VA rating of the transformer should be the maximum load 3 Mount and wire remote control panel thermostat temperature sensors and any other field installed controls as indicated on the unit control wiring diagram 4 Connect all wiring to the appropriate field wiring terminal and any shielded or twisted wires as indicated on the unit control wiring diagram H Locating Temperature Controls The room or outdoor thermostats should be mounted where they will not be subjected to direct impact of the heated air or radiant heat from the sun It is also recommended that the thermostats especially those with mercury bulb contacts be mounted on a vibration free surface The sides of building columns away from the heater or interior walls are usually the location best suited for mounting thermostats Controls with outdoor bulbs require that the outdoor bulb be shielded from direct radiation from the sun Unit mounted sensors are factory located and mounted Drains and Traps Heat Exchanger Some furnaces may be supplied with condensation removal pipe connections Condensate from the heat exchanger is acidic and may contain chemical compounds requiring special drainage The drain must be installed in accordance with all plumbing codes The condensate is to b
7. 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 below On initial startup it may be necessary to fill the trap manually or after unit has operated sufficiently for a small amount of condensate to collect in the drain pan turn off the unit and the trap will automatically fill During the winter months when the cooling system is turned off and the unit is exposed to freezing conditions an antifreeze solution should be poured into the condensate pan trap to prevent freezing and possible damage The condensate drain trap may also be drained and capped but be sure to remove the cap when starting the cooling for the next season NOTICE TO INSTALLER Complete the following information Refrigerant Type Refrigerant Pressure Condenser Type 1 1 27 PVC 90 ST ELBOWS NOTE HY TO BE MINIMUM OF 1 2 PLUS TOTAL STATIC PRESSURE TO EXCEED THE NEGATIVE STATIC PRESSURE IN INCHES OF THIS SECTION OF UNIT WHERE APPLICABLE AND DOUBLE WHEN SPACE PERMITS DRAIN PLUG 1 1 4 MPT GALV NIPPLE T DRAIN PAN 1 1 47 MPT x i 1 72 PVC FEMALE ADAPTER FITTING 1 1 2 PVC PIPE NIPPLE 1 1 8 PVC RETURN BEND C000659 Coil Assembly and Piping Drawing p EE J SECOND STAGE SUCTION V FIRST STAGE SUCTION COIL ASSEMBLY END ELEVATION
8. 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 carriers agent places a notation on your freight bill explaining the nature and extent of damage Upon inspection of article make claim to the delivering carrier CONCEALED DAMAGE IN TRANSIT Sometimes transit damage is not noticed until the goods are unpacked In such cases notification to the carrier must be made within fifteen 15 days of receipt of shipment In such cases save the packages and packing material then notify the transportation company at once and request an inspection When the inspector calls have him make out and leave a concealed bad order report He is obliged to give you one Insist on it DISPOSITION OF DAMAGED ARTICLES Never return damaged articles to us They are the property of the transportation company when the claim is filed They will give you disposition instructions PACKING We comply with the packing requirements of the transportation companies and your bill of lading proved that everything was in good condition when shipped That bill of lading contract requires them to deliver in perfect condition SECTION Il GENERAL INFORMATION A Purpose The purpose of this manual is to present a guide for proper inst
9. to 100 HP ODP TEFC Recommendation See following note Bronze sleeve bearings All 1 phase motors Fractional HP ODP TEFC or TEAO Recommendation See following note Century G E or equal Fractional HP Century Bronze sleeve single phase or equal bearings ODP or TEFC Recommendation See following note Fan shaft Browning Self aligning bearings or equal single row or double row roller of ball bearings resilient mounted Recommendation See following note Mestex Sleeve or equal Recommendation See following note Dampers 1 Blower Motors Some motors require lubrication while others do not Those that require lubrication can be identified by the presence of grease plugs in the motor casing at each end Motors that do not have grease plugs cannot be greased and are lubricated for the life of the motor bearing Lubrication of motors should be done while the motor is warm and at a standstill Remove and clean all grease plugs and insert a grease fitting in the upper hole in the motor casing at each end Viewed as if motor was 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 Chevron SR1 2 or Exxon Polyrex EM with a low pressure grease gun Run the motor five minutes before removing the grease fittings and replacing the plugs CAUTION An excess of grease will o
10. ARM STATUS GA 04 RE 90 24 E 4 2 EXHAUST FAN INTERLOCK E 33 7 PILOT DUTY RATED 2 6 w o 5 INTERLOCKING RELAY EH E 32 2 1 30 UC 01 Format Short Pins we Cree L Stat Format LStat Rnet Port IN 5 Jumper Selector Jumper Power Jumper Rn pot Err x By en TS 02 vdc A lt 3 2 1 Communication Selection Jumper JUMPER HERE FOR DAMPER CONTROL Communications Selection EIA 485 Comm Selector DIP Switch BACnet over ARC 156 PROTOCOLS Swi OFF BACnet off Off MS TP DAMPER CONTROL BURNER CONTROL N2 On Modbus Off INPUTS 3 amp 4 THERM OR DRY 1 0 ZONE 583 0 CYCLE IRS ONLY INPUTS 5 amp 6 THERM DRY or LStat CAUTION To Reduce The Risk of Fire or Power for 0 0 5 or Electrical Shock Do Not Interconnect Outputs of Diferent Class 2 BACnet SHI
11. Applied Air INSTALLATION OPERATION AND MAINTENANCE MANUAL FOR IFL COMFORT SYSTEMS IOMIFL 1 ATTENTION READ THIS MANUAL AND ALL LABELS ATTACHED TO THE UNIT CAREFULLY BEFORE ATTEMPTING TO INSTALL OPERATE OR SERVICE THESE UNITS CHECK UNIT DATA PLATE FOR TYPE OF GAS AND ELECTRICAL SPECIFICATIONS AND MAKE CERTAIN THAT THESE AGREE WITH THOSE AT POINT OF INSTALLATION RECORD THE UNIT MODEL AND SERIAL No s IN THE SPACE PROVIDED RETAIN FOR FUTURE REFERENCE FOR YOUR SAFETY The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous POUR VOTRE S CURIT L utilisation et l entreposage d essence ou d autres liquides ou produits mettant des vapeurs inflammables dans des r cipients ouverts proximit de cet appareil est dangereux FOR YOUR SAFETY POUR VOTRE S CURIT If you smell gas Si vous sentez une odeur de gaz 1 Open Windows 1 Ouvrez les fen tres 2 Don t touch electrical switches 2 Ne pas actionner d interrupteur 3 Extinguish any open flame 3 Eteindre toute flamme ouverte 4 Immediately call your gas supplier 4 Appelez imm diatement votre i e fournisseur de gaz WARNING Improper installation adjustment alteration service or maintenance cause property damage injury death Read the installation operating maintenance instructions thoroughly before installing or serv
12. Depending on sling length one or more spreaders are recommended In no case should the lift be less than 80 degrees from horizontal or more than 30 degrees from threaded shank direction When unloading and setting the unit use the lifting points provided or move the equipment on rollers Hooks jacks or chains must not be used around the casing main control panel or exterior mounted controls During transit unloading and setting of the unit bolts and nuts may have become loosened particularly in the pillow block ball bearing assemblies in the fan section It is recommended that all nuts and setscrews be tightened Turn fan shaft by hand to make certain that wheel does not rub against venturi and that bearing setscrews are tight Open the cover on the electrical control box located on the unit and ensure that all connections are tight LIFTING LUGS PROVIDED IN ONE OF TWO LOCATIONS zj A USE WHEN LIFTING OVER 3 000 LBS B USE WHEN LIFTING UNDER 3 000 LBS C000539 B Locating The Unit Prior to locating the unit authorities having jurisdiction should be consulted before installations are made Approval permits should be checked against the unit received For indoor application combustion air shall be pro vided at a rate of at least 10 CFM or 1 square inch of free opening per 1000 BTU per hour of rated input If a separate mechanical means provides this air an inte
13. ELDED CABLE 7 HH Applied Air 4830 Transport Drive Dallas TX 75247 Phone 214 638 6010 Fax 214 905 0806 www appliedair com
14. IN SUCTION LINE AS ILLUSTRATED IF COMPRESSOR IS LOCATED BELOW THE THE DX COIL 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 COMPONENT IDENTIFICATION HOT GAS BYPASS TEE LIQUID LINE SOLENOID VALVE HOT GAS BYPASS VALVE FIRST STAGE THERMAL EXPANSION VALVE TXV 1A CIRCUIT 2 THERMAL EXPANSION VALVE TXV 24A CIRCUIT 1 DX EVAPORATOR COIL INTERTWINED REFRIGERANT DISTRIBUTOR CONDENSATE PAN PROVIDED WITH DRAIN CONNECTIONS ON ONE END C 000658 ed SECTION IV PRE START UP Do not attempt start up without completely reading and understanding this manual Pre Start Up The owner s representative or equipment operator should be present during start up to receive instruc tions on care and adjustments of the equipment All equipment has been factory tested adjusted metered and inspected to meet conditions set at the time the order was placed Only minimal adjustments should be required All information in this service manual is typical All products are semi custom and changes may occur The following procedures should be performed to assure the unit has not been damaged or misaligned during shipping NOTE All servicing and adjustments to the Indirect Gas Fired unit should be performed by a qualified service engineer CAUTION Line side o
15. ONAL PILOT RE 02 ASSEMBLY RE 90 ALARM STATUS RELAY RS 01 RESISTOR 1K OHM RS 02 RESISTOR 2K OHM 202 TO DDC CONTROL RS 03 RESISTOR 4 02K OHM 0 10VDC LT 59 a poce egeo RS 04 RESISTOR 8 06K OHM RS 11 RESISTOR 10 OHM SD 01 SUPPLY AIR SMOKE DETECTOR OP TONALS 50 02 RETURN AIR SMOKE DETECTOR OPTIONAL ST 01 MAIN SUPPLY FAN MOTOR STARTER SW 01 MAIN DISCONNECT SWITCH OPTIONAL SW 09 AUXILLARY UNIT ENABLE BY OTHERS SW 18 DAMPER MOTOR END SWITCH OPTIONAL SW 72 100 PERCENT OUTSIDE AIR SWITCH BY OTHERS BH AY 50 02 A 6 17 161 4 LT 31 TR 01 CONTROL CIRCUIT TRANSFORMER 12 RE 34 f g 4 g sl TR 05 LOW VOLTAGE TRANSFRMER TO NEXT ns RE 35 TR 08 BURNER TRANSFORMER PAGE 16 MT 13 lt gt 1 TS 01 OUTSIDE AIR TEMPERATURE SENSOR FL 01 prr 90 STA TS 02 SPACE TEMPERATURE SENSOR OPTIONAL ON 125 115 Oe 1 TS 03 DISCHARGE AIR TEMPERATURE SENSOR RE 57 FL 06 FL 05 QLOLOL 7 UC 01 UNIT CONTROL MODULE ei fe 15 MS v el 7 O gt VG 02 MAIN GAS VALVE TO NEXT PAGE 23 bad RE 81 bad RE 80 m LOW ALERT HIGH ALERT Si road 4 HIGH ALERT TO PREVIOUS TO PREVIOUS ca vs COOLING INTERLOCK 3 2 z ES 24 iei m os AL
16. SE FU 10 120V TR 01 1000VA GA 03 COMBINATION CO amp NO2 DETECTOR OPTIONAL GA 04 CARBON DIOXIDE DETECTOR OPTIONAL KP 01 KEYPAD DISPLAY MODULE OPTIONAL y g GH DRESS 1 LT 05 BURNER ON LIGHT OPTIONAL RE 78 LT 15 FAN ON LIGHT OPTIONAL 1 LT 31 COOLING ON LIGHT OPTIONAL RE 56 LT 59 CLOGGED FILTER LIGHT OPTIONAL FL 04 r4 PS 04 PS 07 LT 05 MP 05 DAMPER CONTROL POTENTIOMETER OPTIONAL 6 eS 7 i 8 Le 19 a 10 MP 15 UNIT ENABLE POTENTIOMETER OPTIONAL MT 01 MAIN SUPPLY FAN MOTOR MT 08 BURNER MOTOR lus ELLE T 0 S MT 11 MODULATING GAS VALVE MOTOR Bk MT 13 DAMPER MOTOR OPTIONAL OL 01 MAIN FAN MOTOR OVERLOAD PS 02 BURNER AIRFLOW PROVING SWITCH PS 04 LOW GAS PRESSURE SWITCH OPTIONAL PS 07 HIGH GAS PRESSURE SWITCH OPTIONAL PS 12 CLOGGED FILTER SWITCH OPTIONAL PT 13 BUILDING PRESSURE TRANSDUCER OPTIONAL BL VG 02 He RE 02 FLAME SAFEGUARD RELAY RE 06 PURGE HOLDING RELAY RE 12 CLOGGED FILTER RELAY OPTIONAL RE 28 BURNER ENABLE RELAY RE 34 COOLING ENABLE RELAY RE 35 COOLING INTERLOCK RELAY RE 56 SAFTEY CIRCUIT STATUS RELAY RE 57 UNIT ENABLE RELAY RE 65 FAN STATUS RELAY RE 78 INTERLOCKING RELAY OPTIONAL RE 80 LOW ALERT RELAY OPTIONAL RE 81 HIGH ALERT RELAY FOTONA SPARK SENSE F R RE 82 C02 ALARM RELAY OPTI
17. allation maintenance and operation of the IFL Indirect Fired Comfort System and supplement but not to replace the services of qualified field service personnel to supervise the initial start up and adjustment of the unit Persons without previous experience with large commercial and industrial heating and cooling 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 Applied Air equipment not all possibilities are addressed in this manual The customer or installer can obtain information from Applied Airs sales representative or the Applied Air factory B Shipping Base IFL Indirect Fired Comfort Systems are shipped completely assembled where shipping limitations allow Optional inlet hoods filter and or damper sections or other large accessories are assembled and shipped mounted and wired whenever possible within limita tions of shipping and handling Some optional acces sories shipped separately may require field assembly Any wired accessories which have been disassembled for separate shipment require no additional conduit or wire for field reassembly All wire leads will be tagged for ease of reconnection in the field If the unit and or accessories cannot be installed imm
18. applicable standard or optional accessories will be placed inside the fan section of the unit for shipment and must be removed and installed by the mechanical or electrical contractor Remotely located discharge or inlet dampers must be equipped with an end switch and interlocked to insure maximum design opening before starting and running circuits may be energized D Electrical Connections Warning Open all disconnect switches secure in that position before wiring unit Failure to do so may result in personal injury or death from electrical shock Warning Controls must be protected from water Do not allow water to drip on the electrical controls Note Before installing any wiring check the unit rating plate for power supply voltage and mini mum amperage All wiring must comply with all applicable local state provincial and national electric 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 equip ment Complete all wiring to any optional accessories as shown on unit bill of material and electrical wiring diagram as required before applying voltage to the unit Entry location for all field installed and control wiring is through the con
19. cide with those of the unit NOTE Return air units must be ducted The minimum clearance to combustible material must be maintained as listed in Table 1 Table 1 Minimum clearance to combustible material also consult local codes and regulations Clearances to Combustible Material Horizontal Units Front 48 Inches Rear 18 Inches Right 18 Inches Left 18 Inches Top 18 Inches Floor 6 Inches Consider control side as front of unit In addition to the combustible clearances listed above access for service should be allowed around the unit The recommended minimum access is 36 on front and rear sides for service access Optimum clearance for coil removal for units with cooling coil section would be equivalent to cabinet width DETAIL A C000660 On outdoor curb mounted installations flash and seal the roof curb to prevent leakage The cross section of factory provided curb is formed to accept wood nailing strip and insulation provided by others It is the customer and installation personnel responsi bility to determine if the unit is equipped with all of the safety devices required for the particular application Safety considerations include the accessibility of the unit to non service personnel the provision of electrical lockout switches maintenance procedures and automatic control sequences Clearly mark all emergency shutoff devices C Location Of Accessories Where
20. do not connect gas piping to this unit until a supply line pressure leak test has been completed Connecting the unit before completing the pressure leak test may damage the unit gas valve and result in a fire hazard DANGER Never use an open flame to detect gas leaks Explosive conditions may exist which would result in personal injury or death The gas line should be supported so that no strain is placed on the unit Pipe compounds which are not soluble to liquid petroleum gases should not be used on threaded joints The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 PSIG The appliance must be isolated from the gas supply piping system by closing it s individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressure equal to or less than 1 2 PSIG Correctly sized piping must be run to the unit Please note that gas line pressure must be as shown on specification plate when unit is operat ing 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 G Field Wiring and Remote Control Installation 1 Connect the power lines to the line side of the power distribution block or optional main disconnect switch 2 Field wiring is
21. e drained via PVC or steel pipe with an indirect connection to the plumbing wastes Where a condensate neutralizer is used an overflow shall be provided such that condensate will be directed to the drain in the event that the neutralizer becomes plugged Indoor units typically require a condensate trap to be installed to prevent combustion gasses from entering the space Outdoor units may 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 add extra height to provide enough hydrostatic head to overcome the frictional losses Always slope piping down a minimum of 1 8 per foot in the direction of the flow Condensate Drain Drawing Evaporator Coil The cooling coil section is located in the unit so that supply air is drawn through the evaporator coil s This results in the condensate being induced to the area of low static pressure Unless some means of pressure equalization is provided in the condensate drain the air rushing through the drain will cause the condensate to accumulate in the drain pan As the unit continues to operate the accumulated water will be picked up by the in rushing air and carried with the air over the side of the drain pan causing possible water leaks into the
22. e 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 Check the supply voltage before energizing the unit The maximum voltage variation should not exceed 10 Phase voltage unbalance must not exceed 2 NOTE Should any original wire supplied with the heater have to be replaced it must be replaced with wiring material having a temperature rating of at least 105 C REMARQUE Dans le cas un quelconque des cables livr s avec l unit devait tre remplac il doit tre remplac avec des c bles pr vus pour r sister une chaleur d au moins 105 C SECTION 11 INSTALLATION 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 FOR CANDIAN INSTALLATIONS ONLY 1 All installations must conform with local building codes or in the absence of local codes with current CAN CGA B149 Installation Codes for Gas Burning Appliances and Equipment 2 All electrical connections must be in 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 T
23. eck for power at damper its end switch not making or motor and that end switch has dampers binding been wired correctly End switch should be wired N O normally open Clear linkage 8 Overload protection on motor 8 Reset the starter by pushing red starter tripped button on starter check amp draw 9 Belts loose or broken 9 Turn power off and check belts 10 Motor may be burned or 10 Turn power off and check motor incorrectly wired and wiring 11 Time clock or field installed 11 Check time clock and field controls not closed installed controls for correct settings and voltage 12 Night set back thermostat not 12 Check night set back thermostat closed for correct settings 13 Bearing seized on shaft 13 Turn power off and check bearings 16 SECTION Vil TROUBLE SHOOTING continued Symptom Cause Remedy B Burner motor does not Low or no voltage Check power source operate 2 Fuse s blown 2 Replace fuse s 3 Customer s interlock not closed 3 Close or connect customer or connected interlock 4 Burner Manual Auto switch in 4 Place switch in Manual Auto Off position position 5 Safety and limit circuits open 5 Close safety and limit circuits 6 Ignition control not closed 6 Check for power or replace 7 Overload protection on motor or 7 Reset the motor or starter and starter tripped check amps 8 Motor may be d
24. ediately they should be stored in a clean dry environment If this is not possible and the unit must be stored outdoors it should be protected from the weather with tarpaulins or plastic coverings Do not assume that simply covering a unit will keep insects dust and condensation out of the unit and critical components Rotate the fan monthly Shipments are made F O B Dallas Texas by truck The unit is securely strapped tied and blocked to prevent shipping damage All shipments are checked by an inspector before they are accepted by the carrier Parts that are shipped un mounted are noted on the bill of lading These parts where feasible are packaged and shipped with the unit Upon receipt of shipment all units should be checked against the bill of lading to insure all items have 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 you should request an inspec tion and a claim should be filed immediately with the carrier All IFL Indirect Fired Comfort Systems are given a complete operations test and control circuit checkout before shipment Copies of the wiring diagram piping diagram and bill of material are included with each unit shipped If correspon dence with the factory is necessary please provide the unit model and serial number C Optional Factory Service Periodic serv
25. efective 18 SECTION VIII FLUE GAS ANALYSIS PERCENT EXCESS AIR PERCENT CARBON DIOXIDE XCO2 net 1 abes WHICH ARE BELOW THE FUEL LIS mette o NON SNA TTT Et SORA LECT SSNS CO2 02 RATIO CURVES FOR FUEL OILS amp GASES FUEL MAX CO 2 4 5 6 7 8 S9 10 11 12 13 14 15 16 17 18 19 20 20 93 PERCENT OXYGEN X02 ed SECTION IX MAINTENANCE 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 b Initial start up has a tendency to relieve the tightness of nuts bolts and setscrews on the blower bearings and burner assembly Recheck for tightness of hold down bolts all setscrews and keys and tighten if necessary after approximately the first eight 8 hours of continuous operation Weekly a Check that fan belts are tight and sheaves are aligned CAUTION Do Not Over Tighten Belts The fan belts can be checked every 30 days after the first 60 days of new belt run in b Check gas pressure at regulator Monthly a Check all valves piping and connecti
26. efective or 8 Turn power off and check power incorrectly wired and wiring 9 Burner relay not closed 9 Check for power or replace 10 Pre purge timer not closed 10 Check for power or replace C No voltage at flame 1 See burner motor does not 1 See burner motor does not safeguard relay input operate Clause 1 2 3 4 5 operate Remedy 1 2 3 4 5 terminals amp 10 amp 10 2 Burner motor air proving switch 2 Check for correct rotation and or open adjust switch D Flame safeguard 1 See technical data sheets on 1 Determine the cause of lockout relay goes into safety flame safeguard relay Reset the flame safeguard relay shutdown Lockout E Pilot does not light after 1 Manual pilot shut off valve closed 1 Slowly open valve pre purge has timed out if applicable and voltage is present on 2 Inlet gas pressure lower than 2 Increase gas pressure flame safeguard output minimum gas pressure required terminals 3 No gas through pilot regulator 3 Clear obstruction in vent orifice with sufficient inlet gas pressure or line replace if defective if applicable 4 No gas flow through pilot 4 Check for proper installation solenoid valve if applicable and voltage Correct or replace if defective 5 Type of gas supplied natural 5 Connect to proper fuel supply gas or propane different than or contact factory for field shown on unit rating plate conversion parts 6 Flame detection system not 6a U V Sen
27. equired to prevent sagging Refer to the rating plate for the category of appliance to select the venting system Consult the authorities having jurisdiction and use a gastight watertight venting system constructed of material resistant to corrosion by condensate The National Fuel Gas Code ANSI Z223 1 specifies a 4 foot 1 22m horizontal vent terminal clearance from gas and electric meters regulators and relief equipment The Canadian B149 1 Natural Gas Installation Code specifies a 6 foot 1 83m horizontal vent terminal clearance to gas and electric meters and relief devices Through the wall vents for these heaters shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators relief valves or other equipment The vent pipe diameter must be as shown in following chart Minimum Stack Diameter 200 MBH Input 4 400 MBH Input 6 600 MBH Input Any exhaust stack shall have a minimum of at least 36 clearance to combustible material 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 heater collector box Be sure drip leg is made so water will not fall on heater controls when drain plug is removed Vents should
28. f disconnect switch may be energized Follow proper lockout tagout procedures Perform a visual inspection internally and externally of the unit to make sure no damage has occurred and everything is secure This inspection is very important and should be completed with greatest care given to detail A good pre start inspection will insure against possible unit damage on start up and will save valuable analysis time Check that the physical condition of the unit exterior is acceptable Check that the insulation inside of unit is properly secured Remove all shipping blocks brackets and bolts from bases on units with optional isolation base Check that system ductwork is installed properly and free from obstructions Check to make sure blower turns freely Check all wiring for loose connections and tighten if necessary Inspect all blower and motor bearings and lubricate if necessary Optional extended lube lines are shipped filled from the factory Inspect sheaves and belts for tightness tension and alignment Do not over tighten belts Inspect setscrews on bearings and blower for tightness CAUTION OVER GREASING BEARINGS WILL RUPTURE GREASE SEALS Before starting up this equipment study and famil iarize yourself with the wiring diagram sequence of operation flame safeguard control components gas train and burner Check any dampers or mixing boxes if supplied Make certain that all damper linkage is free
29. g If the burner or draft proving switches open this could cause the flame safeguard to go into lockout 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 safety and controls are working properly SECTION VI UNIT SHUTDOWN A Extended Shutdown 1 De energize the heating control turning the burner off 2 Close the Manual Firing Valve in the heater gas piping manifold 3 If the furnace was firing at the time of shutdown allow the main supply blower to run for a sufficient period to cool off the heat exchanger The furnace may have an automatic blower override that will perform this function automatically running the blower until the air reaches a fan cut off temperature 4 Turn the furnace control to the off position 5 Turn the unit main power disconnect to the off position 6 Close all the manual gas shut off valves 7 Ifthe unit is to remain idle for an extended period the blower and motor shafts should be rotated by hand to spread the grease over the bearings B Emergency Shutdown Only Open the main electrical disconnect switch Close the main manual gas valve po 56 SECTION VII TROUBLE SHOOTING Check Safety Shutdown Performance WARNING Fire or explosion
30. he following recommendations are not intended to supplant any requirements of federal state or local codes having jurisdiction Authorities having jurisdiction should be consulted before installations are made Local codes may require additional safety controls and or interlocks All installations in airplane hangers must be in accordance with current ANSI NFPA No 409 All installations in public garages must be in accordance with current NFPA No 88A and NFPA No 88B CAUTION Do not install heating system in corrosive or flammable atmospheres Premature failure of or severe damage to the unit will result IFL Rigging CAUTION Heating system must not be installed in locations where air for combustion would contain chlorinated halogenated or acidic vapors If located in such an environment premature failure of the unit will occur A Handling The Equiment The IFL Indirect Fired Comfort System has been designed for rigging and handling through the use of special lifting lugs installed on the base of each unit As explained previously the basic unit is designed for shipping in one piece where shipping limitations allow Some optional accessories may require field mounting During lifting operations slings or chains with hooks and l beam spreader are recommended see figure below Lifting must be equal to all lugs furnished The spreader bar I beam or equal must be equal in length to the longest span between lifting points
31. ice on any piece of mechanical equipment is necessary for efficient operation A nationwide service support network is available to provide quick and dependable servicing of make up air heating ventilating or air handling types of equipment The factory also offers start up service which includes the presence of a service engineer to supervise the initial start up and adjustment of the equipment and provide instructions for the owner maintenance personnel in proper operations and maintenance Consult factory for quotations on periodic or start up service D Curb Mounted Units Outdoor units can be supplied with an optional roof curb The curb greatly facilitates installation thereby reducing installation costs All connections to the unit duct piping electrical power and control wiring can be made 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 suppor
32. icing this equipment AVERTISSEMENT Une installation d ficiente de m me qu un mauvais r glage modification entretien ou maintenance peuvent occasionner des dommages mat riels corporels voire causer la mort Lire attentivement les instructions d installation d utilisation et d entretien avant d installer ou d intervenir sur cet appareil WARNING Install operate and maintain unit in accordance with manufacturer s instructions to avoid exposure to fuel substances or substances from incomplete combustion which can cause death or serious illness The state of California has determined that these substances may cause cancer birth defects or other reproductive harm INSTALLER S RESPONSIBILITY Installer Please Note This equipment has been test fired and inspected It has been shipped free from defects from our factory However during shipment and installation problems such as loose wires leaks or loose fasteners may occur It is the installer s responsibility to inspect and correct any problems that may be found 111111 13 4830 Transport Drive Dallas TX 75247 Phone 214 638 6010 Fax 214 905 0806 Applied Air www appliedair com SECTION I FOREWORD As is the case with any fine piece of equipment care Table of Contents must be taken to provide the proper attention to the Section Foreword and Table of Contents 2 operation and maintenance detail of this machine Section Il General Information
33. ion of filter coating after washing to maintain optimum filter performance The frequency of cleaning and replacing air filters applies twelve months of the year where blowers are used for ventilation and heating D Belt Tensions and Adjustments Belt tension is adjusted during the initial run in and test periods at the factory However the belts are run as slack as possible to prevent excessive damage to the bearings yet tight enough to prevent slippage It is necessary therefore to tighten all belts during the first few months of operation and to check for proper tension weekly during the first 60 days after which 30 day check intervals are sufficient NOTE Turn off all power to the equipment before checking belt tensions CAUTION Do not attempt to tighten 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 over tighten belts Suggested Belt Tension Method 1 Check tension frequently during the first 24 48 hours of run in operation Ideal tension is the low est tension at which the belt will not slip under peak load conditions Over tensioning shortens belt and bearing life 2 To properly tension a conventional V belt drive use the following procedure a Measure the span length b At the center of the span apply a force perpendicular to the span to deflect the belt 1 64 inch for every inch of span le
34. n for leaks using a soap bubble solution f When the duct furnace installation is complete recheck the amperage draw of each motor g Insure all safety controls are operative i e flame relay high limit air proving switches etc h Reset all operating controls back to proper set points for normal running conditions FINAL CHECKS AND ADJUSTMENTS With the gas input pressure established the flue gas analysis can now be preformed This is done at the stack The following readings should be taken but not limited to CO2 Net Stack Temperature Combustion Efficiency 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 CO Fuel input too low Excess burner air Wrong draft setting Detectable Carbon Monoxide CO Fuel input too high Not enough burner air Restricted draft Flame impingement Excessive Stack Temperature Draft setting too high Excess burner air Fuel input too high Low Oxygen O Oxygen reading must always be a positive percentage Cycle burner several times to ensure smooth light off and proper operation Visually observe the flame pattern There must be n
35. ngth 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 following table 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 loosening the motor mounting bolts and adjusting the position of the motor on its base can adjust it NOTE A new drive can be tightened to two times the minimum value shown to allow for normal drop in tension during the run in period B Section small Pounds pulley Pounds Force for diameter Belt Forcefor 1 2times rangein Manufacturer Normal Normal inches amp Type Belt Tension Tension 3 4 4 2 Gates Hi Power 4 4 6 6 4 4 4 6 Gates Hi Power 4 9 7 4 5 8 8 6 Gates Hi Power 5 8 8 7 Note For recommendation of other types of belts consult respective manufacturers E 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 CAUTION Solutions used to clean coils must not be corrosive to metals or materials used in the manufacturer of this equipment If cleaning solutions are applied through means of high pressure spray care must be taken to avoid damaging coil fins 2 Condensate Drain Pan Periodically flush the conden
36. o 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 14 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 close manual pilot gas valve if applicable The flame safeguard must trip out within 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 the switch returned to its original settin
37. o start the burner when furnace is full of vapor or combustion chamber is very hot Connect test instruments thermometers and meters on the furnace and controls to measure and record the appropriate data 110 Suggested Tools and Instruments Volt Ohm meter Tachometer Stack and Temperature Thermometer Gas Pressure Gauge Ammeter Amprobe or equal U Tube Manometer 0 10 W C Flue Gas Test Equipment Standard Hand Tools D C Volt Meter Microammeter FL 01 FL 02 FL 02 FL 04 PS 02 PS 04 PS 07 PS 12 RE 21 TC 09 Suggested Control Settings Fan Control 95 125 F High Limit Horz Discharge 210 F High Limit Down Discharge 230 F Auxiliary High Limit ssssse 210 F Burner Proving WIECH Adjust to field condition Low Gas Pressure iiic eto eed rais 1 0 W C High Gas Pressure oit 125 above burner firing rate Clogged Filter SWITCH itte Adjust to field condition Time Clock Customer Discretion Night Setback Thermostat Customer Discretion See Digital Control System User s Manual for DDC Controller default settings BEFORE ATTEMPTING TO START THE HEATER READ THE TYPICAL SEQUENCE OF OPERATION AS SHOWN BELOW Typical Sequence of Operations Note This sequence is written for only the burner safety and operating portion of the heater O
38. off position Check supply blower for proper rotation The burner rotation can be checked when the heat section is started NOTE To change rotation of the blowers simply interchange any two 2 of the line leads of the motor starter for three phase motors On single phase motors refer to motor nameplate Turn Fan on off switch to on position Check for proper blower 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 Make sure all manual gas shut off valves are still in the closed position Setting Burner CAUTION Do not attempt to start the burner when furnace is full of vapor or combustion chamber is very hot 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 Refer to burner manufacturer s Installation Operation and Maintenance instructions for proper set up operation and settings Turn the main and pilot if applicable manual shutoff valves upstream of the firing rate valve on and check for leaks in the gas piping using a soap bubble solution Correct any leaks that are found Check the gas supply pressure to the heater making sure it does not exceed the maximum on the unit rating plate Connect the test inst
39. ons for leaks b Check the pilot and burner flame signal c Check the fuel pressure in the fuel supply line to each heater Check the burner manifold pressure and draft Do a flue gas analysis Inspect filters Clean or replace as necessary Inspect main blower bearings lubricate if necessary See following section on bearing lubrication h Check all dampers damper actuators and linkages Adjust and tighten if necessary i Inspect area and make sure that 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 remains clean and open Quarterly a Complete the monthly maintenance schedule b Inspect all drives for proper belt tension wear and alignment c Check that bearings blowers and drives setscrews are securely locked to the shaft D Inspect the burner and pilot assembly Clean and adjust if necessary Check the voltage and amps on all motors Check the operation of all safety limits and controls Clean and recalibrate or replace Check the operation of the automatic gas shut off valves and check them for leakage at the pressure test ports provided Inspect all electrical components connections and terminals Clean or replace and tighten as necessa
40. rlock with the combustion blower shall be provided The rated output of gas burning appliances decreases with higher altitudes above 2 000 feet the furnace shall be de rated 4 for each 1 000 feet of altitude above sea level Factory testing rating plate informa tion is recorded on sea level conditions High altitude ratings may be obtained by a change in manifold pressure Appliances must be suitably marked to indicate their altitude adjusted input rating Under no circumstances should this equipment be installed in a negatively pressurized space Consult jurisdictional authority for proper ventilation requirements Combustion air containing or recirculation of room air may be hazardous in the presence of a Flammable solids liquids and gases b Explosive materials i e grain dust coal dust gunpowder etc c Substances which may become toxic when exposed to heat i e refrigerant aerosols etc Field Assembly Drawing GASKET TYPICAL C000660 DETAIL B 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 coin
41. roller bearings should be lubricated Speed Temperature Cleanliness Interval 100RPM Upto125 F Clean 6 Months 500RPM Upto150 F Clean 2 Months 1000 RPM Upto210 F Clean 2 Weeks 1500 RPM Over 150 F Clean Weekly Any Speed Upto 150 F Dirty 1 Week to 1 Month Any Speed Over 150 F Dirty Daily to 1 Week Any Speed Any Temp Very Dirty Daily to 1 Week Any Speed Any Temp Extreme Daily to Conditions 1 Week 3 Dampers Dampers should be inspected monthly daily in icy weather for securely fastened linkages and smooth operation If dampers are binding or excessively noisy then lubrication may be required Place one drop of 20 wt Machine oil on each blade bearing and linkage ball joint Do not over lubricate and wipe any excess from the area Be sure to note that dampers over 49 inches long have intermediate bearings which require lubrication EL 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 manu facturer s recommended final value Dirty filter elements should be replaced with a clean element of the same type and size In addition the manufacturer not only suggests but insists that air filters be checked every 30 days and replaced with new filters throwaway type or cleaned washable type as required Cleanable filters should be given a new applicat
42. ruments meters and thermo meters on the heater and controls to measure and record the appropriate data Close the main manual valve leaving the pilot valve open if applicable Set the thermostat at the highest setting and energize the heating control burner motor starts closing the air switch and energizing the ignition control With power supplied to the ignition controller and all the safety limiting devices are satisfied a 30 90 second pre purge will start the pilot valve if appli cable or main gas valve is energized and a 6 15 second trial to ignite If the flame sensing probe fails to prove the pilot or main flame it de energizes the spark igniter and the controller will lockout on flame failure 10 30 seconds This safety step is performed to establish the flame sensing and test any of the safety devices before main burner light off Frequently the cause for safety lockouts relates to gas pressures that are too high and or combustion air dampers that are not set correctly For units with pilot cycle pilot several times to make sure that the combustion air and pilot gas pressure is sufficient to provide instant ignition and you have a steady flame Check to make sure the pilot flame signal is steady Pilot regulator adjustment may be necessary if the adjustment of the needle valve does yield the required flame signal Install a manometer at the test port to check burner manifold pressure Once pilot has been
43. ry Off Season or Yearly a b C j Complete the monthly and quarterly maintenance schedules Inspect blower wheel and clean if necessary Check that blower wheel and sheaves are securely set to the shaft Inspect all bearings and check condition and alignment Inspect all fan belts and sheaves Replace if necessary Check the condensation lines for any leaks or blockages if applicable Test ignition spark Adjust gap if necessary Clean flame sensor ignition electrodes and check for cracks Test the flame safeguard relay RE 02 and replace components if necessary Inspect all regulators relief valves motorized valves solenoid valves vent valves manual shut off valves and safety shut off valves Check their operation and clean or replace as neces sary Inspect and clean all drip legs in fuel lines and in the flue Inspect the combustion chamber for carbon deposits soot scale or flame impingement Clean if necessary If there is evidence of flame impingement complete burner adjustment must be made Lubricate blower and burner motors as directed by motor manufacturer Inspect motors for loose connections Lightly oil all door latches Check that the cabinet is weather tight Replace door gaskets and re caulk as needed B Lubrication Instructions Motor Manufacturer Bearing Type All 3 phase Baldor or equal Single row fan motors ball bearings 1 HP
44. sate 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 Support Means Inspect the entire unit support means to be sure everything is firmly in place 22 SECTION X REPLACEMENT PARTS Replacement parts may be ordered from the factory When parts are ordered MODEL NUMBER SERIAL All warranty parts will be shipped freight allowed from NUMBER FACTORY ORDER F O and PART factory for normal ground service Warranty parts must be NUMBERS are required Belts filters and fuses are returned prepaid within 30 days Credit will be issued if not covered under warranty part is complete defective and returned on time Dealer Contractor Name Address City State Zip Ph SECTION TYPICAL WIRING DIAGRAM C000641 sw 01 ne OL 01 COMPONENT IDENTIFICATION 200 230 460 575 VOLT 64 too gt T2 BM 01 X4 700 MODULATING BURNER 3 PHASE Ts 01 CAUTION OPEN MAIN 13 CB 09 CONTROL CIRCUIT TRANSFORMER BREAKER DISCONNECT SWITCH 60 HERTZ Fo e 7 BEFORE SERVICING 3 WRE Srt FL 01 SWITCH EQUIPMENT FL 02 HIGH TEMPERATURE LIMIT SWITCH FL 04 MANUAL RESET HIGH LIMIT SWITCH OPTIONAL CB 09 FL 05 SUPPLY AIR FIRESTAT OPTIONAL FL 06 RETURN AIR FIRESTAT OPTIONAL FU 10 CONTROL TRANSFORMER FU
45. sor Clean lens check sensing pilot flame See section wiring and spark rod 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 trans of ignition transformer former if defective Er SECTION Vil TROUBLE SHOOTING continued pilot OK and no voltage is present at flame safeguard relay output terminals flame safeguard relay Symptom Cause Remedy F If pilot does not light after See technical data sheets on Check wiring and replace if pre purge has timed out flame safeguard relay defective and there is no voltage at flame safeguard relay output terminals G If there is no heat with Manual gas shut off Turn heat off on switch to the off pilot OK if applicable valve closed position Slowly open all manual and voltage is present gas shut off valves at flame safeguard relay No gas on outlet side of regulator Clear obstruction in vent orifice output terminals with proper inlet pressure or line Check for correct size spring Replace if defective No gas on outlet side of butterfly Check wiring voltage and valve or actuator with proper inlet adjustment Correct wiring or pressure replace if defective Burner does not modulate Check wiring and replace if defective H If there is no heat with See technical data sheets on Check wiring and replace if d
46. t is required for certain applications Placement of the curb is critical in squareness and leveling Shims for leveling must be applied to the curb application of shims to the unit will tend to destroy the sealing effect after installation Make sure sealing tape is in place before unit is set Be careful not to allow gaps where two pieces of sealing tape meet A bubble level must be used in leveling process Measure across diagonals to check for squareness Allowable tolerance is 1 4 difference between diagonal measurements Double check approval prints before setting the unit Upon completion of setting the curb apply roofing material and flashing as required E Location Of Accessories Where applicable standard or optional accessories will be placed inside the fan section of the unit for shipment and must be removed and installed by the mechanical or electrical contractor Remotely located discharge or inlet dampers must be equipped with an end switch and interlocked to insure maximum design opening before starting and running circuits may be energized Field constructed intake accessories should be properly designed to minimize the entry of rain and snow Adequate building relief must be provided so as to not over pressurize the building when the unit is operating at its rated capacity This can be accomplished by taking into account through standard engineering methods the structure s designed infiltration rate
47. terminate that will not cause a down draft to occur This could affect the over fire draft pressure in the heat exchanger Do not install dampers or other restrictive devices in the flue vent pipe The stack should not be installed in such a manner that access to the components is obstructed Guy wires may be required to brace the stack above rooflines Outdoor units are supplied with a stack The stack shall have a minimum of at least 36 clearance to combustible materials The pressure measured with a manometer at the test port in the burner compartment must not exceed the Maximum Overfire Positive pressure on positive fired heaters The flue draft should be adjusted at the damper of the burner fan when the heater is operating on high fire F Field Piping All gas piping must be in accordance with the requirements outlined in the National Fuel Gas Code ANSI 2223 1 It is required that a ground union be installed adjacent to the manifold for easy servicing A drip leg and or filter should be provided upstream of the unit s inlet gas connection An additional shut off must be located external of the unit s enclosure where required by local code The location of this valve must comply with all local codes 1 8 inch N P T plugged tapping accessible for test gauge connection must be installed immediately upstream of the gas supply connection to the unit WARNING To avoid equipment damage or possible personal injury
48. ther control Systems for dampers mixing boxes and temper ature controls are included in the unit typical sequence of operation and or wiring diagram 1 With main supply air blower on thermostat calling for heat and all switches and operating controls in their normal position the burner motor will run and pre purge the combustion chamber Pre purge timing is not adjustable and is approximately 30 to 90 seconds 2 With pre purge timing complete the pilot solenoid if applicable and ignition transformer are energized The pilot burner flame will be established and sensed by the flame sensor 3 Ignition transformer is de energized and pilot valve remains on if applicable 4 Main fuel valve s will open The main burner flame will be established 5 Pilot valve if applicable is de energized 6 Once thermostat is satisfied the main fuel valves s and burner motor will be de energized Main supply air blower will continue to run edo SECTION V UNIT START UP A PURPOSE Check the incoming line voltage to match unit name plate rating If voltage is over 10 of nameplate rating or phase voltage unbalance is over 2 notify contractor or the power company If power supply meets requirements turn main disconnect switch on Turn Fan on off switch to on position Inlet shut off damper if applicable opens after end switch has proven damper is open the blower runs Turn Fan on off switch to
49. to move and no binding will occur If dampers are of the modu lating 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 make sure all vent lines if applicable are run to atmosphere on gas regulators and pressure switches Vent lines should terminate outside the building with a turndown elbow and bug screen Vent limiters may be used which do not require vent lines to be run If vent lines are even partially plugged this will interfere with the proper venting of pressure control devices Check to make sure all filters accessories and ship loose items are installed correctly Check to make sure the flue stack is installed properly and free from obstruction Check all thermostats for normal operation Check to make sure all manual reset safety devices have been reset and limits are in their normal operating position Check to make sure all doors and inspection panels are secured or closed Check that all piping connections particularly unions are tight Check all gas piping for leaks using a soap bubble solution The most common types of problems found relative to the gas train itself is foreign material within the gas piping This will interfere with the proper operation of the gas train components and burner Purge all air from gas lines per gas codes Check that all manual gas valves are closed CAUTION Do not attempt t
50. trol panel If optional disconnect is not furnished with the unit 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 Cana dian 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 2 NOTE Should any original wire supplied with the unit have to be replaced it must be replaced with wiring material having a temperature rating of at least 105 C E Venting All venting installations must conform to Part 7 Vent ing of equipment in the current version of the National Fuel Gas Code ANSI Z223 1 or applicable provisions of local building codes All indoor units must be vented Each unit must have an individual vent pipe and vent terminal The customer must provide a rain cap or weatherproof cap Insulate single wall vent pipe exposed to cold air or running through unheated areas A vent connector shall be equivalent to a minimum of 24 gauge galvanized steel It shall have a minimum of at least 9 to combustible material All horizontal runs should have a minimum rise of 1 4 per foot of horizontal run Support horizontal runs as r
51. verheat 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 blowers These bearings have been prelubricated with a number 2 lithium base grease Lubrication 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 accompanying 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 suggests too much grease Frequency of Lubrication Frequency of lubrication depends upon operating conditions The bearing operating temperature is the best index for determining a lubrication schedule The following chart gives the frequency of lubrication based upon continuous operation for various operating temperatures and can be used as a satisfactory guide for determining when all ball and
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