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Installation/Operation Manual for IFJ

1. H 160 16 4 150 15 G 7 140 14 5 7 190 13 ain UNE 120 12 z i 7 110 11 7 100 10 7 o0 x Z 80 8 70 x 7 I I 7 tc 60 2 6 E 50 5 E 5405 4 22 5 5 30 8 1 271 OQ 2 205 2 4 a a pd 10 1 _ 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2093 PERCENT OXYGEN CURVE FUEL MAXIMUM CO CURVE FUEL MAXIMUM CO A Nautral Gas 11 7 E 2 Fuel Oil 15 2 B Natural Gas 12 1 F 5 Fuel Oil 16 0 12 1 6 Fuel Oil 16 9 D Butane 14 0 H Excess Air vs O 45 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 HSG 400 Burners 13 16 20 64mm REF PROBE DIM A REF 3 4 IGNITER 1 5 8 41 28 19 05mm SENSOR 1 4 31 75mm 2 9 16 65 08 75 3 32 2 381mm 1 16 1 588mm Figure 13 FLAME SENSOR CURRENT CHECK USE uA SCALE DISCONNECT WIRE FROM SENSE TERMINAL BLACK 0 8 uA DC MINMUM AND STEADY S89 FLAME CURRENT MEASUREMENT Figure 14 44 The Honeywell S89 series primary ignition controls utilize the flame current rectification principal for
2. lt 3 3 8 86 q 4 1 16 103 2 51 7 8 22 12 305 LEADS M2331 Fig 1 S89 dimensions in in mm Fire or Explosion Hazard en Installing This Product Can cause severe injury death or property Read these instructions carefully Failure to follow them damage 2 could damage the product cause hazardous 1 Disconnect power supply before wiring to avoid condition electrical shock explosion or equipment damage 2 Check the ratings given in the instructions and on the 2 If a new gas control is being installed turn off gas product to make sure the product is suitable for your supply before starting installation Conduct Gas application Leak Test after gas control is installed 3 Installer must be a trained experienced service 3 In an LP gas installation remember that LP gas is technician heavier than air and will not vent upward naturally 4 After installation is complete check out product Do not operate electric switches lights or _ operation as provided in these instructions ee until you are sure that work area is free of gas 4 Never install an S89 where water can flood drip or condense on the device It can malfunction if it gets wet 5 Never try to use a device that has been damp or wet replace it 6 If the control might be exposed to water or moisture install it in a suitable waterproof enclosure 7 Any replacement S89 must have the same or shorter lock
3. 68 0066 4 36 S89E F DIRECT SPARK IGNITION CONTROL MODULE IMPORTANT 1 The following service procedures are provided as a general guide Follow appliance manufacturer ser vice instructions if available 2 All meter readings must be taken within the trial for ignition period Once the ignition period ends the system must be reset by setting the thermostat down for at least 45 seconds before continuing 3 If any component does not function properly make sure it is correctly installed and wired before replacing it 4 The ignition module cannot be repaired If it malfunctions it must be replaced 5 Only trained experienced service technicians should service direct spark ignition systems Before beginning troubleshooting review the normal operating sequence of the S89 See the Operation section Then follow the steps in Fig 5 to identify the source of the problem Some steps are explained in greater detail below Besides standard hand tools you will need the following to complete the troubleshooting 1 Honeywell W136 Test Meter or equivalent 2 Testlead a length of ignition cable or other heavily insulated wire with both ends stripped 1 2 in 13 mm Check Ignition System Grounding Nuisance shutdowns are often caused by a poor or erratic ground A common ground is required for the module igniter flame sensor and main burner 1 Check good metal to metal contact between the igniter b
4. COMPONENT IDENTIFICATION RP 09 RP 10 RP 11 RP 12A RP 12B RP 16 RP 17 RP 18 RP 19 HOT GAS BYPASS TEE LIQUID LINE SOLENOID VALVE HOT GAS BYPASS VALVE FIRST STAGE THERMAL EXPANSION VALVE FOR CIRCUIT 1 THERMAL EXPANSION VALVE FOR CIRCUIT 2 DX EVAPORATOR COIL A DX EVAPORATOR COIL B REFRIGERANT DISTRIBUTOR CONDENSATE PAN PROVIDED WITH DRAIN CONNECTION ON ONE 1 END ONLY H Locating Temperature Controls The room or outdoor thermostats should be mounted where they will not be subjected to direct impact of the heated air or radiant heat from the sun It is also recommended that thermostats especially those with mercury bulb contacts be mounted on a vibration free surface The sides of building columns away from the heater or interior walls are usually the location best suited for mounting thermostats I Drains and Traps 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 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 SUGGESTED P TRAP DESIGN FOR CONDENSAT
5. Typical Procedure For Changing The Shaft And Bearings k 8 9 10 11 12 Remove protective shaft coating 2 3 Remove the drive side sheave Disconnect the grease lines from the existing bearings Identify the 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 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 13 14 15 16 17 18 19 20 2 22 23 50 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
6. 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 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 ignition module RE 02 and replace if necessary i 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 necessary j Inspect and clean all drip legs in fuel lines and in the flue Remove the front panel on the heat exchanger section and the header box cover Inspect the header box and tubes Look for carbon deposits Soot scale or rust Clean if necessary 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 co
7. D Electrical Connections Warning Open all disconnect switches and secure in that position before wiring unit Failure to do so may result in personal injury or death from electrical shock Warning Controls must be protected from 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 andlocal 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 disconnect is not furnished with heater the field provided disconn
8. SPARK STOPS BEFORE END OF IGNITER TIMING YES SYSTEM RUNS UNTIL CALL FOR HEAT ENDS MAKE SURE FLAME DOES NOT TOUCH SENSOR INSULATOR AND THAT SENSOR INSULATOR IS BELOW FLAME EXCESSIVE HEAT YES OVER 1000 F 538 C WILL CAUSE SHORT TO GROUND RELOCATE SENSOR OR SHIELD INSULATOR IF EXCESS HEAT IS SUSPECTED IF CHECKS ARE OKAY REPLACE S89 MODULE CHECK FOR PROPER TEMPERATURE CONTROLLER OPERATION REMOVE VALVE LEAD AT S89 IF VALVE CLOSES RECHECK TERMPERATURE CONTROLLER AND WIRING IF NOT REPLACE GAS CONTROL CALL FOR HEAT ENDS SYSTEM SHUTS OFF YES TROUBLESHOOTING ENDS REPEAT PROCEDURE UNTIL TROUBLE FREE OPERATION IS OBTAINED M19839A Fig 5 Troubleshooting S89E F 9 68 0066 4 38 S89E F DIRECT SPARK IGNITION CONTROL MODULE Measure Flame Current The S89 provides ac power to the flame sensor which the flame rectifies to direct current If the flame signal back to the S89 is less than 0 8 pA the S89 will shut down the system To measure the flame current 3 If the meter reads less than 0 8 pA or reading is unsteady recheck points under Check Flame Sensor and Igniter above FLAME SENSOR CURRENT CHECK USE pA SCALE TO SENSOR W136 OR EQUIV 1 Connect a meter set to the dc microammeter scal
9. for 100 megohm resistance between wire and ground Mounting Mounts in any position Dimensions See Fig 1 When purchasing replacement and modernization products from your TRADELINE wholesaler or distributor refer to the TRADELINE Catalog or price sheets for complete ordering number If you have additional questions need further information or would like to comment on our products or services please write or phone 1 Yourlocal Honeywell Automation and Control Products Sales Office check white pages of your phone directory 2 Honeywell Customer Care 1885 Douglas Drive North Minneapolis Minnesota 55422 4386 In Canada Honeywell Limited Honeywell Limit e 35 Dynamic Drive Scarborough Ontario M1V 4Z9 International Sales and Service Offices in all principal cities of the world Manufacturing in Australia Canada Finland France Germany Japan Mexico Netherlands Spain Taiwan United Kingdom U S A 68 0066 4 2 4 S89E F DIRECT SPARK IGNITION CONTROL MODULE Approvals CSA International Certified 158158 1047805 Underwriters Laboratories Inc Component Recognized File No MP268 Guide No MCCZ2 lt 2 51 7 8 22 7 8 22 k 3 16 IN Q C 5 1 4 IN Q C 1 5 13 16 132 3 3 8 86 1 4 IN Q C Y 3 8 86 HOLE 4 lt 2 7 8 73
10. 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 equipment or property only damage HARDWARE GASKET FANIHEATER DISCHARGE SECTION SECTION DISCHARGE SECTION GASKET LIFTING LUG FANIHEATER SECTION LIFTING LUG Y d gggoggogoeggoggogggogg gogggoggggogoogg LERRA RRRA AAA ggggggoegggggogg agggggogggggogg goggggcoggog 2720200002 200000000 200000000 200000000 22222222 22000002 20000000 22000002 22222220220202020202 goagggggoggogooogg ggggggogggggcogogg 20000000000000 CONNECTION DETAIL C000725 B Locating the Unit Prior to locating the unit authorities having jurisdiction should be consulted before ins
11. Air 4830 Transport Drive Dallas TX 75247 Phone 214 638 6010 Fax 214 905 0806 www appliedair com
12. Explosive materials i e grain dust coal dust gunpowder etc 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 electrical and fuel connection points 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 Front 48 inches Rear 18 inches Right 18 inches Left 18 inches Top 18 inches Floor Zero 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 clearance is shown in Table 2 Table 2 Unit Minimum Size Access All Front and Sides Sizes 48 inches 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 If the unit is located within ten 10 feet of a wall place the solid blank side of the discharge facing the wall Place the base section with blower or fan in the desired location Attach the bottom flange of the unit to floor using anchors lag bolts or screws Gasket the top flange and carefully position coil box extension plenum or discharge section
13. NotOccupied Start Time System Fan Run Copy HEAT COOL ON AUTO Schedule Lo 45 fh m 9 Le Lo 19610 Fig 5 Thermostat key locations 3 62 0195 06 25 T7350 COMMERCIAL PROGRAMMABLE THERMOSTAT INSTALLER SETUP For most applications the thermostat factory settings do not need to be changed Review the factory settings in Table 2 NOTE When power is first applied to the thermostat the display will show all segments see Fig 6 Table 2 Default setpoints Control Occupied Not Occupied Standby Heating 70 F 21 C 55 F 13 C 67 F 19 C Cooling 75 F 24 C 85 F 29 C 78 F 26 C Temporary Standby Room teal E StartTime 2 L m EE p NR 1 System Em Heat i 3 Off CoolAuto Dehumid S OnAuto M19611 Fig 6 LCD display of all segments N CAUTION Possible Equipment Damage Fan must be running when system is operating Heat pump and electric heat systems must be configured correctly to prevent equipment damage caused by the system running without the fan Setup Using Keypad The installer uses the Installer Setup to customize the thermostat to specific systems For basic setup functions the thermostat can be configured using the keypad NOTE The T7350 has serial communications to facilitate use of an installer configuration tool More advanced features are a
14. 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 to make sure it 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 12 Check that inlet gas pressure is the same as shown on the rating plate 13 Check that all accessories requiring field wiring have been properly installed 14 Check burner for proper location and alignment 15 Check that filters filter stops accessories and any ship loose items are installed properly 16 Check that vent lines if applicable are run to atmosphere 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 not required If vent lines are even partially plugged this will interfere with proper venting of pressure control devices 17 Check that all manual gas shut off valves are closed 18 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 19 Motor overload relay setting should match the motor s nameplate full load amperage 20 Check any damper
15. can result if compressor is cycled too quickly The minimum off time for compressors is bypassed during Test Mode Equipment damage can occur if the compressor is cycled too quickly Use Test Mode to check the thermostat configurations and operation To start the system test 1 Press Schedule Day Occupied and Not Occupied simultaneously 2 The display gives the option to TEST a enter test mode press up A or down Y until the display indicates IN TEST b To cancel this option ensure display indicates NO TEST 3 Press Run Schedule NOTES verify whether or not the system test is still active repeat the above process The system test times out after ten minutes with no key pressed Save User Schedule Info Copy Performing this operation saves the current schedule including holidays to memory overwriting the old saved schedule 1 Press both nfo and Copy 2 The display gives the option to revert to SAV SHD a To save the current schedule press up A or down V until the display indicates YES b To cancel this option ensure display indicates NO 3 Press Run Schedule Get User Schedule Info Run Getting the user schedule restores the schedule including holidays from saved memory overwriting the schedule currently in use 1 Press both Run Schedule and Info 2 The display gives the option to GET SHD a Toretrieve the saved schedule press up A or down V until the display indicates YES b To c
16. 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 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 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 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 Inspect burner assembly Clean and adjust if necessary Refer to burner manufacturer IOM e Check the voltage and amps on all motors
17. is Auto Fan default setting is On NOTE Use System and Fan keys to change settings System Settings Auto Thermostat automatically changes between heating and cooling based on indoor temperature Cool Thermostat controls cooling Off Heating cooling and fan are all off Heat Thermostat controls heating Em Heat Auxiliary heat serves as first stage Compressor stages are locked off Fan Settings On See Table 1 Auto Fan always cycles with call for heat or cool Conventional The equipment i e plenum switch controls fan operation in heat mode Thermostat controls fan operation in cool mode Electric Heat Thermostat controls fan operation in both heat and cool modes NOTES Fan operation can extend delay Off after the heating cooling turns off Heating choices 0 or 90 seconds Cooling choices are 0 40 seconds Table 1 Fan on control logic Occupancy Call for Heat Cool Scheduled Sensor Signal Yes No Occupied Occupied On On Occupied Unoccupied On Off Standby Doesn t Matter Off Not Occupied Doesn t Matter Off a n heat mode when set for conventional heat the equip ment i e plenum switch could power the fan despite the T7350 Set Day Time ld Override F Temporary Temporary Day Time Occupied Not Occupied 9 2 B e o t Schedule Clear Day Occupied
18. main burner flame sensing The flame rectification phenomenon occurs as follows The ignited gas flame causes the immediate atmosphere around the flame to become ionized gas atoms become electrically charged The ionization causes the atmosphere around the flame to become electrically conductive An AC voltage output from the control sensing circuit is routed through the flame sensor probe When the sensor probe and the burner head are both in contact with a properly adjusted flame the burner head with its larger surface attracts more free electrons thus becoming negatively charged The sensor probe with its small surface area gives up free electrons thus becoming positively charged The free electrons from the AC voltage in the sensor probe flow through the ionized gas flame to the grounded burner head As the AC current passes through the gas flame it is rectified into a DC current flowing back to the grounded side of the sensing circuit The flame in actuality is a switch When the flame is present the switch is closed allowing current to flow through the sensing circuit of the control When no flame is present the switch is open with no current flowing through the sensing circuit of the control The DC current flow is measured in units called DC microamperers A steady DC microamp current of 8 minimum and steady or higher through the sensing circuit of the primary ignition control is sufficient to keep the burner running with
19. or counterclockwise to decrease pressure Check main gas line for leaks using a soap solution Setting the Main Flame CAUTION Do not attempt to start the heater 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 56 Connect manometer to the outlet pressure tap of the unit gas valve Connect a DC microammeter between the SENSE terminal and the flame rod sensing wire Depress the combination gas valve manual control knob and turn to OFF position Adjust the primary air to No 4 and off cycle damper to No 1 1 2 Turn Fan and Heat Off On switches to the ON position and check rotation of burner fan and field supplied draft inducer if applicable Set all thermostats to call for heat Set inlet ductstat if applicable above outside air temperature If limits and all safety controls are closed the burner and field supplied draft inducer if applicable will run for approximately 30 seconds before ignition trial as a pre purge cycle Allow the burner to run a MINIMUM of five 5 minutes to purge combustion chamber and appliance heat exchanger Set the thermostat or operating control below room temperature shutting the burner and field supplied draft inducer if applicable OFF for one 1 minute to RESET the primary control Depress the combination gas valve manual control now and turn to ON position Set the thermostat
20. or operating control to call for heat The burner will start and go through the applicable sequence of burner primary gas control operation NOTE 3 or 4 trials may be needed to purge air from gas line CAUTION If main flame does not light within a few seconds 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 WARNING If any flame is observed when the burner is on standby or if the ignition spark or valve operator is heard to come on before the burner reaches operating speed immediately turn off the gas control and main power A dangerous condition has developed and MUST be corrected After the burner lights adjust the orifice manifold pressure regulator if necessary using a manometer to match normal manifold pressure shown on unit nameplate Make sure the combustion air and gas pressure is sufficient to provide instant ignition a stable flame and flame signal After the desired input has been obtained readjust the primary air damper open or closed to visually obtain a blue flame with well defined orange or yellow tips for natural gas or well defined yellow tips for propane gas Check all gas piping again for leaks using a soap bubble solution See final checks and adjustments FINAL 5 AND ADJUSTMENTS After the burner has been in operation for at least ten 10 minutes
21. paper or other approved material 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 the negative draft shown on rating plate in high fire The vent pipe diameter must be a minimum of 8 in diameter 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 heat exchanger Be sure drip leg is made so water will not fall on heater controls when drain plug is removed 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 draft regulator or field supplied draft inducer are the only approved devices to be used on this heater 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 WARNING CARBON MONOXIDE Your venting system must not be blocked by any snow snow drifts or any foreign matter Inspec
22. s if applicable opens after end switch has proven damper is open the blowers or props run Turn Fan on off switch to off position Check supply fans for proper rotation The burner and draft inducer if applicable 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 Check the gas supply pressure by replacing the plug fitting on the inlet pressure tap of the gas valve with a pressure gauge with appropriate range Check that pressure reading is within the specified range on the raring plate NOTE To adjust gas pressure on supply lines where a regulator has been installed to set inlet pressure to rating plate maximum pressure remove dust cap of main gas regulator and turn adjusting screw clockwise to increase pressure
23. sure the L1 Hot and L2 Ground leads are connected to the right leads If they are reversed the S89 will not detect the flame and will go into safety lockout 5 Connect spark igniter flame sensor main burner and S89 to a common ground Use thermoplastic insulated wire with a minimum rating of 221 F 105 C for the ground wire Connect the ground wire as follows a Connect one end of the ground wire to the quick connect GND burner terminal on the S89 using a 1 4 in 6 mm quick connect AMP 41772 or equivalent b Strip the other end of the wire and fasten it under the igniter bracket mounting screw c If necessary install a shield to protect the wire from radiant heat generated by the burner d The burner serves as the common ground If metal to metal contact between the burner and the appliance cabinet is poor run a lead from the burner to the cabinet The cabinet must be earth grounded START UP AND CHECKOUT If this is a replacement application refer to the specific instructions provided by the heating appliance manufacturer if available Also since the auxiliary controls used on any system may differ refer to the control manufacturer instructions for start up and checkout procedures for other System components Perform Gas Leak Test WARNING Fire or Explosion Hazard Can cause severe injury death or property damage 1 Never use a flame to check for gas leaks only a soap and water solution 2 T
24. the main burner The 24V GND terminal internally grounds one side of the transformer Auxiliary controls or limits must be in the ungrounded leg A WARNING Electrical Shock Hazard Can cause severe injury death or property damage Disconnect the power supply before beginning wiring More than one disconnect may be required Use wiring diagrams and instructions provided by the appliance manufacturer if available Otherwise follow the general procedures and diagrams outlined below All wiring must comply with all applicable electrical codes and ordinances 1 Make sure the transformer has adequate power VA rating See Table 1 in Specifications section 2 If you are replacing an S89 that was used with an external valve on delay timer you must disconnect the external timer and use an S89F to provide the delay function External timers cannot be used with either S89E or S89F controllers because the safety circuit in 68 0066 4 4 the controls may repeatedly set the timer to zero preventing burner start Always disconnect the external timer when using an S89E or F To disconnect the timer a Turn off power b Cutthe two leadwires at the external timer c Strip the ends of the wires 1 2 in 13 mm and connect with a solderless connector d Restore power 3 Wire system components and S89 as shown in Fig 2 and 3 Refer to appliance manufacturer instructions for connections to other auxiliary controls 4 Make
25. with the shaft keyway and the drive side sheave can be aligned with the motor sheave Ideally the blower sheave should be as close to the drive side bearing as possible the motor sheave should be as close to the motor housing as possible and the belts should be straight Be sure the shaft does not rub on or interfere with the closing of the access door Align all bearing setscrews so that the same set screw on each bearing is pointed in the same 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 or vibration duri
26. 45 seconds and then turn it on Final Checkout With power and gas supply on set thermostat to call for heat and observe operation through at least one complete cycle to make certain that all controls are operating safely OPERATION The S89 is powered by a 24V transformer It operates in response to a call for heat from the thermostat 35 S89E F DIRECT SPARK IGNITION CONTROL MODULE On every call for heat the S89 performs a safe start check If a flame or a flame simulating condition is present the S89 locks out without starting the igniter and must be reset Following the safe start check and on the S89F a valve on delay period the S89 spark generator contacts close to energize the spark generator and the igniter At the same time the gas control powered through the gas valve relay contacts in the S89 opens so gas can flow to the burner The igniter is on during approximately the first 80 percent of the ignition or lockout timing period During the balance of the lockout timing period the ignition is off and the flame sensor attempts to prove the flame The flame is proved when current from the flame sensor through the burner flame to ground reaches 0 8 pA dc START THERMOSTAT CALLS FOR HEAT SAFE START CHECK SAFE START CHECK VALVE ON DELAY VALVE ON DELAY S89F ONLY 24 S89F ONLY COMBUSTION AIR BLOWER STARTS TRIAL FOR IGNITION BEGINS AND GAS CONTROL OPENS BURNER LIGHTS IGNITI
27. 8 The cooling relays provide dry contacts for operating remote equipment FAN SETTINGS In the ON mode The fan will run continuously in the occupied mode and will cycle with a call for cooling or heating in the unoccupied mode The thermostat energizes the fan enable relay RE 15 which will then enable the fan starter ST 01 In the AUTO mode Fan always cycles with call for heat or cool The thermostat energizes the fan enable relay RE 15 which will then enable the fan starter ST 01 DEFAULT SETPOINTS Heating Occupied 70 F 21 C Heating Unoccupied 55 13 Cooling Occupied 75 F 24 Cooling Unoccupied 85 29 LOSS The room thermostat 01 maintains programmed times and temperatures for the life of the product Clock and day information is retained for a minimum of 48 hours NOTE To achieve the 48 hour power loss clock retention the T7350 must be powered for at least five 5 minutes SERVICE SWITCH The service switch SW 24 will de energize the control circuit disabling the unit from running Caution the service switch does not disconnect all power NIGHT SET BACK The night set back function is integral to the room thermostat TC 01 TIME CLOCK The time clock function is integral to the room thermostat TC 01 which has 365 day programming with up to two occupied and two unoccupied periods per day For a more detailed setup procedure see the Tro
28. ARK IIGNITER A GND BURNER SAFE START CHECK CIRCUIT 2K1 X WIRING EXTERNAL 589 WIRING INSIDE 589 Fig 8 S89E simplified control system schematic 11 40 M19842A 68 0066 4 S89E F DIRECT SPARK IGNITION CONTROL MODULE L1 HOT 12 4 ON OFF LIMIT SWITCH CONTROL qum mm ras 1 Lom I LON o i XAAAAJ I Sa L 2 lrI I ns LL T 1 owen 124 lt XA COMBUSTIONI 4 4 4 1 Hon rO 1 AIR BLOWER I A bot 4 1 T I AIR PROVING COMBUSTION ALTERNATE SWITCH AIR BLOWER LIMIT I 1 reer I toJLo4 e 4 07 6 p oNLo t ue cpuemeed LERRA THERMOSTAT L1 15 1 1 12 21 1 FLAME SENSOR I I e 1 r SENSOR I 1 L CIRCUIT Sedd ae SAFE START 1K CHECK VALVE ON DELAY CIRCUIT SPARK IGNITER RELAY TIMING DUAL VALVE 2K1 2K2 T Ld ye d Ab NC oe Sa WIRING EXTERNAL TO S89 WIRING INSIDE 589 Fig 9 S89F simplified control system schematic Honeywell Automation and Control Solutions Honeywell International Inc Honeywell Li
29. B SIZE 24 COIL ASSEMBLY END ELEVATION THE ABOVE PIPING SCHEMATIC SHOULD BE USED AS A GUIDE ONLY ALTERNATE PIPING SCHEMES FOR ADDITIONAL STAGES OF DESIRED COOLING ARE POSSIBLE PROPER ENGINEERING DESIGN OF THE OVERALL REFRIGERATION SYSTEM MAY DICTATE AN ALTERNATE PIPING SCHEMATIC BE USED TO THE ONE ILLUSTRATED ABOVE GENERAL NOTES 1 10 11 12 13 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 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 410A BE SIZED FOR A Bou MAXIMUM PRESSURE DROP OF 6 PSIG RP 11 RECOMMEND SUCTION LINES FOR R 410A BE SIZED FOR A RP 12A MAXIMUM PRESSURE DROP OF 3 PSIG RECOMMEND CONDENSER SUBCOOLING CIRCUIT FOR R 410A RP 12B BE CAPABLE OF SUBCOOLING LIQUID BETWEEN 12 TO 19 F CONNECT 1 4 O D EXTERNAL EQUALIZING LINE GENERALLY RP 16 LOCATED IN EACH SUCTION HEADER OF EACH DX COIL TO RP 17 THE APPROPRIATE THERMAL EXPANSION VALVE TXV SENSING BULB FROM THERMAL EXPANSION VALVE BE LOCATED ON THE SIDE OF A HORIZONTAL PORTION OF THE
30. 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 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 1 COIL A THERMAL EXPANSION VALVE TXV 1B CIRCUIT 1 COIL DX EVAPORATOR COIL A DX EVAPORATOR COIL B REFRIGERANT DISTRIBUTOR CONDENSATE PAN PROVIDED WITH DRAIN CONNECTION ON ONE 1 END ONLY A FRAME COIL SIZE 36 AND SIZE 42 SEE NOTE 12 COIL SEE NOTE Tj RP 16 12 12 24 ai 24 r 11 08 10 P000983D SECOND STAGE SUCTION FIRST STAGE SUCTION SIZE 36 AND SIZE 42 COIL ASSEMBLY END ELEVATION THE ABOVE PIPING SCHEMATIC SHOULD BE USED AS A GUIDE ONLY ALTERNATE PIPING SCHEMES FOR ADDITIONAL STAGES OF DESIRED COOLING ARE POSSIBLE PROPER ENGINEERING DESIGN OF THE OVERALL REFRIGERATION SYSTEM MAY DICTATE AN ALTERNATE PIPING SCHEMATIC BE USED TO THE ONE ILLUSTRATED ABOVE GENERAL NOTES 1 10 11 12 13 RECOMMEND FIRST STAGE OF COOLING BE
31. E DRAIN PANS UNDER A POSITIVE PRESSURE 90 LONG RADIUS ain errr PLUG ELBOW 90 LONG RADIU ELBOW 1 DRAIN 1 PVC NIPPLE PVC PIPE NIPPLE G uc PVC RETURN BEND DRAIN x SLIP NOTE G TO BE A MINIMUM OF 1 2 PLUS THE TOTAL SYSTEM 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 10 30 09 C000659B 10 30 09 C000659B edid SECTION IV PRE START UP Do not attempt start up without completely reading and understanding this manual Pre Start Up The owners representative or equipment operator should be present during start up to receive instructions 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 Allinformation in this service manual is typical All products are semi custom and changes may occur CAUTION Line side of disconnect may be energized Follow proper lockout tagout procedures NOTE A qualified service engineer should perform all servici
32. EATER 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 The following sequence assumes all safety interlocks are closed and optional unit main disconnect switch SW 01 is closed Other control Systems for dampers mixing boxes and temperature controls are included in the unit typical sequence of operation and or wiring diagram 3 At the start of each heat cycle there is a trial for ignition period of four 4 seconds duration Normally burner flame will be established before the end of this period Once the flame is established sparking will cease and the flame rod will provide flame monitoring to the S89F gas control primary for the remainder of the heat cycle If the flame should be extinguished during the heat cycle the S89F gas control primary will go into the 30 second prepurge and a 8 second 1 With main supply air fan s on thermostat calling for safe start check then re energize the gas valve and heat and all switches and operating controls in their normal position the field supplied Draft Inducer if applicable will be energized At this time voltage 24VAC is applied to motor start relay and air switch Once the fan motor reaches operating rpm combustion air pressure is sensed by the air proving switch and closes the switch contacts energizing the S89F gas primary control The S89F
33. ING ALSO AIR AND 120 VAC NORMAL PROVING SWITCH ON PREPURGE SYSTEMS SEE WIRING HOOKUPS S89E 10 SEC MAX DELAY FOR SAFE START CHECK S89F ONLY 38 SECOND MAXIMUM VALVE ON DELAY SPARK ACROSS IGNITER GAP CHECK SPARK IGNITION CIRCUIT SEE COMPONENT CHECKS CHECK FOR 120V TO SPARK GENERATOR SPARK OKAY REPLACE SPARK GENERATOR IF VOLTAGE OK IF NO VOLTAGE REPLACE S89 MAKE SURE IGNITION CABLE PROVIDES ELECTRICAL CONTINUITY DOES NOT TOUCH ANY METAL SURFACES CONNECTIONS ARE METAL SURFACES SHOWS NO SIGNS OF MELTING OR BUCKLING REPLACE AND SHIELD CABLE IF NECESSARY MAKE SUE BURNER SPARK IGNITER AND S89 GROUND BURNER TERMINAL HAVE EFFECTIVE COMMON GROUND POOR OR ERRATC GROUND WILL CAUSE NUISANCE SHUTDOWNS CHECK FOR CRACKED INSULATOR ON IGNITER OR FLAME SENSOR REPLACE DEVICE WITH CRACKED INSULATOR TO PREVENT SHORT TO GROUND NOTE IF S89 LOCKS OUT RESET BEFORE CONTINUING MAIN BURNER LIGHTS CHECK FOR 24 VAC ACROSS VALVE AND VALVE GROUND TERMINALS ON 589 IF NO VOLTAGE REPLACE S89 MAKE SURE IGNITER AND SENSOR ARE PROPERLY POSITIONED SEE COMPONENT CHECKS CHECK ELECTRICAL CONNECTIONS BETWEEN 589 AND GAS CONTROL IF OKAY REPLACE GAS CONTROL REPLACE S89 NO NOTE IF S89 LOCKS OUT RESET BEFORE CONTINUING MAKE SURE FLAME CURRENT IS AT LEAST 0 8 MICRO AMPS SEE COMPONENT CHECKS MAKE SURE L1 12 ARE CONNECTED TO THE PROPER TERMINALS
34. ON STOPS AND FLAME CURRENT IS SENSED BURNER OPERATION BURNER RUNS 589 MONITORS FLAME CURRENT THERMOSTAT SATISFIED GAS CONTROL CLOSES BURNER GOES OFF END SPARK GENERATOR POWERED IGNITION If flame is proved the gas control remains open and the burner on until the call for heat ends If flame is not proved the gas control closes and the system is locked out until the S89 is reset If flame is lost after being proved the S89 will close the gas control perform a safe start check and on the S89F valve on delay then return ignition as described above The S89 is reset by turning the thermostat below room temperature or removing power to the system for 45 seconds POWER INTERRUPTION SYSTEM SHUTS OFF RESTARTS WHEN POWER IS RESTORED IF FLAME SIMULATION CONDITION IS PRESENT SYSTEM WILL NOT START IF NO SPARK S89 LOCKS OUT AND SHUTS DOWN SYSTEM MUST BE RESET IF FLAME CURRENT IS ABSENT WEAK OR UNSTEADY S89 LOCKS OUT AND SHUTS DOWN SYSTEM MUST BE RESET IF FLAME IS LOST 589 CLOSES GAS CONTROL THEN RESTARTS SAFE START CHECK AND TRIAL FOR IGNITION M19838A Fig 4 Normal sequence of operation TROUBLESHOOTING WARNING Fire or Explosion Hazard Can cause severe injury death or property damage Any replacement S89 must have the same or shorter lockout timing and the same or longer delay timing as the original control
35. 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 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 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 presen
36. 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 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 410A BE SIZED FOR A MAXIMUM PRESSURE DROP OF 6 PSIG RECOMMEND SUCTION LINES FOR R 410A BE SIZED FOR A MAXIMUM PRESSURE DROP OF 3 PSIG RECOMMEND CONDENSER SUBCOOLING CIRCUIT FOR R 410A BE CAPABLE OF SUBCOOLING LIQUID BETWEEN 12 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 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
37. SBHHBH pplied Air INSTALLATION OPERATION AND MAINTENANCE MANUAL FOR IFJ INDIRECT GAS FIRED HEATERS IOMIFJ 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 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 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 ire fournisseur de gaz WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury death Read the installation operating and maintenance instructions thoroughly before instal
38. TE The fan motor is directly below the coil and must not be exposed to water or cleaning solutions 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 for recommended burner maintenance _ 52 SECTION X REPLACEMENT 5 Replacement parts may be ordered 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 53 5 54 5 55 Applied
39. TION Do not remove blower wheel from motor shaft during periodic cleaning 3 Should removal of the blower wheel be necessary for cleaning or replacement of it or the motor the blower wheel must be positioned correctly on the motor shaft Figure 16 HSG400 The blower wheel is positioned 2 3 16 55 5625mm measured from the blower wheel inlet ring face to the side plate face 46 To remove or interchange main orifice discs refer to Figure 15 1 Remove orifice spring Item 36 to access and Replace orifice spring and securely tighten orifice cap SECTION VIII SERVICING THE BURNER Remove slotted orifice cap 38 making sure orifice cap gasket 37 stays attached to orifice cap and is not damaged remove orifice disc Install desired orifice from Figure 10 making sure it is seated flat in the orifice holder Item 35 against orifice cap gasket in orifice holder DRAWER ASSEMBLY Figure 15 ORIFICE MANIFOLD PRESSURE SIZE amp DRILL 2 0 498 2Pa 3 0 747 3Pa 4 0 996 4Pa HSG400 NATURAL GAS T 358 9 0932mm 200 000 BTU 211000kJ 248 000 BTU 261640kJ 285000 BTU 300675kJ NOTE For 15 32 468 11 8872mm 265 000 BTU 279575kJ 343 000 BTU 361865kJ 400 000 BTU 422000kJ 50 cycle 2 HSG400 L P GAS application K 281 7 1374mm 190 000 BTU 200450kJ 242 500 BTU 255837 5kJ 295 000 BTU 311225 derate input Q 332 8 4328m
40. URNER GROUND A POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED A ALTERNATED LIMIT CONTROLLER LOCATION A IMPORTANT CONNECT L1 TO THE BLACK LEAD CONNECT L2 TO THE WHITE LEAD OTHERWISE THE 589 WILL NOT DETECT THE FLAME AND WILL LOCK OUT A FACTORY TEST TERMINAL DO NOT USE M19837 Fig 3 S89F typical hookup in direct spark control system See Fig 9 for control system ladder diagram 10 Turn off gas supply 11 Gas control closes 12 The module begins the safe start check S89E 10 seconds maximum or safe start check plus valve on delay 38 seconds maximum after which the igniter starts and gas control opens 13 Time system until gas control closes 589 is now in safety lockout The lockout time should be within the specifications in Table 2 14 Open gas supply System remains off and no gas flows to the main burner Table 2 S89 Lockout Times Lockout Time Safety Lockout Time Shown on 589 Module Minimum Maximum 4 seconds 3 0 seconds 5 5 seconds 11 seconds 8 0 seconds 15 0 seconds 68 0066 4 6 Resetting S89 After Safety Lockout Once the S89 locks out it must be reset before the system will operate To reset set the thermostat below room temperature wait at least 45 seconds then turn the thermostat up to call for heat The system should start normally If adjusting the thermostat does not reset the S89 turn off power to the appliance for
41. ancel this option ensure display indicates NO 3 Press Run Schedule TROUBLESHOOTING GUIDE TABLE 4 Table 4 Troubleshooting Information Symptom Possible Cause Display will not Thermostat is not being powered come on Action Check that X terminal is connected to the system transformer Check for 24 Vac between X and RH terminals If missing 24 Vac e Check if circuit breaker is tripped if so reset circuit breaker Check if system fuse is blown if so replace fuse Check if the HVAC equipment power switch is in the Off position if so set to the On position Check wiring between thermostat and HVAC equipment Replace broken wires and tighten loose connections If 24 Vac is present proceed with troubleshooting Room temperature display has been recalibrated Temperature display is Use PDA configuration software to recalibrate as desired incorrect Thermostat is configured for F or C display Press both Run Schedule and Copy then reconfigure the display Bad thermostat location Relocate the thermostat sign all systems shut down Display shows three dashes and a degree T7350 is set for remote sensing and sensor is missing or circuit is either open or shorted 62 0195 06 28 T7350 COMMERCIAL PROGRAMMABLE THERMOSTAT Table 4 Troubleshooting Information Continued Symptom Temperature settings will not change E
42. assuring combustion chamber and heat exchanger are fully warmed take combustion analysis flue gas samples just ahead of the draft control in the flue pipe NOTE ALWAYS USE RELIABLE COMBUSTIONTEST INSTRUMENTS BEING PROFICIENT IN THE USE OF THESE INSTRUMENTS AND INTERPRETING COLLECTED DATA IS NECESSARY FOR SAFE RELIABLE AND EFFICIENT BURNER OPERATION The following readings should be taken but not limited to CO Net Stack Temperature O Combustion Efficiency CO If necessary make adjustments on burner air shutter DO NOT change the fuel input rate The draft regulator must be adjusted by adding or removing the washer type weights supported by the two chains Do not move the weight attached directly to the gate 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 480 F Above Ambient Draft setting too high Excess burner air Fuel input too high Blocked and or restricted secondary tubes Low Oxygen Oxygen reading must always be a positive percentage Make sure there is a
43. ce 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 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 con
44. d conversion on unit rating plate parts 7 Flame detection system not sensing 7 Assure flame rod is in flame flame See section for servicing check wiring and flame rod burner 8 No voltage on secondary side of 8 Check wiring Replace transformer ignition transformer if defective 9 Gas orifices obstructed or 9 Clear obstruction or blockage plugged G If burner lights but loses 1 Flame proving circuit grounded 1 Check for proper installation and flame during cycle anda by moisture or correct stable microampere 2 Damaged insulation on flame rod 2 Check wiring along with flame current of 0 8 cannot be or not properly positioned in flame rod position Correct and or re obtained 3 Poor ground path to primary place if defective control module 3 Check to be sure unit is properly 4 Ignition control locks out grounded 4 Check wiring and connections Correct and or replace if defective 5 Poor combustion levels 5 Perform a flue gas analysis and correct any combustion setup issues H Burner cycles erratically 1 Low voltages 1 Check for proper voltage and amperage on burner motor and gas valve Replace if defective 2 Thermostats safeties and or 2 Check operation and replace if switches opening and closing defective See burner Installation Operation and Maintenance Manual for additional troubleshooting 4 SECTION VII TROUBLESHOOTING continued Symptom Cause Reme
45. dy A Insufficient cooling Cooling thermostat not working properly RE 77 and RE 78 contacts not closed Evaporator coil freezing Incorrect refrigerant charge 3a 3b See Troubleshooting Guide for T7350 thermostat Check for power and or replace if defective Thermostat setting too low Check filters Clean or change as needed Check adjustments of TXV and bulb location Check airflow Check for correct superheat and subcooling a DD Honeywell T7350 Commercial Programmable Thermostat FOR SINGLE OR MULTI STAGE CONVENTIONAL HEAT PUMP SYSTEMS APPLICATION The T7350 Commercial Programmable Thermostat controls 24 Vac commercial single zone heating ventilating and air conditioning HVAC equipment The T7350 consists of a thermostat and subbase The thermostat includes the display and keypad for 7 day programming The subbase includes equipment control connections The subbase mounts on the wall and the thermostat mounts to the subbase MERCURY NOTICE If this control is replacing a control that contains mercury in a sealed tube do not place your old control in the trash Dispose of properly Contact your local waste management authority for instructions regarding recycling and the proper disposal of an old control If you have questions call Honeywell Customer Care Center at 1 800 468 1502 INSTALLATION When Installing this Product 1 Read t
46. e in Mrd o EQUI METER series with the flame sensor as shown in Fig 6 Use the VALVE GND Honeywell W136 Test Meter or equivalent Connect the DISCONNECT meter as follows HANS SENSE a Disconnect the sensor lead at the S89 GND SENSE TERMINAL b Connect the red positive meter lead to the S89 GND BURNER sense terminal Q c Connect black negative meter lead to the free 2 of the sensor lead RED 2 Restart the system and read the meter The flame 0 8 pA DC MINIMUM sensor current must be at least 0 8 and steady AND STEADY M19840 Fig 6 S89 flame current measurement CHECK BURNER FLAME CONDITION NOISY LIFTING FLAME CHECK FOR HIGH GAS PRESSURE Bl EXCESS PRIMARY AIR OR DRAFT BURNER WAVING FLAME CHECK FOR POOR DRAFT EXCESS DRAFT HIGH VELOCITY OR SECONDARY AIR INSTALL SHIELD IF NECESSARY SMALL BLUE FLAME CHECK FOR CLOGGED PORTS OR ORIFICE FILTER WRONG SIZE ORIFICE LAZY YELLOW FLAME CHECK FOR LACK OF AIR FROM DIRTY PRIMARY AIR OPENING LARGE PORTS OR ORIFICES GOOD RECTIFYING FLAME 1 IN 25 4 MM 1 4 TO 1 2 IN 6 4 TO 12 7 MM M18055 Fig 7 Check burner flame condition 68 0066 4 10 39 S89E F DIRECT SPARK IGNITION CONTROL MODULE ON OFF SWITCH LIMIT CONTROL moc mec 3 ant ami I I I bud 1 I I wn I I l I SENSOR CIRCUIT FLAME 1 SP
47. e loose Do not assume con trols are defective until all associated setpoints and wiring are checked The following is a simplified list of possible problems and typical causes and remedies However it does not cover all possibilities and is intended as a guide only Refer to the burner manufacturer IOM for additional instructions WARNING Many of the steps listed on the follow ing pages require 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 ed SECTION VII TROUBLESHOOTING continued Symptom Cause Remedy A Supply fan does not run Low or no voltage Check power source 2 Fuse s blown 2 Replace fuse s 3 Customers interlock not closed or Close or connect customer inter connected lock 4 Room thermostat TC 01 not 4 See Troubleshooting Guide for working T7350 thermostat 5 Fan On Off Switch SW 24 in 5 Place switch in On position Off position 6 RE 15 Contacts open 6 Check for power and or replace 7 Damper motor not operating its 7 Check for power at damper motor end switch not making or and that end switch has been dampers binding if applicable wired correctly End switch shou
48. e 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 Over 150 F Clean weekly Any Speed Upto150 F Dirty 1 week to 1 month Any Speed Over 150 F Dirty daily to 1 week Any Speed Temp Very Dirty daily to 1 week Any Speed Any Temp Extreme daily to Conditions 1 week gc Browning Bearing Set Screw Torque Values Model Shaft Size Torque 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 When replacing bearings refer to the manufacturers installation instructions included with the bearing
49. ect 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 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 E Venting All venting installations must conform to Part 7 Venting of Equipment in the current version of the National Fuel Gas Code ANSI Z223 1 or applicable provisions of local building codes The National Fuel Gas Code is subject to change questions regarding venting requirements should be directed to the local authority having jurisdiction Indirect Fired Units are Category 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 DO NOT support the weight of the stack draft regulator or field supplied draft inducer on the unit Insulate single wall vent pipe exposed to cold air or running through unheated areas Use as few elbows as possible and tape flue pipe joints with fireproof
50. eneral Information 3 Section 111 Installation uu uui sasa 4 This manual of instructions along with the burner and Section IV Pre Start Up 12 draft regulator IOM s has been prepared in order for Section V Unit Start Up 15 you to become well acquainted with those details and Section VI Unit Shut Down 18 in doing so you will be able to give your Indirect Gas Section VII Troubleshooting 19 Fired System the care and attention which any piece of Section VIII Servicing the Burner 44 equipment needs and deserves Section IX Maintenance Schedule and Lubrication Requirements 48 It is the customer and installation personnel Section X Replacement Parts 53 responsibilty to determine if the unit is equipped 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 Applied Air assumes no responsibility for loss or dam age in transit therefore you should protect yourself by followin
51. est for gas leaks whenever work is done on a gas system 3 Soap and water must not touch the S89 With the main burner in operation paint the pipe joints and gas control gasket edges with a rich soap and water solution Bubbles indicate a gas leak To stop the leak tighten joints and screws or replace the gas control Never use a flame to check for gas leaks 33 S89E F DIRECT SPARK IGNITION CONTROL MODULE THERMOSTAT OR CONTROLLER TRANSFORMER DUAL VALVE LIMIT CONTROLLER COMBINATION GAS CONTROL S89E GAS PRIMARY VALVE VALVE GND GND BURNER FLAME SENSOR IGNITER 120 V SPARK GENERATOR GROUND BURNER A POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED A ALTERNATED LIMIT CONTROLLER LOCATION A IMPORTANT CONNECT L1 TO THE BLACK LEAD CONNECT L2 TO THE WHITE LEAD OTHERWISE THE 589 WILL NOT DETECT THE FLAME AND WILL LOCK OUT A FACTORY TEST TERMINAL DO NOT USE M19836 Fig 2 S89E typical hookup in direct spark control system See Fig 8 for control system ladder diagram Check Out S89 NOTE If operation is not as described below refer to Troubleshooting section Set thermostat to call for heat Turn on power and gas supply Igniter starts to spa
52. form 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 IFJ 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 or move the equipment on rollers Hooks jacks o
53. g the thermostat appliances Contents ADDIICALION eem 1 Features io Specifications 2 2 Ordering Information 2 2 Installation 3 Wiring 4 Start Up and Checkout 4 6 7 ig t 2003 Honeywell International Inc 68 0066 4 All Rights Reserved 30 S89E F DIRECT SPARK IGNITION CONTROL MODULE SPECIFICATIONS IMPORTANT The specifications given in this publication do not include normal manufacturing tolerances Therefore this unit may not match the listed specifications exactly Also this product is tested and calibrated under closely controlled conditions and some minor differences in performance can be expected if those conditions are changed Models S89 Direct Spark Ignition Control Modules Provide electronic control of direct spark ignition system on gas fired atmospheric and power burners S89E 10 second maximum delay for safe start check S89F 38 second maximum delay for safe start check plus valve on delay Complete DSI system also includes 120 Vac Spark Generator with 1 5A or less current draw Q347 Spark Igniter or equivalent Q354 Flame Sensor or equivalent VR845 VR854 VR8450 or VR8305 Combination Gas Controls or any dual valve rated 2A or less and designed for DSI applications 24 to 30 Vac Thermostat High Tempe
54. g 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 DAMAGED ARTICLES Never return damaged articles to us They are the prop erty of the transportation company when the claim
55. gas primary control has an internal 30 second prepurge timer After the initial 30 second prepurge an internal 8 second safe start check of the 89F will commence Once this is successfully completed the S89F simultaneously energizes the gas valve and ignition transformer Gas flows and the transformer produces an approximate 7300 volt spark end point grounded at the burner head establishing main burner flame 9 ignition transformer in an attempt to establish the main burn flame If this does not occur within the 4 second trail for ignition period the S89Fgas primary control will go into lockout de energizing the gas valve and ignition transformer To restart the system the main power or thermostat must be de energized momentarily then re energized If at any time during the heat cycle there is an insufficient supply of combustion air to the burner the air switch will open putting the system into lockout closing the gas valve ROOM THERMOSTAT TC 01 SEQUENCE KEYS ARE USED TO set current time and day program times and setpoints for heating and cooling override the program temperatures display present setting set system and fan operation perform simple configuration SYSTEM SETTINGS In the AUTO mode Thermostat automatically changes between heating and cooling based on indoor temperature In the COOL mode Thermostat controls two stages of cooling by energizing the optional cooling relays RE 77 and RE 7
56. hese instructions carefully Failure to follow them could damage the product or cause a hazardous condition 2 Check ratings given in instructions and on the product to ensure the product is suitable for your application 3 Installer must be a trained experienced service technician 4 After installation is complete check out product operation as provided in these instructions N CAUTION Electrical Shock or Equipment Damage Hazard Can shock individuals or short equipment circuitry Disconnect power supply before installation INSTALLATION INSTRUCTIONS Location Do not install the thermostat where it can be affected by drafts or dead spots behind doors and in corners hot or cold air from ducts radiant heat from sun or appliances concealed pipes and chimneys unheated uncooled areas such as an outside wall behind the thermostat IMPORTANT To avoid electrical interference which can cause erratic performances keep wiring runs as short as possible and do not run thermostat wires adjacent to the line voltage electrical distribution systems Use shielded cable The cable shield must be grounded only at the controlled equipment case Subbase WHEN USED TO SENSE ROOM TEMPERATURE Install the thermostat about 5 ft 1 5m above the floor in an area with good air circulation at average temperature See Fig 1 WHEN NOT USED TO SENSE ROOM TEMPERATURE When using the remote mounted temperatu
57. in 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 operation Ideal tension is the lowest tension at which the belt will not slip under peak load conditions Over tensioning shortens belt and bearing life 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 be
58. ing If the Gap Was Then 1 8 in 3 mm or more Generator output voltage is okay Less than 1 8 in 3 mm Check for 120 Vac at the spark or no spark generator terminals If okay replace the spark generator Check Flame Sensor and Igniter 1 Make sure burner flame is capable of providing a good rectification signal See Fig 7 2 Make sure about 3 4 to 1 in 19 to 25 mm of the flame sensor is continuously immersed in the flame for best flame signal See Fig 7 Bend the bracket or flame sensor or relocate the sensor as necessary Do not relocate the igniter 3 Make sure flame does not touch sensor or ignitor ceramic insulator and that insulators are below he flame Excessive heat over 1000 F 538 will cause short to ground Move sensor to cooler location or shield insulators if excessive heat is suspected Do not relocate the igniter 4 Check for cracked igniter or sensor ceramic insulator which can cause short to ground and replace unit if necessary 5 Make sure electrical connections are clean and tight 6 Replace damaged wire with moisture resistant no 18 wire rated for continuous duty up to 221 F 105 C HT S89E F DIRECT SPARK IGNITION CONTROL MODULE START REVIEW NORMAL OPERATING SEQUENCE TURN GAS SUPPLY ON TURN THERMOSTAT UP TO CALL FOR HEAT CHECK LINE VOLTAGE POWER LOW VOLTAGE TRANSFORMER POWER TO S89 24 VAC LIMIT CONTROLLER THERMOSTAT AND WIR
59. ing the on indicator and then check the registers Heating or cooling equipment is not operating Verify operation of heating or cooling equipment in self test 7 62 0195 06 29 Honeywell S89E F Direct Spark Ignition Control Module PRODUCT DATA FEATURES Requires separate 120 Vac spark generator Honeywell S89E has 10 second maximum delay for safe start GAS PRIMARY gt check before ignition S89F has 38 second maximum delay for safe start check plus valve on delay before ignition Available with 4 or 11 second nominal lockout timing 100 percent shutoff for use with all heating gases Ambient temperature rating is 40 F to 175 F 40 C to 80 C Separate electrodes for spark ignition and flame sensing Uses Honeywell or any other 2 or less dual valve combination gas control designed for Direct Spark Ignition DSI applications Locks out system after trial for ignition if main burner APPLICATION fails to ignite Flame rectification principle used to monitor flame The Honeywell S89E F Direct Spark Ignition Control Modules false flame signals resulting from short to ground control the ignition sequence and gas control operation in results in safety shutdown direct spark systems used primarily on gas fired atmospheric After safety shutdown S89E and F can be reset from and power burners in residential furnaces and heatin
60. 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 Il 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 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 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 WARNING Failure to comply with general safety information may result in extensive property damage severe personal injury or death B Shipping Base Indirect Gas Fired units are shipped completely assembled where shipping limitations allow
61. ld be wired N O normally open Clear linkage 8 Overload protection on motor 8 Reset starter by pushing red starter tripped button on starter check amp draw 9 Belt s loose or broken if applicable 9 Turn power off and check belts 10 Motor may be burnt out or 10 Turn power off and check motor incorrectly wired and wiring 11 Bearing seized on shaft 11 Turn power off and check bearings B Line voltage is not present 1 Fan On Off Switch SW 24 in 1 Place switch in On position at burner Off position 2 Room thermostat TC 01 not 2 See Troubleshooting Guide for working T7350 thermostat 3 Auxiliary switch on starter not 3 Check auxiliary circuit wiring and closed contacts 4 RE 28 Contacts open 4 Check for power and or replace 5 High temperature limit is open 5 Check limit for proper settings 6 High Low gas pressure switches 6 Correct gas pressure and reset open switches 7 Field installed Draft Inducer motor 7 Check wiring fuses and amp draw not running on motor 8 Field installed Draft Inducer air 8 Check for correct rotation and proving switch is open Switch operation See Operating Manual for proper installation and adjustment C Burner motor does not run 1 24 Volts is not present on low 1 Check wiring and connection voltage transformer Correct or replace if defective 2 Motor start relay contacts do not 2 Check wiring and connection close Correct or replace if defec
62. lect the desired configuration On the summary screen tap CnfgID The PDA determines the proper CnfgID Make note of the values Press both Copy and Run Schedule Tap until C1 appears on the right of the dis play o m P t O NOTE While stepping toward C1 check other items to ensure they are set properly See Setup Using Keypad section 8 To adjust each variable to match PDA indication a Hold down the up A or down Y key to adjust the value quickly b Tap the up A or down Y key for fine control 9 Tap to switch to another variable 10 Return to step 8 and repeat the process until all configuration values are set properly 11 To exit the Installer Setup press Run Schedule 12 Display prompts SAV CFG save configuration a If you want to save the new configuration use the up A or down Y key to change NO to YES before pressing Run Schedule b If you want the configuration to remain as it was before starting this change ensure the display indicates SAV CFG NO and press Run Schedule Setting Keypad Lockout Proper keypad sequences activate the lockout features To change the keypad lockout state 1 Enter the Installer Setup press and hold both the Run Schedule and the Copy keys until DEG F or DEG C displays 2 Press until KYLCK displays 3 Use the up A or down V key to change the setting Options are 0 No lockout 1 Lockout all keys except Temporary Occupied Temporary Not Occ
63. ling or servicing this equipment 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 Itis the installer s responsibility to inspect and correct any problems that may be found s 4830 Transport Drive Dallas TX 75247 Phone 214 638 6010 Fax 214 905 0806 Applied 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 op Section Foreword and Table of Contents 2 eration and maintenance detail of this machine Section Il G
64. lt 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 Force for 1 times 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 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 CAUTION Solutions used to clean coils 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 NO
65. m 242 500 BTU 255837kJ 332 500 BTU 350787 5kJ 400 000 BTU 422000kJ by 15 HSG SERIES POWER GAS CONVERSION BURNERS ORIFICE CHART Figure 10 A MOTOR SIDEPLATE P N 21658 PART NUMBER DIM A 21664 HSG200 2 1 16 5 1 4 O D 52 3875mm 133 35mm 21642 HSG400 2 3 16 5 1 2 O D 55 5625mm 139 7mm MOTOR BLOWER ASSEMBLY Figure 16 _ 47 SECTION IX MAINTENANCE SCHEDULE AND LUBRICATION REQUIREMENTS WARNING Electric shock hazard and danger of explosion can cause injury death or property damage Turn off gas and electrical power to the unit before performing any maintenance or servicing operations to the unit Follow lighting instructions attached to the unit when putting the unit back in operation and after service or 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 2 After 8 hours of operation a Check that fan belts are tight and sheaves are aligned The fan belts can be checked every 30 days after the first 60 days of new belt run in CAUTION Do not overtighten belts b Check set screws and bolts on the fan bearings cou plings and burner assembly c Check gas pressure at regulator 3 After 48 hours of operation
66. minimum of 0 02 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 There 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 Ignition Module Close the manual gas valve before burner Operate unit in heat mode The ignition module must trip out within 5 seconds after try for ignition is complete Temperature Controls The temperature controls are checked by adjusting control to a higher temperature to allow burner to cycle on Adjust control to a lower temperature to allow burner to cycle off Return the adjustment to its original setting Limit Controls The limit controls are checked by adjusting control to a lower temperature setting while the unit is operating on high fire and observe cut off Return the adjustment to its original setting Manual reset may be required on some controls Make sure all the safeties and controls are working properly Eras SECTION VI UNIT SHUTDOWN A Extended Shutdown B Emergency Shutdown Only 1 Disable the heat for 3 minutes or a sufficient 1 Open the main electrical disconnect switch amount of
67. mited Honeywell Limit e 1985 Douglas Drive North 35 Dynamic Drive Golden Valley MN 55422 Scarborough Ontario MIV 4Z9 Printed in U S A on recycled 68 0066 4 GR Rev 12 03 paper containing at least 10 www honeywell com post consumer paper fibers _ 41 SECTION VII TROUBLESHOOTING THE BURNER NUISANCE LOCKOUTS FLAME SENSING PROBLEMS HSG200 amp HSG400 GAS BURNERS Wayne s HSG series direct spark ignition DSI gas burners prove flame through the process of flame rectification Flame rectification is achieved by placing a small voltage on the flame sensing probe When the probe is surrounded by flame the voltage on the probe leaks to ground through the flame resulting in an electrical current This current is interpreted by the ignition control as the presence of flame One of the most common problems with gas appliances utilizing this type of electronic flame sensing system is the nuisance lockout Lockouts are not generally due to the burner failing to ignite but rather simply the failure of the system to sense the establishment of flame Should this situation exist for a period of time longer than the ignition control s state lockout timing the control will shut down or go into permanent lockout The only way to get the burner to recycle is to break and then reinstate power to the burner The following situations can lead to flame sensing problems and can be checked without disassembling the burner The bu
68. mplete burner adjust ment must be made m Lubricate fan motors as directed by motor manu facturer Inspect motors for loose connections Lightly oil all door latches Check that the cabinet is air tight Replace gas kets 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 2 NOTE Keep screened air intakes clear of obstruc tions at all times 48 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 G E Bronze sleeve single phase or equal bearings ODP or TEFC Recommendation See following note Fan shaft Fafnir Self aligning bearings or equal single row or double row ball bearings resilient mounted Recommendation See following note Dampers Factory Sleeve or equal Recommendation See following note 1 Blower Motors Some motors require lubrication while others do not Those that require lubrication can be identified by the pre
69. n 50 8 mm by 101 6 mm wiring box can be accomplished for a horizontal box no extra hardware is required for a vertical box part 209651A is required Mount to European standard wall box having 2 4 in 60 3 mm between mounting screws in a horizontal line with or without adaptive hardware 1 Position and level the subbase NOTE A level wallplate is only for appearance The thermostat functions properly even when not level 62 0195 06 2 Use a pencil to mark the mounting holes See Fig 3 3 Remove the subbase from the wall and drill two 3 16 in 4 8 mm holes in the wall if drywall as marked For firmer material such as plaster or wood drill two 7 32 in 5 6 mm holes 4 Gently tap anchors provided into the drilled holes until flush with the wall 5 Position the subbase over the holes pulling wires through the wiring opening 6 Loosely insert the mounting screws into the holes 7 Tighten mounting screws WIRES THROUGH WALL MOUNTING 7 MOUNTING SCREWS M19608 Fig 3 Mounting the subbase Mounting Thermostat on Subbase Fig 4 With the subbase installed mount the thermostat 1 Engage top subbase tabs into the thermostat top 2 Swing the thermostat down 3 Press the lower edge of the case to latch NOTE To remove the thermostat from the wall first pull out at the bottom of the thermostat then remove the top Wiring Follow equipment manufact
70. ng operation 25 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 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 filter elements should be replaced with a clean element of the same type and size In addition the factory not only suggests but insists that air filters be checked every 30 days daily in icy weather and replaced with new filters throw away type or cleaned washable type as required Cleanable filters should be given new application of filter coating after washing to mainta
71. ng 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 Checkthat the physical condition of the unit exterior is acceptable 2 Check that any insulation inside the unit is properly secured 3 Check all terminals for loose connections and inspect all wiring terminations to insure that all crimped connections are tight 4 Inspect the fan and motor bearings and lubricate if necessary CAUTION DO NOT RUPTURE GREASE SEALS 5 Inspect pulleys and belts for tightness tension and alignment Do not overtighten belts 6 Check set screws on all bearings pulleys fans and couplings for tightness 7 Check voltage supplied to disconnect switch the maximum voltage variation should not exceed 1096 Phase voltage unbalance must not exceed 296 8 Check thermostat s for normal operation 9 Check that fans turn freely in housing 10 Check that the area around the unit is clear of flammable vapors or containers of flammable liquids 11 Visually inspect all fuel lines for damage and or contact with a surface that can cause damage over time from rubbing Check that all piping connections particularly unions
72. not rub against the cabinet or other refrigerant lines G 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 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 EH A FRAME COIL SIZE 24 11 08 10 P000983E FOR A SIZE 24 DOUBLE DUPLICATE THE PIPING SCHEMATIC BELOW FOR THE SECOND COIL SECTION BUT DO NOT INSTALL A SECOND SET OF HOT GAS BY PASS TEES ITEM RP 09 SEE NOTE 12 24 FIRST STAGE SUCTION RP 12
73. oleum gases should be used on threaded joints CAUTION The burner itself has been shipped attached to the front of the heater and combustion chamber After shipping it is possible the burner is no longer positioned properly as far as proximity to the chamber This must be checked against the dimensional drawing for correct burner insertion into the chamber and set if necessary 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 the additional shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 12 PSIG The appliance must be isolated from the gas supply piping system by closing it s individual manual shutoff gas valve during any pressure testing of the gas supply piping system at test pressure equal to or less than 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 gas valve on the unit if applicable Refrigerant Piping Refer to drawing on following pages Check to ensure refrigerant lines do
74. on top of base section and attach with nuts and bolts and caulk the seams Continue adding other sections on top as required WARNING BASE SECTION MAY TIP OVER The base section with the control box is top heavy to the front side This section MUST be securely fastened to the non combustible pad or concrete flooring BEFORE attempting to assemble the other section s to it IMPORTANT Barriers should be provided to protect the unit and the integrity of utility piping to the unit from any collision with forklifts or other hazards within the selected location Do not obstruct combustion air openings or ventilation grilles 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 Each unit comes with a Draft Regulator and a field supplied Draft Inducer may also be supplied It is very important that you follow the installation instructions provided with these parts regarding location mounting and adjustments These instruction sheets should be available for the start up technician
75. out a safety lockout See Figure 13 for sensor probe and electrode dimensional settings Figure 14 for flame current measurement _ 45 SECTION VIII SERVICING THE BURNER Caution Make sure the main manual combination valves and main power switch are turned off before opening burner or removing any parts for service A BURNER HEAD AND ELECTRODE SENSOR ASSEMBLY The burner head electrode sensor probe combination valve orifice housing and housing cover are part of the gas train assembly which can be removed as one unit See Figure 15 1 Disconnect gas line from combustion gas valve inlet flame sensor lead wire from gas primary gas valve lead wires from gas valve operator and orange ignition lead wire from ignition transformer ignition lead wire 2 Remove the two 1 4 6 35mm hex slotted screws on the top front of the housing cover and the two 5 16 7 9375mm hex slotted screws on the left and right side back of the housing cover 3 To remove gas train assembly gently lift up rear of housing cover pulling rearward slightly on the drawer assembly gradually positioning the rear of the drawer assembly upward 90 degrees 1 57RAD Gently extract burner head and electrode sensor assembly out opening in housing taking extreme care to not dislocate or damage electrode or sensor probe 4 When servicing clean burner head ports electrodes and sensor probe Inspect the sensor probe and electrode wires and porcelain ins
76. out time and the same or longer delay timing as the original control Replacement Application Requirements If this is a replacement application follow the appliance manufacturer instructions if available The manufacturer usually provides wiring diagrams start up and checkout 3 68 0066 4 32 S89E F DIRECT SPARK IGNITION CONTROL MODULE instructions and service procedures for their appliance If the manufacturer instructions are not available use the general guidelines that follow Mount the S89 Select a convenient location on the burner or furnace chassis or cabinet protected from moisture due to splashing dripping or condensation Allow room to easily reach the S89 terminals for wiring and servicing Do not exceed the ratings given in the Specifications section The S89 may be mounted in any position See Fig 1 for mounting dimensions Mount with 1 in 25 mm long no 6 32 machine screws or no 8 sheet metal screws Fasten securely Mount Auxiliary Controls Mount the spark generator igniter flame sensor thermostat transformer gas control and any other auxiliary controls according the control manufacturer instructions WIRING N CAUTION Equipment Damage Hazard Can cause equipment malfunction or damage 1 The sensor leadwire must be no more than 3 ft 0 9m long Do not allow the wire to touch grounded metal surfaces 2 A common ground is required for the S89 the spark ignitor and
77. r all of the above listed items have been carefully checked the burner still fails to work it is due to one or more of the following problems 1 Unit sparks and fires but will not stay lit Ignition control module is malfunctioning and must be replaced 2 Unit does not spark Ignition transformer is bad and must be replaced 42 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 4 O to curve H and the dotted line on the hori zontal axis to the left the excess air column shows that 4 O equals 25 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 CO column shows that 4 O and 25 ex cess air correlate to 9 1 2 CO for Natural Gas Table 13 Again following the 4 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 secondary fuel when the burner has been properly adjusted for the primary fuel inputs CO O Ratio Curves for Fuel Oils and Gases 170 17
78. r 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 WARNING BASE SECTION MAY TIP OVER The base section with the control panel is top heavy to the front side Use extreme caution when moving this section from the sides or rear with a fork lift or similar machine RIGGING AND MOUNTING IFJ UNITS Warning To insure that a proper unit lift is made lift unit approximately 24 inches and
79. racket and the main burner 2 Check the ground lead from the GND Burner terminal on the module to the igniter bracket Make sure connections are clean and tight If the wire is damaged or deteriorated replace it with no 14 to 18 gauge moisture resistant thermoplastic insulated wire with a 221 F 105 C minimum rating Use a shield if necessary to protect the ground wire from radiant heat Check Spark Ignition Circuit The S89 spark generator relay switches 120 Vac to the remote mounted spark generator which in turn powers the spark igniter at the burner Check as follows 1 Shut off gas supply to the gas control 2 Disconnect the ignition cable at the spark generator stud terminal 68 0066 4 8 3 Setthe thermostat to call for heat 4 Resetthe S89 by removing power to the module for 45 seconds WARNING Electrical Shock Hazard Can cause severe injury death or property damage In the next step do not touch either the stripped end of the test lead or the stud terminal 5 Restore power Before the S89 locks out touch one end of the test lead firmly to the S89 GND terminal Do not remove the existing ground lead 6 Slowly move the other end of the test lead toward the stud terminal on the spark generator until sparking stops 7T Slowly pull the wire away from the stud terminal and note the size of the gap when sparking stops 8 Follow instructions in Table 3 Table 3 Spark Ignition Troubleshoot
80. rature Limit Controller 24V Transformer See Table 1 for VA rating Electrical Ratings Power supply Requires two power supply connections 24 and 120 Vac 50 60 Hz Current at 24V input 2 2A maximum Valve Contacts 2 0A maximum run 20A maximum inrush at 24 Vac Spark Generator Relay Contacts 1 5A at 120 Vac 50 60 Hz Transformer Rating See Table 1 Thermostat Heat Anticipator Setting 0 2A plus gas control current Delay Timing S89E Safe Start Check 10 seconds maximum S89F Safe Start Check plus Valve On Delay 38 seconds maximum Table 1 Transformer Rating S89 Current Gas Control Current Transformer VA Transformer in Amperes In Amperes Rating Required Model No 0 2 0 to 0 6 20 AT20A or AT120A 0 2 0 6 to 1 0 30 AT72D or AT140A 0 2 1 0 to 1 4 40 AT72D or AT140A 0 2 1 4 to 2 0 50 AT87A or AT150A Safety Lockout Timing 4 or 11 seconds nominal Ignition is on during approximately the first 80 percent of lockout timing and off during the last 20 percent for flame proving Specify lockout timing when ordering Flame Failure Response Time 2 seconds maximum with 2 5 pA flame current Flame Current Signal 0 8 uA minimum Ambient Temperature Range 40 F to 175 F 40 C to 80 ORDERING INFORMATION Wiring Connections 24 Vac 3 16 in quick connects 120 Vac 12 in 305 mm color coded leadwires Sensing Lead Up to 36 in 0 9m Insulation must be rated
81. re and humidity sensor s to sense ambient conditions install the thermostat in an area that is accessible for setting and adjusting the temperature and settings N CAUTION Equipment Damage Hazard Can damage the TIM connection beyond repair Disconnect the TIM cable prior to opening or closing the thermostat cover NOTE Allow sufficient clearance below the thermostat to plug in the TIM cable Install the remote mounted sensor s about 5 ft 1 5m above the floor in an area with good air circulation at average temperature See Fig 1 If multiple remote sensors are required they must be arranged in a temperature averaging network consisting of four sensors See Fig 2 62 0195 06 xD e T7350 COMMERCIAL PROGRAMMABLE THERMOSTAT NOTE Only TR21 models with no setpoint adjustment can be used for temperature averaging Fig 1 Typical location of thermostat or remote mounted sensor M29184 Fig 2 Four TR21 sensors providing temperature averaging network for T7350 Thermostat Mounting Subbase The subbase mounts horizontally IMPORTANT When using the internal temperature or humidity sensor the device must be mounted horizontally with the LCD facing upwards Precise leveling is not needed When using remote room temperature and humidity sensors thermostat mounting orientation does not matter Wall mounting using standard drywall screws is standard Mounting to a 2 in by 4 i
82. reases current day same effect as Up Arrow key D Time Sets time Tapping key with Set Value segment on increases time in one hour increments Override Temporary Temporary occupied setting for length of time defined by installer User can Occupied modify setpoints F Temporary Not Sets holiday length User selects number of days 0 99 or for Occupied continuous override Schedule Day Selects day schedule modify Used also with key Occupied Selects occupied event start times for specified day Repeatedly press this key to toggle between two occupied events Not Occupied 71 4 Selects not occupied event start times for specified day Repeatedly press this key to toggle between two not occupied events Clear Start Time R Clears start time for specified period and day Copy Copies schedule from one day to another System Selects System Mode Toggles through Em Heat Heat Off Cool and Auto Fan e Selects fan operation mode Toggles between On and Auto Run Schedule Resumes running schedule cancels Temporary Occupied action Holiday or Temporary setpoint changes 8 On Continuous fan operation occupied and standby During not occupied periods fan cycles with call for heat or cool Auto Fan cycles with call for heat or cool during all periods See Product Data Sheet form 63 2605 for more details NOTES The display retu
83. rk and gas control opens after safe start check S89E 10 seconds maximum or safe start check plus valve on delay S89F 30 seconds minimum Main burner lights while igniter is on NOTE non 34 Ifthe gas control has been replaced serviced lightoff may be unsatisfactory until air has been purged from the gas line or the gas input and combustion air have been adjusted see appliance manufacturer instructions Turn off gas supply Gas control closes The module begins the safe start check S89E 10 seconds maximum or safe start check plus valve on delay 30 seconds minimum after which the igniter starts and gas control opens Time system until gas control closes S89 is now in safety lockout The lockout time should be within the specifications in Table 2 Open gas supply System remains off and no gas flows to the main burner 68 0066 4 S89E F DIRECT SPARK IGNITION CONTROL MODULE THERMOSTAT OR A CONTROLLER LIMIT TRANSFORMER CONTROLLER COMBINATION AIR BLOWER RELAY COMBUSTION AIR BLOWER MOTOR DUAL VALVE COMBINATION GAS CONTROL S89F GAS PRIMARY VALVE VALVE GND H GND BURNER AIR PROVING SWITCH A o t FLAME __ SENSOR 120 V SPARK GENERATOR U B
84. rner is not properly grounded to earth ground on the line voltage e The ignition control is not properly grounded to the burner itself Using an ohmmeter check the wire attached to both parts for good contact and continuity e The burner ignition control is polarity sensitive The polarity of the incoming line voltage may be reversed Verify that black and white wires are hot and neutral respectively and that they are connected to the corresponding black and white wires on the burner The remaining checks and or adjustments require removal of the gas train The connections from the SENSE terminal of the ignition control to the end of the flamerod may be broken at some point Check all quick connect terminations and connections Check the continuity with an ohmmeter while flexing wires to assure no hidden conductor breakage exists If replaced wiring must be of equal or heavier gauge and equal or better temperature rating flamerod probe may be grounded out Assure that the flamerod probe is not touching the burner head The probe should be positioned in the center of the clearance groove on the outer edge of the burner head with approximately 1 16 1 5875mm clearance from the head The probe must not be positioned to far away from the head as this may result in grounding out of the probe against the inside surface of the air tube The flamerod probe should be free of soot and creosote Deposits may ins
85. rns to default screen after pressing Run Schedule or after a period of time without keypress ten seconds when returning from temporary setpoint changes info screen temp occ and temp not occ one minute when returning from setting clock day ten minutes when returning from System Checkout five minutes when returning from all other modes 5 62 0195 06 27 T7350 COMMERCIAL PROGRAMMABLE THERMOSTAT Special Functions Restore Factory Configuration Run Clear IMPORTANT This operation erases current configuration and restores factory defaults for all configuration parameters setpoints and schedules To regain the old configuration requires device reconfiguration Press both Schedule Clear Start Time 2 The display gives the option to revert to FAC CFG a restore the factory defaults press up or down V until the display indicates YES b To cancel this option ensure the display indicates NO 3 Press Run Schedule Get Factory Schedule Info Clear Performing this operation reverts the schedules to the factory defaults 1 Press both nfo and Clear Start Time 2 The display gives the option to revert to FAC SCH a Torestore the factory schedule press up A or down V until the display indicates YES b To cancel this option ensure display indicates NO 3 Press Run Schedule Test Mode Occupied Not Occupied Schedule Day N CAUTION Possible Equipment Damage Equipment damage
86. s 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 21 Check to ensure all manual reset safety devices have been reset and limits are in the normal operating position 22 Check to make sure the draft regulator and field supplied draft inducer if applicable and airflow switch is wired and installed in the proper location See the installation instructions accompanying these accessories 23 Check that all fuses are installed 24 Check to ensure the flue stack is installed properly and is free of obstructions eda SUGGESTED TOOLS AND INSTRUMENTS U Tube Manometer 0 10 W C Flue Gas Test Equipment Standard Hand Tools D C Volt Meter Microammeter Draft Gauge Volt Ohm meter Tachometer Stack amp Temperature Thermometer Gas Pressure Gauge 0 35 Ibs Ammeter Amprobe or equal SUGGESTED CONTROLS SETTINGS FL 02 High 2 222 200 F PS 10 Main Air Proving Switch Adjust to field condition PS 04 Low Gas Pressure Switch 1 0 W C PS 12 Clogged Filter Switch Adjust to field condition PS 07 High Gas Pressure Switch 125 above 01 Room Thermostat Customer Discretion burner firing rate BEFORE ATTEMPTING TO START THE H
87. sence 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 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 th
88. t your venting system to ensure adequate ventilation exists at all times Failure to heed these warnings could result in carbon monoxide poisoning symptoms include grogginess lethargy inappropriate tiredness or flu like symptoms F Field Piping Gas Piping All gas piping must be in accordance with the requirements outlined in the National Fuel Gas Code ANSI Z223 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 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 and does not rub on any surface Pipe compounds which are not soluble to liquid petr
89. tallations are made Approval permits should be checked against the unit received The unit should be installed on a non combustible pad or concrete flooring with adequate clearances for service air intake and air discharge The unit should be located with the rear of the cabinet as close to the wall as the applicable codes will allow In the absence of any code position as near to the wall as the flue pipe draft regulator and field supplied draft inducer if applicable will allow Combustion air shall be provided at a rate of at least 10 or 1 square inch of free opening per 1000 BTU per hour of rated input If a separate mechanical means provides this air an interlock with the combustion blower shall be provided The rated output of gas burning appliances decreases with higher altitudes above 2 000 feet the furnace shall be de rated 4 for each additional 1 000 feet of altitude 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 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
90. time to allow the heat exchanger to 2 Close the main manual gas valve 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 ROI 18 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 ignition 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 ignition module specifications 4 Time the length of the spark operation See the flame safeguard relay module specifications 5 After the module locks out open the manual gas cock and make sure no gas is flowing to the pilot or main burner 6 Resetthe ignition 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 com
91. tion is set to Off or Cool Set system selection to Heat or Auto Cooling will not come on No power to the thermostat Check that X terminal is connected to the system transformer Check for 24 Vac between X and RH terminals If missing 24 Vac Check if circuit breaker is tripped if so reset circuit breaker Check if system fuse is blown if so replace fuse Check if the HVAC equipment power switch is in the Off position if so set to the On position Check wiring between thermostat and HVAC equipment Replace broken wires and tighten loose connections If 24 Vac is present proceed with troubleshooting Thermostat minimum off time is activated Wait up to five minutes for the system to respond Use PDA to configure cooling response System selection is set to Off or Heat Set system selection to Cool or Auto System indicator flame heat snowflake cool is displayed but no warm or cool air is coming from the registers The call for heat or cool is not yet given Check if any stage indicators dots next to the system indicator are displayed With no display of stage indicators no call for cool heat is yet given For T7350M models only Check the information screens AMODHEAT or MODCOOL percentage of zero indicates a signal of 4 mA from the given terminal Conventional heating equipment turns the fan on only after the furnace has warmed to a setpoint Wait one minute after see
92. tive 3 Motor shaft does not turn freely 3 Check for motor clearance Cor rect or replace motor if defective D SECTION VII TROUBLESHOOTING continued Symptom Cause Remedy D Ignition Control Module 1 See technical data sheets on 1 Determine the cause of goes into safety shut Ignition Control Module lockout down Lockout E If burner does not light 1 Low voltage transformer defective 1 Check wiring and connection after pre purge has timed Correct or replace if defective out and there is no 2 Burner air proving switch is open 2 Check for correct switch operation voltage at Ignition or replace if defective Control Module input terminals F Burner does not light after 1 Ignition Control Module defective 1 Replace Ignition Control Module pre purge has timed out 2 Manual gas shut off valve closed 2 Slowly open valve and voltage is present on 3 Inlet gas pressure lower than 3 Increase gas pressure Ignition Control Module minimum gas pressure required input terminals 4 No gas through high gas pres 4 Clear obstruction in vent orifice or sure regulator with sufficient inlet line replace if defective gas pressure 5 No gas flow through combination 5 Check for proper installation and gas valve voltage Correct or replace if defective 6 Type of gas supplied natural gas 6 Connect to proper fuel supply or or propane different than shown contact factory for fiel
93. ubleshooting Guide section for the T7350 14 SECTION V UNIT START UP Before attempting to start the heater you must read and understand this manual as well as the burner IOM sequence of operation electrical schematic ignition control module and gas component instructions You must also be familiar with the adjustment of the draft regulator and field supplied draft inducer if applicable WARNING During installation testing servicing and trouble shooting of this product it may necessary to work with live electrical components Have a qualified licensed electrician or other individual who has been properly trained in handling live electrical components to perform these tasks Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury CAUTION Danger of sharp metallic edges that can cause injury Take care when servicing unit to avoid accidental contact with sharp edges 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
94. ulate the probe leading it not to pass the electrical charge to the flame The probe can be cleaned with steel wool emery paper or fine sandpaper NOTE This is the leading cause of nuisance lockouts in dual fuel wood gas fired appliances flamerod probe be burned away Check it against dimensions on the ELECTRODE AND FLAMEROD PROBE SETTINGS drawing e dimensional location of the flamerod probe may be incorrect or the probe may be bent out of shape Check it against dimensions on the ELECTRODE AND FLAMEROD PROBE SETTINGS drawing and adjust if necessary e The spark electrode gap may be incorrect resulting in no spark or an inadequate spark that will not ignite the gas properly Check the electrode gap against the ELECTRODE AND FLAMEROD PROBE SETTINGS drawing and adjust if required e The high tension lead conductor from the ignition transformer to the tip of the spark electrode may be broken preventing the high voltage current from getting to the electrode tip Check all connections thoroughly and or check to continuity of the lead wire assembly with an ohmmeter Once all of the items listed previously have been carefully checked and corrected if necessary reinsert the gas train assembly into the burner NOTE Be careful not to bend the air proving switch sail arm if so equipped or accidentally reposition either the flamerod probe or electrode during reinstallation of the gas train assembly If afte
95. ulators carefully for hairline cracks which might provide an electrical leak path that could short out the ignition spark or flame signal 5 Examine the electrode and sensor probe for any serious corrosion or deterioration of metal at the tips Check for proper dimensional settings of the sensor probe and electrode see Figure 13 Adjust and or replace these assemblies as necessary Make sure that the ignition and sensor probe wires go to the correct electrodes and the ignition wire boot is in place over the electrode porcelain 6 Make sure that the burner tube end is properly positioned in the combustion chamber entry It must be set flush with the inside face of the combustion chamber B AIR PROVING SWITCH The air proving switch is mounted to the housing cover with 2 6 self tapping screws under the gas valve A clear plastic tube protected by a spring cover is connected to the barbed fitting on the pressure switch while the other end is connected to a brass barbed fitting The plastice tube allows pressurized air from the blower housing to travel to the pressure switch causing the diaphragm contacts to close thus completing the circuit The function of the air proving switch is to ensure sufficient combustion air is being developed by the blower motor and blower wheel Should the blower motor fail or the blower wheel malfunction the burner gas valve will shut off 1 Theair proving switch should never require maintenance Ho
96. upied up down Y and e 2 Lockout all keys except 5 Options 1 and 2 do not allow adjustments on dehumidification high limit No options lockout special keypress func tions See the Special Functions section for details Once the proper option is chosen exit Installer Setup by pressing Run Schedule 5 Display prompts SAV If you want to save it use the up A or down Y key to change NO to YES before pressing Run Schedule again 26 T7350 COMMERCIAL PROGRAMMABLE THERMOSTAT Table 3 T7350 Key Function Summary mm I Grouping Button Definition Information Down Arrow w Lowers setpoint day or time When setting times or temperatures hold key down to continuously decrease value Also can make temporary change in temperature setpoint Information e Obtains information where humidity high limit can be set cycles through setup options Up Arrow A Raises setpoint day or time When setting times or temperatures hold key down to continuously increase value Also can make temporary change in temperature setpoint Temperature Occupied gt Sets Occupied Heat setpoint Heat it 4 Occupied Sets Occupied Cool setpoint 4 al Not Occupied Sets Not Occupied Heat setpoint Heat 1 0 Not Occupied Sets Not Occupied Cool setpoint Cool T Set Day Sets day of week Tapping key with Set Value segment on inc
97. urer wiring instructions when available Refer to the Wiring Diagram section starting on page 8 for typical hookups A letter code is located near each terminal for identification IMPORTANT All wiring must comply with local electrical codes and ordinances NOTE Maximum and recommended wire size is 18 gauge Do not use wire smaller than 22 gauge 1 Loosen subbase terminal screws and connect system wires 2 Securely tighten each terminal screw 3 Push excess wire back into the hole in the wall 4 Plug the hole with nonflammable insulation to prevent drafts from affecting the thermostat 2 24 ENGAGE TABS AT TOP OF THERMOSTAT AND SUBBASE OR WALLPLATE B PRESS LOWER EDGE OF CASE TO LATCH M19609 Fig 4 Mounting thermostat on subbase SETTINGS Using Thermostat Keys The thermostat keys are used to set current time and day program times and setpoints for heating and cooling override the program temperatures display present setting Set system and fan operation perform simple configuration Temperature Occupied Tet Not Occupied The HEAT COOL HEAT COOL T7350 COMMERCIAL PROGRAMMABLE THERMOSTAT NOTE See Fig 5 for keypad information Setting Temperature Refer to Table 2 for the default temperature setpoints See the Product Data form 63 2605 for complete instructions on changing the setpoints Setting System and Fan System default setting
98. vailable using this tool Refer to form 63 2605 for details A combination of key presses are required to use the Installer Setup feature 1 Toenter the Installer Setup press and hold both the Run Schedule and the Copy keys until DEG F or DEG C displays 2 advance to the next Installer Setup number press NOTE Pressing Run Copy again while in this mode displays the T7350 firmware version number 3 Toreturn to a Setup item cycle through the options 4 To change a setting use the up or down Y key 5 To exit the Installer Setup press Run Schedule 6 Display prompts SAV CFG save configuration a If you want to save the new configuration use the up A or down V key to change NO to YES before pressing Run Schedule b If you want the configuration to remain as it was before starting this change ensure the display indicates SAV CFG NO and press Run Schedule 62 0195 06 NOTE Installer Setup is automatically exited after five minutes with no key pressed Upon this auto matic exit all changes are lost Configuration Limited configuration can be done with the keypad using the Configuration ID In order to determine the proper codes to use for the Configuration Variables CnfgID NOTE Spreadsheets of the CnfgID values are available online at http customer honeywell com The PDA T7350 Configuration Tool or the PC Tool LonSpec can also be used as follows Open the PDA Config Tool Application Se
99. wever should nuisance lockouts occur the pressure switch can be checked This is done by disconnecting the yellow and white leads from the Air Proving switch and jumpering the leads together If the burner functions correctly the switch needs to be replaced WARNING If a jumper is used to check the switch it must be removed or an unsafe condition can occur resulting in death or property damage 2 As mentioned above the switch should never require maintenance However a pinched tube will shut off the flow of pressurized air to the diaphragm creating a failure made similar to bad Air Proving switch Always check to ensure that the clear tubing is not pinched Make sure the spring cover is reinstalled over tube 3 Switch is mounted in the horizontal position with terminals up from factory Final burner mounting should maintain horizontal switch position WARNING Damage to internal components of burner may result if burner is mounted in other than horizontal position C COMBUSTION AIR BLOWER AND MOTOR 1 Cleaning of the combustion air blower is indicated if the blades show an accumulation of dust and lint or if the character of the flame indicates a deficiency of combustion air 2 The side plate motor and blower wheel are removed as one assembly Disconnect the motor wire inside the junction box beneath the ignition transformer Remove the four 4 5 16 7 9375mm hex slotted screws securing sideplate to fan housing CAU
100. xample Cannot set heating higher or cooling lower Possible Cause Upper or lower temperature limits were reached Action Check the temperature setpoints Heating limits are 40 to 90 F 7 to 31 C Cooling limits are 45 to 99 F 9 to 37 C Occupied setpoint temperature range stops were configured Using a PDA check setpoint stops If necessary reconfigure the stop s Keypad is locked When a locked key is pressed LOCKED appears momentarily on the LCD Use PDA Set Display to unlock keypad Press both Run Schedule and Copy then change keypad lock level Room temperature is out of control Remote temperature sensing is not working Check all remote sensors Heat will not come on No power to the thermostat Check that X terminal is connected to the system transformer Check for 24 Vac between X and RH terminals If missing 24 Vac Check if circuit breaker is tripped if so reset circuit breaker Check if system fuse is blown if so replace fuse Check if the HVAC equipment power switch is in the Off position if so set to the On position Check wiring between thermostat and HVAC equipment Replace broken wires and tighten loose connections If 24 Vac is present proceed with troubleshooting Thermostat minimum off time is activated Wait up to five minutes for the system to respond Use PDA to configure heating response System selec

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