Applied Air GAS-FIRED HEATERS Installation & Operation Instruction Download Page 25 | Manualshive

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TYPICAL SEQUENCE FOR MODULATING THERMOSTAT WITH 4-20 mA CONTROLS

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Summary of Contents for GAS-FIRED HEATERS

Page 1: ... fenêtres 2 Ne pas actionner d interrupteur 3 Éteindre toute flamme ouverte 4 Appelez immédiatement votre fournisseur de gaz AVERTISSEMENT Une installation déficiente de même qu un mauvais réglage modification entretien ou maintenance peuvent occasionner des dommages matéri els corporels voire causer la mort Lire attentivement les instructions d installation d utilisation et d entretien avant d in...

Page 2: ...lf by following these instructions Failure to do so is your responsibility BILL OF LADING Save your bill of lading It is a contract and you will need it provided you have to file a loss or damage claim Re member claims are outlawed after nine months LOSS IN TRANSIT Before you sign for this shipment check against the bill of lading also the transportation company s delivery ticket Make sure that yo...

Page 3: ...uld be protected from the weather with tarpaulins or plastic coverings Rotate the fans monthly Prior to beginning installation of a unit that has been in storage for weeks or months the unit and its components should be closely inspected Prior to beginning installation of a unit that has been in storage for weeks or months the unit and its components should be closely inspected Shipments are made ...

Page 4: ...red unit has been designed for rigging and handling through the use of special lifting lugs installed on the top and or sides of each unit When unloading and setting the unit use the lifting lugs provided as shown in Drawing C000539 or move the equipment on rollers Hooks jacks or chains must not be used around the casing main control panel or exterior mounted controls During transit unloading and ...

Page 5: ...g as required B Locating the Unit Prior to locating the unit authorities having jurisdiction shouldbeconsultedbeforeinstallationsaremade Approval permits should be checked against the unit received Combustion air shall be provided at a rate of at least 10 CFM or 1 square inch of free opening per 1000 BTU per hour of rated input If a separate mechanical means provides this air an interlock with the...

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Page 10: ...X 4 DIRECTION OPTIONAL GASKET PROP FAN SECTION GASKET V BANK AND INLET SECTION DISCHARGE BOX GASKET PLENUM EXTENSION SHEET METAL SCREW LIFTING LUG GASKET COOLING SECTION OPTIONAL C000712 IN PLACE ALIGNMENT FLANGE CAP ALIGNMENT FLANGE CAP ...

Page 11: ...g the standing roof seam Fig 3 and side seams where the sections come together Fig 1 It is mandatory to seal the roof and side seams along the entire outside of the unit and it is strongly suggested that the seams also be sealed along the inside of the unit if possible 4 Apply caulking material along the top of both sides of the standing roof seam Fig 4 Place roof cap Fig 4 on top of the seam and ...

Page 12: ...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 hav...

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Page 14: ...CED DRAFT FAN 2 RECOMMENDED STACK MATERIAL IS 14 GAGE SERIES 400 STAINLESS STEEL CONTINUOUSLY BUTT WELDED EXHAUST STACK 3 PITCH HORIZONTAL RUNS UPWARD 1 4 INCH PER FOOT TOWARD OUTLET FOR CONDENSATE DRAINAGE SUPPORT HORIZONTAL RUNS AS REQUIRED TO PREVENT SAGGING 4 FOR NON HIGH TURNDOWN BURNERS WHENEVER USING SIDE WALL VENTING A DRAIN LINE SHOULD BE ADDED TO THE BOTTOM OF THE EXHAUSTER HOUSING FOR C...

Page 15: ... incorrectly wired components may cause some motors to have nuisance shutdowns and others will not have proper overload protection 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 exc...

Page 16: ...ID BETWEEN 12 TO 19 F 1 RECOMMEND FIRST STAGE AND SECOND STAGE OF COOLING BE PROVIDED WITH HOT GAS BYPASS 10 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 11 SENSING BULB FROM THERMAL EXPANSION VALVE TXV TO BE LOCATED ON THE SIDE OF A HORIZONTAL PORTION OF THE DX COILS SUCTION LINE PIPING AT AN ANGLE...

Page 17: ...ydrostatic head to overcome the frictional losses Always slope piping down a minimum of 1 8 per foot in the direction of the flow Evaporator Coil Draw Through The cooling coil section can be located in the unit so that supply air is drawn through the evaporative coil s This results in the condensate being induced to the area of low static pressure Unless some means of pressure equalization is prov...

Page 18: ... RADIUS PVC PIPE NIPPLE 10 30 09 C000659B DRAIN TO DRAIN PANS UNDER A NEGATIVE PRESSURE SUGGESTED P TRAP DESIGN FOR CONDENSATE DRAIN PAN 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 PVC ADAPTER FITTING FPT x SLIP NIPPLE 10 30 09 C000659B DRAIN PANS UNDER A POSITIVE PRE...

Page 19: ... is clear of flam mable vapors or containers of flammable liquids 13 Check that all piping connections particularly unions are tight Check all gas piping for leaks using a soap bubble solution The most common types of problems found relative to the gas train itself is free of foreign material within the gas piping This will interfere with the proper operation of the gas train components and burner...

Page 20: ...uctstat 100o F TC 07 Low Limit Discharge Ductstat 60o F TC 08 Freeze Thermostat 45o F 3 Minutes TC 55 Return Air Ductstat Customer Discretion TC 58 Night SetbackThermostat Customer Discretion MP 15 Unit Enable Potentiometer Customer Discretion PT 13 Building Pressure Transducer Adjust to Field Condition BEFORE ATTEMPTING TO START THE HEATER READ THE TYPICAL SEQUENCE OF OPERATION AS SHOWN BELOW Typ...

Page 21: ...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 SECTION V UNIT START UP WITHOUT DDC CONTROLS Open pilot and first main gas shut off valves slowly Last main gas shut off valve before the burner must remain closed at this time Reset high low gas pressure switches if applicable Check pilot and mai...

Page 22: ...outside air temperature Restart unit After the pilot proves the main automatic fuel valves will be energized Slowly open the last gas shut off valve and the burner should light immediately CAUTION If main flame does not light within a few seconds after pilot flame is established shut the burner down and repeat steps You may have to eliminate air from the main gas line The main gas pressure and or ...

Page 23: ...out turning the burner off or with power off remove the coil wire on low fire hold relay and restart burner Set low fire with the low fire adjusting screw on the butterfly valve Observe low fire it should be substantial enough to maintain proper combustion and be within the designed turndown range of the burner CAUTION Too low of an input setting will cause condensation of the flue gases this shou...

Page 24: ... 24 TYPICAL SEQUENCE FOR MODULATING THERMOSTAT WITH 135 OHM CONTROLS ...

Page 25: ... 25 TYPICAL SEQUENCE FOR MODULATING THERMOSTAT WITH 4 20 mA CONTROLS ...

Page 26: ... are a Time Clock Heating and Cooling Night Setbacks and signal from an external source to an auxiliary digital input To disable the fans go to Unit Modes and enter OFF NOTE A BACview or PC is required to change Unit Modes For a more detailed control sequence see the Digital Control User Manual If power supply meets requirements turn main disconnect switch on and Enable fans Damper opens if applic...

Page 27: ...start the pilot when furnace is full of vapor or combustion chamber is very hot CAUTION At no time should you stand in front of the relief door Honeywell Flame Safeguard Control RE 02 A keyboard display module Honeywell S7800A1142 is recommended to read the flame signal and is a good troubleshooting device A V O M can also be used on the D C voltage test jacks marked and on flame amplifier Connect...

Page 28: ...it lights off reliably Enable the fans and heat as described earlier in this section Restart unit After the pilot proves the main automatic fuel valve s will be energized Slowly open the last gas shut off valve and the burner should light immediately CAUTION If main flame does not light within a few seconds after pilot flame is established shut the burner down and repeat steps You may have to elim...

Page 29: ...ing quadrants to make sure they are secure and operating correctly Check all gas piping for leaks FINAL CHECKS AND ADJUSTMENTS Flame Safeguard Close the last manual gas valve before burner Operate unit in heat mode After pilot flame has been established quickly close manual pilot gas valve The flame safeguard must trip out in approximately 15 seconds Gas Pressure Switches The low gas pressure swit...

Page 30: ...re range is 55 F to 90 F MRT PRO With Smart Room Sensor To enable the cooling press the Warmer or Cooler button on the face of the remote TS 02 MRT Pro room sensor to the desired room setpoint Each push of the button changes the temperature by 1 F The setpoint can be changed a maximum of 10 F from the default of 73 F Changing the cooling setpoint also changes the heating setpoint MRT or MDT Expert...

Page 31: ... change and wiring can come loose Do not assume con trols are defective until all associated setpoints and wiring are checked You also need to reference the Digital Control System User Manual for additional trouble shooting and diag nostics for units with DDC controls If you do not have the optional BACview 6 KP 01 keypad display it will be difficult to troubleshoot any alarm that may occur on uni...

Page 32: ...Main valve terminal is energized RM7897A e Delayed second stage main valve terminal is energized RM7897C f Internal system fault occurred g Purge card is removed h Purge card is bad 5 MAIN FLAME ESTABLISHING PERIOD MFEP RM7897A teminal 21 a Airflow lockout feature is enabled and the airflow switch opens b Ignition terminal is energized c Ignition pilot valve terminal is not energized d Main valve ...

Page 33: ...ence of flame the main fuel valve terminal 9 is powered If a flame out occurs the relay module locks out or recycles depending on status of jumper JR2 within 0 8 or 3 seconds depending on the Flame Failure Response Time FFRT of the amplifier b The RM7897A terminal 21 has a ten second MFEP After the Ignition Trials the interupted pilot valve terminal 8 is de energized If a flameout occurs the relay...

Page 34: ... SERVICE NOTE Clipping and removing a site con figurable jumper enhances the level of safety Figure 5 Sequence Status LEDs Figure 6 Selectable Site Configurable Jumpers Table 7 Site Configurable Jumper Options Jumper Number Description Intact Clipped JR1 Pilot Flame Establishing Period PFEP 10 Seconds 4 Seconds JR2 Flame Failure Action Recycle Lockout JR3 Airflow Switch ILK Recycle Lockout Failure...

Page 35: ...ECTOR SEE FLAME DETECTOR SPECIFICATIONS FOR CORRECT WIRING PROGRAMMED ON SETUP USING S7800A1142 DISPLAY PURGE TIME DEPENDS ON WHICH ST7800 IS INSTALLED 3 3 4 5 PREIGNITION INTERLOCK 10 SECOND INTERRUPTED PILOT POWER OPERATING CONTROLS AND INTERLOCKS BURNER FLAME SIGNAL INITIATE INITIAL POWERUP ONLY POWER STANDBY POWER PILOT FLAME MAIN PFEP 10 SEC 4 SEC IF JR1 CLIPPED POWER MFEP PILOT FLAME MAIN RU...

Page 36: ... sure they are functioning properly 5 Inspect the Airflow Switch and make sure that it is functioning properly 6 Check the flame detector sighting position reset and recycle Measure the flame signal strength Verify that it meets specifications If not refer to the flame detector and or flame amplifier checkout procedures in the installation instructions 7 Replace the flame amplifier and or the flam...

Page 37: ...t VPS connected to terminal 16 is functioning properly replace if necessary 4 Reset and sequence the relay module 5 If fault persists replace the relay module 1 Make sure the purge card is seated properly 2 Inspect the purge card and the connector on the relay module for any damage or contaminants 3 Reset and sequence the relay module 4 If the fault code reappears replace the purge card 5 Reset an...

Page 38: ... RM7838C1004 only 1 Reset and sequence the relay module 2 If fault reappears remove power from the device reapply power then reset and sequence the relay module 3 If the fault persists replace the relay module 1 Reset and sequence the relay module 2 If fault reappears remove power from the device reapply power then reset and sequence the relay module 3 If fault does not repeat on the next cycle ch...

Page 39: ... wiring 11 Check time clock and field installed controls for correct set tings and voltage 12 Check night set back thermostat for correct settings 13 Turn power off and check bearings SECTION VII TROUBLESHOOTING continued A Supply fan s do not operate 1 Low or no voltage 2 Fuse s blown 3 Customer s interlock not closed or connected 4 Fan on off switch in off position 5 Door switch open 6 Freeze pr...

Page 40: ...lay RE 02 goes into safety shutdown Lockout 1 See technical data sheets on flame safeguard relay 1 Determine the cause of lockout Push reset button on flame safeguard relay D Pilot does not light after 90 second pre purge has timed out and voltage is present on flame safeguard output terminals 1 Manual pilot shut off valve closed 2 Inlet gas pressure lower than minimum gas pressure required 3 No g...

Page 41: ...our condensing section or evaporative cooler SECTION VII TROUBLESHOOTING continued G If there is no heat with pilot on and no voltage is present at flame safeguard relay output terminals H Flame safeguard goes into alarm when main flame is trying to establish on units with interrupted pilot 1 Flame safeguard relay run test switch in test position or is defective 1 Pilot gas pressure may be too hig...

Page 42: ...me clock and field installed controls for correct set tings and voltage 14 Close switch if applicable 15 Turn power off and check bearings 16 See multiplex voltage value chart SECTION VII TROUBLESHOOTING WITH DDC CONTROLS A Supply fan s do not operate 1 Low or no voltage 2 Fuse s blown 3 Customer s interlock not closed or connected 4 Fan is disabled 5 Door switch open 6 DO 1 on UC 01 not energized...

Page 43: ...to safety shutdown Lockout 1 See technical data sheets on flame safeguard relay 1 Determine the cause of lockout Push reset button on flame safeguard relay D Pilot does not light after 90 second pre purge has timed out and voltage is present on flame safeguard output terminals 1 Manual pilot shut off valve closed 2 Inlet gas pressure lower than minimum gas pressure required 3 No gas through pilot ...

Page 44: ...nts See section on trouble shooting PT 13 2 Check wiring and or replace bad components 3 Install correctly See section on trouble shooting PT 13 and manufacturer s cut sheet 4 Check and or replace Contact Factory 5 Check wiring 6 Check and or replace 7 Check and or replace 8 Check and repair SECTION VII TROUBLESHOOTING WITH DDC CONTROLS continued G If there is no heat with pilot on and novoltage i...

Page 45: ...X 1 See butterfly valve adjustment 1 Check Outside or Inlet Air Temperature Sensor TS 01 and orDischargeAirTemperature Sensor TS 03 for open internal circuit SeeThermistor curve 1 Inspect linkage and valve 1 Read pressure at inlet to modulating valve using a manometer with unit operating at full fire Pressure should be equal to the sum of outlet pressure setting plus pressure drop of the valve 2 R...

Page 46: ...certain gas is on and check limit controls for normal operation 1 Arrow on side or bottom of valves should point in direction of gas flow 1 Inspect wiring see check out procedure in Section X 1 Check for 2 10 VDC at input terminals 2 Check 0 10 VDC voltage on AO 1 1 See Butterfly Valve Adjustment 1a Check Space Temperature Sensor TS 02 use a BACview 6 to read TS 02 and Discharge Air Sensor TS 03 f...

Page 47: ...2 Incorrect outlet pressure adjustment 1 Open circuit in Discharge Air Temperature Sensor TS 03 2 Incorrect Maximum Heating Discharge Temperature Setpoint 1 Incorrect Minimum Heating Discharge Temperature Setpoint 2 Incorrect space setpoint 3 Insufficient burner capacity G Continuous High Fire Electronics OK H Continuous High Fire Electronics Problem I Incorrect High Fire J Continuous Maximum Disc...

Page 48: ... relays RE 34 RE 35 and or RE 33 are energized and condensing unit or evaporative cooler is not on C Incorrect Space Temperature 1 Enable the cooling mode 2 Check auxiliary circuit wiring and contact 3 Check for proper CFM Adjust and or replace switch 4 Change to correct setpoints See Digital Control User Manual 5 See Digital Control System User Manual 1 Check and or replace 2 Correct wiring 3 See...

Page 49: ...ioned so that air movement does not affect it The Low side should be to atmosphere and positioned so it is not exposed to the weather 4 With the use of a BACview 6 KP 01 place the unit in the Building Pressure mode See the Digital Con trol System User Manual 5 The voltage at COM and OUT will vary between 0 to 5 VDC O VDC means the building is in a negative pressure and should open the Outside Air ...

Page 50: ...ILURE SW 72 RS 01 100 OA or 100 OUTPUT IN 4 RE 27 RS 04 BURNER STATUS RE 65 RS 03 FAN STATUS RE 12 TO GND RS 02 CLOGGED FILTER SW 09 RS 01 1 36 1 73 1 87 1 92 1 36 1 73 1 87 1 92 AUXILIARY UNIT ENABLE MULTIPLEXED VOLTAGE VALUES CHECK ALL TERMINAL CONNECTIONS FOR TIGHTNESS The DC voltage is to be checked at the UC 01 board With the Fan Enabled When the fan status relay RE 65 is energized the contac...

Page 51: ...losed This is defined as the zero setting 8 Set the controller to output the signal required to drive the motor to the fully open position Wait for the motor to stop driving open 9 Turn the span potentiometer slowly clockwise until motor starts to drive closed The difference between the fully open position signal and the fully closed position signal is defined as the operating span 10 Recheck the ...

Page 52: ...ers are either flame rod or scanner design 2 POOR FLAME SIGNAL Try adjusting needle valve or pilot pressure regulator Should this not be successful check the primary pilot air If neither of these methods improve the reading inspect the flame rod position The spark is to arc against the outside radius of the pilot assembly case not the pilot head nozzle The normal spark gap should be 1 16 3 32 See ...

Page 53: ... for the pilot assembly for the C Burner Pilot Assembly C Burner For C1 C2 Burner Pilot Case to Gas Manifold Adjustment Pilot Assembly C Burner For C3 C4 C5 Burner Pilot case to gas manifold adjustment is very important As depicted the inside radius of the pilot body must be tight against the outside radius of the gas manifold The bottom of the pilot body must also be tight against the notched por...

Page 54: ...trode For Straight G P Gas Burners Using A Flat Diffuser Plate DIFFUSER POSITION ADJUSTMENT Moving the blast tube diffuser assembly fore or aft on gas or oil firing will move the flame front point of re tention in order to attain the best quietest smoothest combustion for specific job conditions If the initial mid way point factory setting does not provide satisfactory results move fore or aft in ...

Page 55: ...not be successful check the primary pilot air If neither of these methods improve the reading inspect the flame rod position MAXON Electrode Flame Rod l e d o M r e n r u B r o t i n g I k r a p S s n o i s n e m i D d o R e m a l F s n o i s n e m i D X Y X Y Z 5 0 4 3 1 4 4 6 9 2 M 7 0 4 M 8 0 4 8 0 4 M 2 1 4 M 3 1 4 5 1 4 5 1 4 M 2 2 4 5 2 4 2 1 4 8 8 0 1 5 3 M 2 3 4 5 3 4 M 2 4 4 5 4 4 3 1 4 4...

Page 56: ...atio Curves for Fuel Oils and Gases Ratio Curves for Fuel Oils and Gases Ratio Curves for Fuel Oils and Gases Ratio Curves for Fuel Oils and Gases Ratio Curves for Fuel Oils and Gases 170 17 160 16 150 15 140 14 130 13 120 12 110 11 100 10 90 9 80 8 70 7 60 6 50 5 40 4 30 3 20 2 10 1 R I A S S E C X E T N E C R E P PERCENT CARBON DIOXIDE CO 2 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 20...

Page 57: ...ng CO into the airstream The leak must be located and repaired or replace the heat exchanger NOTE Keep screened air intakes clear of obstruc tions at all times WARNING Failure to comply with the general safety information may result in extensive property damage severe personal injury or death Periodic maintenance is essential to the efficient operation and extended service life of this equipment F...

Page 58: ... 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 frequ...

Page 59: ... this end of the shaft 10 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 11 Place a bearing on each end of the shaft 12 Replace the old shims with new 13 Bolt the bearings in place and reattach the grease lines When installing a Sleevlock bearing see note at bottom of page 14 Adjust the shaft so ...

Page 60: ...onths 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 ...

Page 61: ...ensate 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 s...

Page 62: ...pical 10 000 Ohm Thermistor Output Curve 0 5000 10000 15000 20000 25000 30000 32 41 50 59 68 77 86 95 104 Temperature in Degrees F Resistance Ohms SECTION X THERMISTOR OUTPUT CURVE FOR UNITS WITH DDC CONTROLS ...

Page 63: ...sued 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 ________________ SECTION XI RE...

Page 64: ...4830 Transport Drive Dallas TX 75247 Phone 214 638 6010 Fax 214 905 0806 www appliedair com ...

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