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Weather-Rite TT Series, Installation, Operation & Service Manual

The Burromax TT Series is a cutting-edge product designed to enhance your riding experience. To ensure you make the most of your purchase, we provide a complimentary Owner's Manual that outlines all the necessary information. You can conveniently download this manual for free from our website for quick and easy reference.

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NOT FOR RESIDENTIAL USE

Weather-Rite LLC

1100 Seven Mile Road NW
Comstock Park, MI 49321
Telephone: +1.612.338.1401
Fax: +1.616.784.0435
Toll Free: 800.589.3691

www.weather-rite.com

WARNING

Installation must be done by a registered installer/

contractor qualified in the installation and service of

gas/oil-fired heating equipment or your fuel supplier.

Improper installation, adjustment, alteration, service

or maintenance can result in death, injury or property

damage. Read the installation, operation and service

manual thoroughly before installing or servicing

this equipment.

Installer

Please take the time to read and understand

these instructions prior to any installation.

Installer must give a copy of this manual to the owner.

Owner

Keep this manual in a safe place in order to provide

your service technician with necessary information.

© 2017 Weather-Rite LLC

WARNING

FOR YOUR  SAFETY

If you smell gas:

 

 1.  Open windows.
  2.  DO NOT try to light any appliance.
  3.  DO NOT use electrical switches.
  4.  DO NOT use any telephone in 
   your building. 
  5.  Extinguish any open flame.
  6.  Leave the building.
  7.  Immediately call your local fuel
   

supplier after leaving the building.

   

Follow the fuel supplier’s

   instructions.
  8.  If you cannot reach your fuel
   

supplier, call the Fire Department.

Fire Hazard

Keep all flammable objects, liquids and 
vapors the minimum required clear-
ances to combustibles away from 
equipment.

Some objects will catch fire or explode 
when placed close to equipment.

Failure to follow these instructions can 
result in death, injury or property 
damage.

  WEATHER-RITE™ TT-Series

Direct, Gas Fired,

 Industrial Air Handler

Installation, Operation &

Service Manual

TT112
TT115
TT118
TT212
TT215
TT218

TT221
TT224
TT230
TT233
TT236

P/N WR161100NA Re

v

 B 09/17

Summary of Contents for TT Series

Page 1: ...in order to provide your service technician with necessary information 2017 Weather Rite LLC WARNING FOR YOUR SAFETY If you smell gas 1 Open windows 2 DO NOT try to light any appliance 3 DO NOT use electrical switches 4 DO NOT use any telephone in your building 5 Extinguish any open flame 6 Leave the building 7 Immediately call your local fuel supplier after leaving the building Follow the fuel su...

Page 2: ......

Page 3: ...17 Weather Rite LLC AVERTISSEMENT POUR VOTRE SECURITE Si vous sentez une odeur de gaz 1 Ouvrir les fenêtres 2 N essayer pas d allumer un appareil 3 N utiliser pas d interrupteurs électriques 4 N utiliser pas de téléphone dans votre bâtiment 5 Eteindre flamme nue 6 Quitter le bâtiment 7 Après avoir quitté le bâtiment appelez immédiatement votre fournisseur local de gaz Suivre les instructions du fo...

Page 4: ......

Page 5: ...1 Inlet Hood Installation Models TT112 TT215 61 13 2 Inlet Hood Assembly Models TT218 and TT221 62 13 3 Inlet Hood Installation Models TT224 and TT230 63 13 4 Inlet Hood Installation Models TT233 and TT236 67 SECTION 14 Service Platform 68 SECTION 15 Dampers 70 15 1 Discharge Damper Installation 70 15 2 Inlet Damper Installation 71 SECTION 16 Discharge plenum and Discharge Louvers 73 16 1 Four Way...

Page 6: ...ents 149 26 5 Combustion Components 149 26 6 Electrical Components 151 26 7 Miscellaneous Mechanical Components 154 SECTION 27 Troubleshooting 156 27 1 Initial Checks 157 27 2 Supply Fan 157 27 3 Burner 158 27 4 Temperature Controls 159 27 5 Series 14 Preliminary Circuit Analysis 159 27 6 Series 44 Preliminary Circuit Analysis 164 27 7 Series 94 Preliminary Circuit Analysis 168 27 8 Series MP Trou...

Page 7: ...ted room air may be hazardous if containing flammable solids liquids and gases explosive materials and or substances which may become toxic when exposed to heat i e refrigerants aerosols etc 1 1 Description of Operation This air handler is a direct gas fired applianc8e It is designed for indoor or outdoor installation with fresh outdoor air delivered to the burner Air handlers are designed to oper...

Page 8: ...quipment s serial plate See label placement drawing on Page 2 Figure 1 through Page 3 Figure 2 for label location Avoid placing label on areas with extreme heat cold corrosive chemicals or other elements To order additional labels please contact Weather Rite LLC or your WEATHER RITE independent distributor 1 5 Label Placement FIGURE 1 TT 112 TT221 Horizontal 3 1 2 4 5 11 6 8 10 9 7 13 13 12 Item P...

Page 9: ...commended Entry 9 91010427 Vent Outdoors 10 14302333 Installation Manual Enclosed 11 14302372 Burner Access 12 14302389 Sight Port 13 14302390 Test 6 3 2 10 10 8 9 4 5 13 11 12 1 7 Item Part Number Description 1 91070002 Danger Severe Injury 2 Ref Logo 3 91070001 Danger Electric Shock 4 91070004 Warning Fire 5 91070006 Warning Burn 6 91070005 Warning Fall 7 19162 Rotation 8 19030 Recommended Entry...

Page 10: ...ber Description 1 91070002 Danger Severe Injury 2 Ref Logo 3 91070001 Danger Electric Shock 4 91070004 Warning Fire 5 91070006 Warning Burn 6 91070005 Warning Fall 7 19162 Rotation 8 19030 Recommended Entry 9 91010427 Vent Outdoors 10 14302333 Installation Manual Enclosed 11 14302372 Burner Access 12 14302389 Sight Port 13 14302390 Test ...

Page 11: ...nded Entry 9 91010427 Vent Outdoors 10 14302333 Installation Manual Enclosed 11 14302372 Burner Access 12 14302389 Sight Port 13 14302390 Test 2 13 13 12 11 7 1 3 6 10 9 8 1 4 5 Item Part Number Description 1 91070002 Danger Severe Injury 2 Ref Logo 3 91070001 Danger Electric Shock 4 91070004 Warning Fire 5 91070006 Warning Burn 6 91070005 Warning Fall 7 19162 Rotation 8 19030 Recommended Entry 9 ...

Page 12: ...Installation Manual Enclosed 21 Ref Serial Data Plate 22 Ref Electrical Schematic 23 91070016 California Proposition 65 24 Ref Agency Approval ETL optional 25 Ref Agency Approval ULC optional 3 6 Exterior 10 22 24 23 21 Interior Item Part Number Description 3 91070001 Danger Electric Shock 6 91070005 Warning Fall 10 14302333 Installation Manual Enclosed 21 Ref Serial Data Plate 22 Ref Electrical S...

Page 13: ...ntrol Panel Item Part Number Description 3 91070001 Danger Electric Shock 20a 91070032 Danger Electric Shock 20b 910700033 Danger Electric Shock Item Part Number Description 3 91070001 Danger Electric Shock 20a 91070032 Danger Electric Shock 20b 910700033 Danger Electric Shock ...

Page 14: ...e installer It is essential that the contractor the sub contractor or the owner identifies the presence of combustible materials corrosive chemicals or halogenated hydrocarbons anywhere in the premises Halogenated Hydrocarbons are a family of chemical compounds characterized by the presence of halogen elements fluorine chlorine bromine etc These compounds are frequently used in refrigerants cleani...

Page 15: ...y for the gas train components Drill motor and various drills U tube manometer or Magnehelic gauge 0 to 1 0 w c U tube manometer or gas pressure gauge 0 to 5 and 0 to 30 w c Volt meter Clamp style ammeter Belt tension gauge Paintable latex caulk silicone caulk is not to be used ...

Page 16: ...filter access panel when equipped The stated clearances to combustibles represent a surface temperature of 90 F 50 C above room temperature 90 F 50 C plus ambient temperature Building materials with a low heat tolerance i e plastics vinyl siding canvas tri ply etc may be subject to degradation at lower temperatures It is the installer s responsibility to assure that adjacent materials are protecte...

Page 17: ...es and Repair Garages Installation in garages must be in accordance with the following codes United States Refer to Standard for Parking Structures NFPA 88A latest revision or the Code for Motor Fuel Dispensing Facilities and Repair Garages NFPA 30A latest revision Canada Refer to Natural Gas and Propane Installation Code Standard CSA B149 1 latest revision 4 5 Electrical Electrical connection to ...

Page 18: ...r ED End Discharge CE Control Enclosure AD2 Filter Access Door AD1 Unit Access Panel TD Top Discharge SD Side Discharge Model A B C D E F G H J K L M N P Q R S T V W X Y Z TT112 in cm 28 0 71 1 36 0 91 4 58 0 147 3 13 4 34 0 15 6 39 6 24 0 61 0 15 0 38 1 5 0 12 7 17 2 43 7 16 0 40 6 10 2 25 9 1 0 2 5 26 0 66 0 34 0 86 4 48 0 121 9 5 0 12 7 19 5 49 5 7 0 17 8 8 0 20 3 1 0 2 5 18 5 47 0 33 0 83 8 2 ...

Page 19: ... Discharge Plenum Double Deflection Discharge Louvers Burner Blower Filter Section TT112 lb kg 400 181 4 63 28 6 30 13 6 75 34 0 40 18 1 75 34 0 98 44 5 70 31 8 125 56 7 400 181 4 80 36 3 70 31 8 TT115 lb kg 525 238 1 63 28 6 30 13 6 75 34 0 40 18 1 75 34 0 98 44 5 70 31 8 125 56 7 400 181 4 80 36 3 70 31 8 Size HP kW 75 56 1 75 1 5 1 1 2 1 5 3 2 2 5 3 7 7 5 5 6 10 7 5 15 11 2 20 14 9 25 18 6 30 2...

Page 20: ...TION MOTORIZED INLET DAMPER OPTIONAL INLET HOOD WITH BIRDSCREEN OPTIONAL SIDE VIEW PLAN VIEW OA OA ED ED BD RA N NOTE S dimension reflects curb angle for horizontal orientation Optional Model A B C D E F G H J K L M N P Q R S T U V X Y BB DD EE TT118 in cm 17 0 43 2 26 0 66 0 60 0 152 4 19 1 48 5 21 9 55 6 50 0 127 16 2 41 1 33 0 83 8 58 0 147 3 19 5 49 5 18 0 45 7 30 0 76 2 8 0 20 3 18 9 48 0 10 ...

Page 21: ...er Roof Curb Legs Stand Serivce Platform Four Way Discharge Plenum Double Deflection Discharge Louvers Burner Blower Filter Section TT118 lb kg 700 317 5 55 24 9 75 34 0 70 31 8 N A 100 45 4 70 31 8 140 63 5 400 181 4 80 36 3 70 31 8 Size HP kW 75 56 1 75 1 5 1 1 2 1 5 3 2 2 5 3 7 7 5 5 6 10 7 5 15 11 2 20 14 9 25 18 6 30 22 4 40 30 0 50 37 0 60 44 7 75 55 9 Standard lb 35 35 45 45 70 85 130 155 2...

Page 22: ...147 3 14 0 35 6 7 0 17 8 6 0 15 2 33 0 83 8 69 0 175 3 72 0 182 9 6 0 15 2 26 0 66 0 10 5 26 7 2 0 5 1 58 0 147 3 10 5 26 7 14 3 36 3 20 0 50 8 33 0 83 8 16 9 42 9 8 0 20 3 TT221 in cm 42 0 106 7 100 0 254 72 0 182 9 24 8 63 0 22 8 57 9 26 0 66 0 20 0 50 8 10 1 25 4 80 0 203 2 14 0 35 6 15 5 39 4 1 0 2 54 38 0 96 5 96 0 243 8 72 0 182 9 6 0 15 2 33 0 83 8 11 3 28 7 2 0 5 1 76 0 193 4 4 8 12 2 23 5...

Page 23: ...5 88 5 70 31 8 160 72 6 480 217 7 140 63 5 130 59 0 TT221 lb kg 1 432 649 5 625 283 5 132 59 9 156 70 8 325 147 4 200 90 7 260 117 9 N A 175 79 4 520 235 9 270 122 5 260 118 0 N BB F C G K D T S R D A Y W S BB M CE AA P Z AD1 RA SD E E X L B J H V AD2 AD2 SIDE VIEW END VIEW OA OA RA SD TD TD MOTORIZED DISCHARGE DAMPER OPTIONAL BURNER BLOWER SECTION FILTER SECTION OPTIONAL MOTORIZED INLET DAMPER OP...

Page 24: ...52 4 145 0 368 3 5 0 12 7 40 0 101 6 115 0 292 1 10 0 25 4 25 0 63 5 31 0 78 7 135 0 342 9 55 0 139 7 15 0 38 1 100 0 254 55 0 139 7 140 0 355 6 26 0 66 0 75 1 9 3 0 7 6 5 0 12 7 4 0 10 2 151 0 383 5 157 0 398 8 6 0 15 2 60 0 152 4 2 0 5 1 A E D F Q B P N E J H CE F R R S L X AD1 C AD2 AD2 D K G M Y D U T T SIDE VIEW PLAN VIEW OA OA ED ED BD RA MOTORIZED DISCHARGE DAMPER OPTIONAL BURNER BLOWER SEC...

Page 25: ...127 5 300 136 1 100 45 4 375 170 1 488 221 4 N A 425 192 8 650 294 8 410 186 0 400 181 4 Size HP kW 75 56 1 75 1 5 1 1 2 1 5 3 2 2 5 3 7 7 5 5 6 10 7 5 15 11 2 20 14 9 25 18 6 30 22 4 40 30 0 50 37 0 60 44 7 75 55 9 Standard lb 35 35 45 45 70 85 130 155 220 275 300 360 500 550 800 950 kg 15 9 15 9 20 4 20 4 31 8 38 6 59 0 70 3 99 8 124 7 136 1 163 3 226 8 249 5 362 9 430 9 2 Speed lb 70 85 125 150...

Page 26: ... 421 6 172 0 436 9 2 0 5 1 TT230 in cm 133 0 337 8 180 0 457 2 31 0 78 7 0 8 2 0 3 0 7 6 6 0 15 2 43 0 109 2 10 0 25 4 72 0 182 9 22 0 55 9 25 0 63 5 110 0 279 4 67 0 170 2 175 0 444 5 4 0 10 2 26 0 66 0 60 0 152 4 186 0 472 4 192 0 487 7 2 0 5 1 AD1 CE S Z Q H R M G F J F N G G A A H K L B C AD2 AD2 P F E D BD SIDE VIEW PLAN VIEW OA OA ED ED BD MOTORIZED DISCHARGE DAMPER OPTIONAL BURNER BLOWER SE...

Page 27: ... Discharge Head Double Deflection Discharge Louvers Burner Blower Filter Section TT224 lb kg 5 600 2 540 1 1 300 589 7 365 165 6 325 147 4 690 313 0 500 226 8 650 294 8 N A 700 317 5 700 317 5 510 231 3 500 226 8 TT230 lb kg 5 900 2 676 2 1 430 648 6 400 181 4 325 147 4 690 313 0 500 226 8 650 294 8 N A 700 317 5 700 317 5 510 231 3 500 226 8 Size HP kW 75 56 1 75 1 5 1 1 2 1 5 3 2 2 5 3 7 7 5 5 6...

Page 28: ...2 4 5 0 12 7 2 0 5 1 TT215 in cm 133 0 337 8 180 0 457 2 31 0 78 7 3 0 7 6 6 0 15 2 0 8 2 0 4 0 10 2 43 0 109 2 170 0 431 8 22 0 55 9 25 0 63 5 72 0 182 9 67 0 170 2 175 0 444 5 75 0 190 5 110 0 279 4 25 0 63 5 36 0 91 4 26 0 66 0 186 0 472 4 192 0 487 7 10 0 25 4 60 0 152 4 5 0 12 7 2 0 5 1 Y AD2 AD2 AD1 CE AA U T R S Q H E M H E H AA X N P J Z B A L K C A E D F SIDE VIEW PLAN VIEW OA OA ED ED BD...

Page 29: ...Way Discharge Plenum Double Deflection Discharge Louvers Burner Blower Fiter Section Recirculating TT224 lb kg 5 600 2 540 1 1 300 589 7 365 165 6 325 147 4 690 313 0 500 226 8 650 294 8 N A 700 317 5 700 317 5 510 231 3 500 226 8 TT230 lb kg 5 900 2 676 2 1 430 648 6 400 181 4 325 147 4 690 313 0 500 226 8 650 294 8 N A 700 317 5 700 317 5 510 231 3 500 226 8 Size HP kW 75 56 1 75 1 5 1 1 2 1 5 3...

Page 30: ... 4 44 Model TT118 AIRFLOW CFM m3 h Outlet Velocity fpm m s Percent age of Capacity Total Static Pressure 50 in wc 1 25 mbar 75 in wc 1 87 mbar 1 00 in wc 2 49 mbar 1 25 in wc 3 11 mbar 1 50 in wc 3 74 mbar 1 75 in wc 4 36 mbar 2 00 in wc 4 98 mbar 2 25 in wc 5 6 mbar 2 50 in wc 6 23 mbar RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 5 000 8 495 1 742 8 85 0 463 0 99 544 1...

Page 31: ...50 in wc 1 25 mbar 75 in wc 1 87 mbar 1 00 in wc 2 49 mbar 1 25 in wc 3 11 mbar 1 50 in wc 3 74 mbar 1 75 in wc 4 36 mbar 2 00 in wc 4 98 mbar 2 25 in wc 5 6 mbar 2 50 in wc 6 23 mbar RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 10 000 16 990 1 278 6 49 0 382 1 53 458 2 06 12 000 20 388 1 534 7 79 10 397 2 11 466 2 72 531 3 35 14 000 23 786 1 790 9 09 20 415 2 85 480 3 5...

Page 32: ... 14 55 000 93 446 2 282 11 59 41 306 17 09 335 19 62 363 22 16 389 24 77 415 27 44 440 30 23 58 000 98 543 2 406 12 22 50 342 21 83 342 21 84 368 24 48 394 27 11 419 29 95 442 32 80 466 35 76 61 000 103 640 2 531 12 86 58 348 24 27 373 27 01 399 29 85 423 32 60 446 35 55 468 38 62 492 41 67 64 000 108 737 2 655 13 49 66 354 26 80 380 29 79 404 32 71 427 35 55 450 38 64 473 41 67 494 44 91 67 000 1...

Page 33: ... be performed 1 Remove all packaging or banding that attached the air handler to the skid and ensure that the air handler is no longer bound to the skid 2 Remove all packaging or blockers 3 Remove all of the accessories or packages that were shipped on the same skid inside the air handler or inside the control enclosure 4 Inspect the air handler to Verify that there is no damage as a result of shi...

Page 34: ...e skid remove the skid The air handler will be hanging at a slight angle 6 Set the lowest edge down slowly on a protec tive surface such as plywood 7 Continue to lower the air handler into the proper position horizontally The unit can now be rigged for installation FIGURE 23 Reposition for Lifting TT112 TT218 2 1 Example of chain Lifting Ring Adjustable Hooks Lifting HookWith Safety Locks 1 2 Lowe...

Page 35: ...uring the lift to prevent tipping twisting or falling If lifted improperly product damage may occur If the air handler is shipped as two pieces lift the two pieces separately and then assemble See Page 30 Section 7 for assembly instructions Refer to the applicable portions of Page 50 Section 10 through Page 55 Section 11 for assembly and mounting instructions for specific accessories FIGURE 24 Lif...

Page 36: ...he sides roof and bottom seams between the section splits Once caulk has been applied to outdoor models TT233 TT236 pitched roof is standard the provided roof seam cover should be screwed over the caulked seam every 12 30 5 cm with the provided screws For outdoor model TT118 roof seam cover is not required unless pitched roof option supplied See Page 30 Table 28 for quantity of screws required Tab...

Page 37: ...ECTIONS BOLT FLAT WASHER FLAT WASHER LOCK WASHER NUT TYPICAL ROOF SEAM DETAIL CAULK END OF SEAM AT INTERSECTIONS SEAM STRIP PITCHED ROOF REF INSTALL DRILL SCREWS APPROX 1 FROM EACH END TO SECURE SEAM STRIP TO ROOF CONNECTING FLANGES BLOWER SECTION BURNER SECTION Model Quantity of 1 2 Nuts Bolts Flat Lock Washers TT233 14 sets TT236 14 sets ...

Page 38: ...98 FIGURE 28 Air Handler Assembly Recirculating Upright Models TT233 and TT236 LOCK WASHER FLAT WASHER FLAT WASHER BLOWER SECTION BURNER SECTION TYPICAL FOR ALL CONNECTIONS NUT BOLT Model Quantity of 1 2 Nuts Bolts Flat Lock Washers TT233 14 sets TT236 14 sets ...

Page 39: ...y selected when noise and vibration are to be considered Spring style is normally selected when only vibration is considered 8 1 Pad Isolator for Curb Mounted Air Handler The pad supplied is 2 5 1 cm wide by 15 38 1 cm long See Page 33 Figure 29 This is a resilient cross ribbed neoprene pad with a high deflection rate Alternatively raised ribs provide effective isolation in both high and low load ...

Page 40: ...ALLATION OPERATION AND SERVICE MANUAL 34 of 198 FIGURE 30 Pad Isolator Installation Unit Waffle Pad Isolator 2 5 08 cm x 2 5 08 cm Curb Angle Curb C Channel Check Unit Dimensions For More Detail 2 Duct Flange or Case ...

Page 41: ...r inserted in the hanger rods See Page 35 Figure 32 For best results isolators should be located at or near the ceiling 3 Install isolators 4 Turn nut on lower rod assembly clockwise on complete turn on each isolator Repeat this procedure until temporary hanging fixtures are loose and load of the equipment is suspended completely on the vibration isolators See Page 37 Figure 34 5 Remove temporary ...

Page 42: ...TT SERIES INSTALLATION OPERATION AND SERVICE MANUAL 36 of 198 FIGURE 33 Hanger Rods Installation instructions Model TT112 TT218 LOCK WASHER HARDWARE BY OTHERS NUT FLAT WASHER ...

Page 43: ...SECTION 8 VIBRATION ISOLATION 37 of 198 FIGURE 34 Hanger Rods Installation Model TT221 FLAT WASHER LOCK WASHER NUT HARDWARE BY OTHERS ...

Page 44: ...TT SERIES INSTALLATION OPERATION AND SERVICE MANUAL 38 of 198 FIGURE 35 Hanger Rods Installation Instructions Model TT224 TT236 NUT LOCK WASHER FLAT WASHER HARDWARE BY OTHERS ...

Page 45: ...n See Page 39 Figure 36 Neoprene style is normally selected when the equipment requires up to 12 7 mm of static deflection FIGURE 36 Pad Mounting of Neoprene Isolator 8 3 1 1 Installation Instructions for Neoprene Mount Isolator All hardware required to mount the isolator to the structure is to be supplied by the installer 1 Install blockers under the air handler equip ment to allow the isolator t...

Page 46: ...TT SERIES INSTALLATION OPERATION AND SERVICE MANUAL 40 of 198 FIGURE 37 Pad Mounting Installation Instructions for Neoprene Isolator Models TT112 TT218 ...

Page 47: ...SECTION 8 VIBRATION ISOLATION 41 of 198 FIGURE 38 Pad Mounting Installation Instructions for Neoprene Isolator Model TT221 ...

Page 48: ...TT SERIES INSTALLATION OPERATION AND SERVICE MANUAL 42 of 198 FIGURE 39 Pad Mounting Installation Instructions for Neoprene Isolator Models TT224 TT236 ...

Page 49: ...Isolator 8 3 2 1 Installation Instructions for Spring Mount Isolator All hardware required to mount the isolator to the structure is to be supplied by the installer 1 Place the spring mount between the structure and support base of the air handler The spring mount housing serves as the blocking during erection 2 Bolt the base of the isolator securely to the structure 3 Secure equipment with adjust...

Page 50: ...TT SERIES INSTALLATION OPERATION AND SERVICE MANUAL 44 of 198 FIGURE 41 Pad Mounting Installation Instructions for Spring Isolator Models TT112 TT218 ...

Page 51: ...SECTION 8 VIBRATION ISOLATION 45 of 198 FIGURE 42 Pad Mounting Installation Instructions for Spring Isolator Model TT221 ...

Page 52: ...TT SERIES INSTALLATION OPERATION AND SERVICE MANUAL 46 of 198 FIGURE 43 Pad Mounting Installation Instructions for Spring Isolator Model TT224 TT236 ...

Page 53: ...d Check that the diagonal measurements are within 1 8 3 mm of each other To ensure a weatherproof seal between the air handler and the curb the curb must be level with no twist from end to end Shim level as required and secure curb to roof deck using best building practices The curb is self flashing Install roofing material as required NOTE Check the installation location to ensure proper clearanc...

Page 54: ...8 0 TT118 in cm 59 2 150 4 89 2 226 6 1 9 4 8 3 0 7 6 16 0 40 6 24 0 lb kg N A N A 100 45 4 130 59 0 TT212 in cm 59 2 150 4 57 2 145 3 81 2 206 2 1 9 4 8 3 0 7 6 16 0 40 6 24 0 61 0 lb kg 100 45 4 154 69 9 130 59 0 169 76 7 TT215 in cm 71 2 180 8 57 2 145 3 85 2 216 4 1 9 4 8 3 0 7 6 16 0 40 6 24 0 61 0 lb kg 125 56 7 192 87 1 163 73 9 212 96 2 TT218 in cm 71 2 180 8 61 2 155 4 85 2 216 4 1 9 4 8 ...

Page 55: ...installer is responsible for tying the air handler to the curb per all applicable codes See Page 49 Figure 45 for details FIGURE 45 Installation of Legs WEATHER RITE UNIT BOLT LEGSTOTHE SECTION THRUTHE LIFTING LUGS 1 2 13NC X 1 5 BOLTS DRILL SCREW MOUNTINS LEG TO UNDERSIDE OF SECTION A MODEL 28 000 TT 112 115 212 215 36 000 42 000 TT 218 TT 221 30 000 TT 118 36 000 B 36 000 36 000 36 000 DIMENSION...

Page 56: ...aching Air Handler to Stand Once the stand is secured to a concrete slab the air handler may be placed on the stand Prior to lifting the air handler apply a 1 27 cm thick double sided urethane foam tape provided by others to the top edge of the stand Lift the air handler on to the mounting stand See Page 27 Section 6 1 for safe lifting practices Once the air handler is placed on the stand secure i...

Page 57: ... 1 lb kg 140 63 5 TT215 in cm 36 0 91 4 72 0 182 9 28 0 71 1 lb kg 150 68 0 TT218 in cm 36 0 91 4 72 0 182 9 36 0 91 4 lb kg 160 72 6 TT221 in cm 36 0 91 4 100 0 254 0 42 0 106 7 lb kg 175 79 4 TT224 in cm 46 0 116 8 110 0 279 4 55 0 139 7 lb kg 300 136 1 TT230 in cm 47 0 119 4 145 0 368 3 60 0 152 4 lb kg 425 192 8 TT233 in cm 55 0 139 7 160 0 406 4 72 0 182 9 lb kg 700 317 5 TT236 in cm 55 0 139...

Page 58: ...8 FIGURE 47 Attaching Air Handler to Mounting Stand TT112 TT221 Quantity of 1 2 Nuts Bolts Flat Lock Washers 115 118 212 215 112 Model 4 4 4 4 221 4 218 4 4 Connecting Point TYP Both Sides TYPICAL FOR ALL CONNECTIONS BOLT FLAT WASHER FLAT WASHER LOCK WASHER NUT ...

Page 59: ...URE 48 Attaching Air Handler to Mounting Stand TT224 TT236 Connecting Point TYP Both Sides 17 17 8 236 230 233 8 224 Model Quantity of 1 2 Nuts Bolts Flat Lock Washers TYPICAL FOR ALL CONNECTIONS BOLT FLAT WASHER FLAT WASHER LOCK WASHER NUT ...

Page 60: ...ing Hole Detail for Floor Slab Models TT221 TT236 B A Short Sides of Air Handler Long Sides of Air Handler Model A B TT221 in cm 43 5 110 5 101 5 257 8 TT224 in cm 53 5 135 9 113 0 287 0 TT230 in cm 58 5 148 6 151 383 5 TT233 in cm 70 5 179 1 166 421 6 TT236 in cm 70 5 179 1 186 472 4 ...

Page 61: ...ust be attached to the filter section using the same techniques listed previously The 1 27 cm thick double sided urethane foam tape should be applied between the air handler and the filter section 11 2 Attaching Legs to Slab To attach the legs to a concrete slab or floor the base of each leg is equipped with two holes Studs provided by others must be installed in the concrete slab or floor The air...

Page 62: ...X 1 5 BOLTS DRILL SCREW MOUNTINS LEG TO UNDERSIDE OF SECTION A MODEL 28 000 TT 112 115 212 215 36 000 42 000 TT 218 TT 221 30 000 TT 118 36 000 B 36 000 36 000 36 000 DIMENSIONS 6 000 10 250 A SECTION A A LAG BOLT HOLES FOR FLOOR MOUNTING WEATHER RITE UNIT DRILL SCREW LEGS INTO SIDE OF CABINET DRILL SCREW CROSS MEMBERTO LEGS B 9 500 1 500 TYP 9 000 6 000 2 500 9 500 4 334 4 019 A A ...

Page 63: ... your WEATHER RITE independent distributor Crush Hazard Use proper lifting equipment and practices Falling Hazard Use proper safety equipment and prac tices to avoid falling Severe Injury Hazard Use proper lifting practices and equip ment Equipment and accessories are heavy Cut Pinch Hazard Wear protective gear during installation operation and service Edges are sharp WARNING Failure to follow the...

Page 64: ...ver should be screwed over the caulked seam every 12 30 5 cm with the provided screws See Page 30 Table 28 for quantity of screws required Verify that the factory installed filters are properly placed and filter access door is secured in the closed position For details See Page 58 Figure 52 FIGURE 52 Filter Section Installation on Horizontal Air Handler TYPICAL FOR ALL CONNECTIONS Amount of hardwa...

Page 65: ...ust be torqued to recommended specifications on Page 10 Table 1 Caulk provided by others both mating surfaces between the filter section and air handler Verify that the factory installed filters are properly placed and filter access door is secured in the closed position For details See Page 59 Figure 53 FIGURE 53 Filter Section Installation on Upright Air Handler TYPICAL FOR ALL CONNECTIONS Amoun...

Page 66: ...nto the inlet of the air handler or to an outside wall After installing an inlet hood all hardware must be tightened with a torque wrench to recommended specifications on Page 10 Table 1 In addition all seams must be caulked supplied by others Crush Hazard Use proper lifting equipment and practices Falling Hazard Use proper safety equipment and prac tices to avoid falling Severe Injury Hazard Use ...

Page 67: ... handler use the supplied hardware See Page 61 Figure 54 To install the inlet hood on an exterior wall drill holes every 8 20 3 cm in the flanges of the inlet hood and mount with lag bolts supplied by others Caulking is required on both mating surfaces FIGURE 54 Inlet Hood Installation to Air Handler Models TT112 TT215 FLAT WASHER TYPICAL FOR ALL CONNECTIONS NUT LOCK WASHER FLAT WASHER BOLT ...

Page 68: ...5 To install the inlet hood on an exterior wall drill holes every 8 20 3 cm in the flanges of the inlet hood and mount with lag bolts supplied by others Caulking is required on both mating surfaces FIGURE 55 Inlet Hood Assembly and Installation to Air Handler Models TT218 and TT221 FLAT WASHER TYPICAL FOR ALL CONNECTIONS NUT LOCK WASHER FLAT WASHER BOLT Model Quantity of 1 2 Nuts Bolts Flat Lock W...

Page 69: ...ood on the cabinet of the air handler use the supplied hardware See Page 63 Step 13 3 1 To install the inlet hood on an exterior wall drill holes every 8 20 3 cm in the flanges of the inlet hood and mount with lag bolts supplied by others Caulking is required on all mating surfaces Step 13 3 1 Drill Screws Step 1 Use supplied drill screws to fasten two large pieces together ...

Page 70: ...1 2 Bolt Caulk mating surfaces Model Quantity of 1 2 Nuts Bolts Flat Lock Washers TT224 TT230 8 sets 10 sets Step 1 Attach assembly made on Page 63 Step 13 3 1 to inlet section of air handler using supplied hardware Drill Screws Caulk mating surfaces Step 1 Use supplied drill screws to fasten the smaller two pieces together ...

Page 71: ...198 Step 13 3 4 Drill Screws Caulk mating surfaces Step 1 Use supplied drill screws to attach assembly made on Page 64 Step 13 3 3 to the larger section of the inlet hood that was attached to the air handler on Page 64 Step 13 3 2 ...

Page 72: ... half of the hood hidden to show support Drill Screws Step 1 Drill screw factory supplied hood support channel through side of support and side flanges of inlet hood NOTE This view shown with half of the hood hidden to show support Step 1 Drill screw factory supplied hood support to bottom flange at base of unit ...

Page 73: ...r handler use the supplied hardware See Page 67 Figure 56 To install the inlet hood sections on an exterior wall drill holes every 8 20 3 cm in the flanges of the inlet hood and mount with lag bolts supplied by others FIGURE 56 Inlet Hood Installation to Air Handler Models TT233 and TT236 Caulk mating surfaces Model Quantity of 1 2 Nuts Bolts Flat Lock Washers TT233 in cm 16 sets TT236 in cm 20 se...

Page 74: ...lower section depending on the application For recirculating models TT233 and TT236 please refer to submittal drawings for specific details See Page 69 Figure 57 for layout and dimensions Crush Hazard Use proper lifting equipment and practices Falling Hazard Use proper safety equipment and prac tices to avoid falling Severe Injury Hazard Use proper lifting practices and equip ment Equipment and ac...

Page 75: ...el A B C Weight TT112 TT115 in cm 48 0 121 9 36 0 91 4 42 0 106 7 lb kg 400 181 4 TT118 TT212 in cm 48 0 121 9 60 0 152 4 42 0 106 7 lb kg 400 181 4 TT215 TT218 in cm 48 0 121 9 72 0 182 9 42 0 106 7 lb kg 480 217 7 TT221 in cm 48 0 121 1 100 0 254 0 42 0 106 7 lb kg 520 235 9 TT224 in cm 72 0 182 9 55 0 139 7 42 0 106 7 lb kg 300 136 1 TT230 in cm 72 0 182 9 60 0 152 4 42 0 106 7 lb kg 425 192 8 ...

Page 76: ...ws through the flanges into the air handler cabinet every 8 20 5 cm on all four sides of the discharge damper See Page 71 Figure 58 which shows discharge damper for horizontal bottom arrangement To install the discharge damper on an interior wall drill holes every 8 20 5 cm in the flanges on all four sides of the discharge dampers to accommodate lag bolts supplied by others See Page 71 Table 31 fo...

Page 77: ...o the face of the air handler drive drill screws through the flanges into the air handler cabinet every 8 20 5 cm on all four sides of the inlet damper for models TT112 TT218 For model TT221 TT236 use bolts See Page 72 Figure 59 for details To install the inlet damper on an exterior wall drill holes every 8 20 3 cm in the flanges on all four sides of the inlet dampers to accommodate lag bolts supp...

Page 78: ...TT SERIES INSTALLATION OPERATION AND SERVICE MANUAL 72 of 198 FIGURE 59 Inlet Damper Drill Screws or Lag Bolts supplied by others ...

Page 79: ... FIGURE 60 Four Way Discharge Plenum Crush Hazard Use proper lifting equipment and practices Falling Hazard Use proper safety equipment and prac tices to avoid falling Severe Injury Hazard Use proper lifting practices and equip ment Equipment and accessories are heavy Cut Pinch Hazard Wear protective gear during installation operation and service Edges are sharp WARNING Failure to follow these ins...

Page 80: ...flanges on all four sides of the discharge louvers to accommodate lag bolts supplied by others See Page 71 Table 31 for recommended quantity of lag bolts to be installed In this type of installation the discharge louvers are self supporting no other support is needed in a standard installation See Page 74 Figure 61 for layout and dimensions FIGURE 61 Double Deflection Discharge Louvers B A C Model...

Page 81: ...ort the weight of ductwork Ductwork must be constructed in a fashion that is self supporting Ductwork should be straight elbows should be minimal and any transitions should be smooth Ductwork fittings i e elbows transitions etc should be located a minimum of 4 1 2 m from the connection Refer to SMACNA guidelines for further information Depending on the options ordered with the air handler flanges ...

Page 82: ...ir handler return air opening height and width See Page 12 Figure 11 through Page 23 Figure 22 for return air dimensions 17 3 Discharge Duct Work Discharge duct work sizes should be determined by the application requirements of the system Units with twin blowers must have a common discharge duct Table 33 Minimum Discharge Duct Connection Size Model Height Width TT112 TT118 in cm 19 5 49 5 26 66 0 ...

Page 83: ...upply pressure of up to 28 in wc or 1 psi maximum for the less than 1 million BTU capacity gas train See Page 78 Figure 62 5 psi maximum for 1 million BTU and over capacity gas trains See Page 79 Figure 63 through Page 81 Figure 68 When gas supply exceeds the above listed maximum gas pressures an additional high pressure gas regulator will be required to assure that the correct gas pressure is sup...

Page 84: ...pipe from the origination point must be same size or larger Make sure vent line is free from obstructions Do not group vent lines together into a common header The outside termination must have a weatherproof cap or be directed downward for protection from the elements and must be screened to prevent the entry of any objects FIGURE 62 ANSI less than 1000 MBH FM Less 700 MBH Manifold PILOT GAS REGU...

Page 85: ... M AXIT ROL Sele ctra Honeywell FLUIDPOWERGASVALVE FLUIDPOWERGASVALVE Honeywell M A X IT R O L Selectra PILOT GAS REGULATOR CONTROLSTHE AMOUNT OF GAS FLOWTOTHE BURNER S PILOTTUBE PILOT SOLENOIDVALVE ALLOWS GASTO FLOWTO THE BURNER PILOT METERINGVALVE CONTROLSTHE FLOW OF GASTOTHE MAIN BURNER TO SETTHE LOW FIRE ONTHE BURNER BLOCK GAS MOTORIZED ACTUATOR SECONDARY BACK UP OPENS AND CLOSESVALVE MAIN GAS...

Page 86: ...RINGVALVE CONTROLSTHEFLOWOF GASTOTHEMAINBURNER TOSETTHELOWFIRE ONTHEBURNER HIGHGASPRESS SWITCH PROTECTSAGAINSTEXCESSIVEGAS PRESSURE Honeywell PILOT GAS REGULATOR CONTROLSTHE AMOUNT OF GAS FLOWTOTHE BURNER S PILOTTUBE POSITION INDICATINGMAIN GAS SOLENOIDVALVE OPENS CLOSES ALLOWING GASTO FLOWTOTHE BURNER PILOT SHUT OFF COCK MANUAL SHUT OFFTHAT ISOLATES THE PILOT GAS ASSEMBLY FROM THE MAIN GAS SUPPLY...

Page 87: ...ENS CLOSES ALLOWING GASTO FLOWTOTHE BURNER SHUT OFF COCK MANUAL SHUT OFFTHAT ISOLATES THE GASTRAIN ASSEMBLY FROM THE BURNER LOW GAS PRESS SWITCH PROTECTS AGAINST INSUFFICIENT GAS PRESSURE HIGH GAS PRESS SWITCH PROTECTS AGAINST EXCESSIVE GAS PRESSURE PILOT GAS REGULATOR CONTROLSTHE AMOUNT OF GAS FLOWTOTHE BURNER S PILOTTUBE POSITION INDICATING BLOCK GAS SOLENOIDVALVE SECONDARY BACK UPVALVETO PREVEN...

Page 88: ...FROM THE MAIN GAS SUPPLY PILOT SOLENOIDVALVE ALLOWS GASTO FLOWTO THE BURNER PILOT POSITION INDICATING BLOCK GAS SOLENOIDVALVE SECONDARY BACK UPVALVETO PREVENT GAS FROM REACHING BURNER DURING SHUTDOWN METERINGVALVE CONTROLSTHE FLOW OF GASTOTHE MAIN BURNER TO SETTHE HIGH LOW FIRE ONTHE BURNER HIGH GAS PRESS SWITCH PROTECTS AGAINST EXCESSIVE GAS PRESSURE LOW GAS PRESS SWITCH PROTECTS AGAINST INSUFFIC...

Page 89: ...the manifold inlet gas pressure and the burner gas pressure during burner setup 18 5 1 Manifold Inlet Gas Pressure 3 8 NPT The pressure test port for measuring manifold inlet pressure is located on the pilot tee which is located on the manifold inlet tee Refer to the unit rating plate for the acceptable inlet gas pressure See Page 84 Figure 71 Honeywell FLUIDPOWERGASVALVE FLUIDPOWERGASVALVE Honeyw...

Page 90: ...he burner See Page 84 Figure 72 FIGURE 72 Burner Gas Pressure Tap 18 6 Line Pressure Test Leak Testing The air handler and its individual shut off valve must be disconnected from the gas supply piping systems during any pressure testing of that system at test pressures in excess of 28 in wc 69 7 mbar The air handler must be isolated from the gas supply piping system by closing its individual manua...

Page 91: ... the air handler control enclosure is run in a single conduit the wire run can be as long as 100 30 m If the interconnection wiring between remote panel and the air handler control enclosure is run in two conduits separating the shielded cable and the 120v power supply for the remote panel the wire run can be as long as 200 60 m For longer wire runs consult the factory Care should be used to avoid...

Page 92: ...19 5 3 Gas Pressure Switches The high gas pressure switch is standard on all models The low gas pressure switch is standard on certain models ANSI and FM compliant gas trains above 2 500 MBH and XL compliant gas trains above 400 MBH and are also available as an option on the others The function of the gas pressure switches is to protect against either a lack of gas or an excessive pressure in the ...

Page 93: ...Hazard Disconnect electric before service More than one disconnect switch may be required to disconnect electric from equipment Equipment must be properly grounded Failure to follow these instructions can result in death or electrical shock WARNING Carbon Monoxide Hazard Do not recirculate air from the heated space over burner Air supply to burner must be from outside Failure to follow these instr...

Page 94: ... in between 20 1 4 Autocycle Air Control The Autocycle Air Control adjusts the positioning of the discharge damper to control the volume of air discharged into the facility The Autocycle includes up to 12 pre set positions adjusted by potentiometers mounted on the printed circuit board Each pre set position is controlled by an exhaust fan interlock requiring two wires per interlock The installer m...

Page 95: ...control module has experienced a fault and will need to be reset The burner control module must be reset at the air handler Refer to the Maintenance and Trouble Shooting sections of this manual to determine the cause of the fault Summer Off Winter Switch Summer position The blower will operate without the burner for summer ventilation Winter position The blower and burner will operate as needed fo...

Page 96: ...ter coil allowing the blower motor to start Auxiliary contacts on the blower starter close powering the flame relay through the high limit and low and high gas pressure switches if provided When airflow is proven by the burner airflow switches the burner firing circuit is powered up After the pilot flame or main flame is proven by the flame detector the main and blocking valves are opened and the ...

Page 97: ...rior are test jacks which permit flame signal mea surement during operation FIGURE 79 Fireye Rectifier Amplifier MERT4 The functions of the indicator lights which are located on the programmer module are as follows They are listed in the order you will find them on the flame safeguard This is also the order in which they will occur in the sequence The indicators are actually a red colored light em...

Page 98: ...lectronic network illuminates the FLAME LED It closes a contact which powers up terminal 5 in the control This terminal powers up the main gas valves allowing the main burner to come on At the same time the electronic network opens a contact which removes power from terminal 4 This shuts off the power to the ignition module which stops the spark at the burner The safeguard control at this point mo...

Page 99: ...r their appropriate setting use the following procedure NOTE READ OVER THE FOLLOWING SECTIONS COMPLETELY BEFORE ATTEMPTING TO SET THE DIPSWITCHES OR MOVING THE CLEAR PLASTIC WINDOW PURGE TIMING Locate dipswitches 1 through 5 Switch 2 is the one for 7 seconds timing Move this switch to the right which is the ON position The remaining switches 1 3 through 5 must remain to the left in the OFF positio...

Page 100: ...LED that will be illuminated at this time will be the OPERATING CONTROL 30 seconds after the lockout has activated the alarm circuit is powered up illuminating the ALARM LED Manual reset is now required Wait 10 seconds before resetting the control to allow the lockout switch to cool down NOTE If the flame signal is lost while the burner is on the pilot and main gas valves will be turned off A safe...

Page 101: ...At the same time the electronic network opens a contact which removes power from terminal 4 This shuts off the power to the ignition module which stops the spark at the burner The safeguard control at this point monitors the flame NOTE If a pilot flame is not detected during the 10 second trial for ignition the pilot gas solenoid valve and the ignition module are turned off A safety lockout occurs...

Page 102: ...alled is always selected See Page 96 Table 38 lists all available purge times and how to select those by cutting jumpers JP2 through JP5 FIGURE 83 Jumper Locations Table 38 Jumper Settings Pilot Trial for Ignition Jumpers JP6 and JP7 are used by the factory only to select the PTFI for the M4RT1 The factory set default PTFI time is 10 seconds JP6 installed JP7 not installed The PTFI time may only b...

Page 103: ...y LED that will be illuminated at this time will be the OPERATING CONTROL 30 seconds after the lockout has activated the alarm circuit is powered up illuminating the ALARM LED Manual reset is now required Wait 10 seconds before resetting the control to allow the lockout switch to cool down NOTE If the flame signal is lost while the burner is on the pilot and main gas valves will be turned off A sa...

Page 104: ...ven with power applied to Terminal 6 Ignition Trials Pilot Flame Establishing Period PFEP A When the PFEP begins 1 The pilot valve and ignition transformer terminals 8 and 10 are energized 2 Flame must be proven by the end of the ten second PFEP to allow the sequence to continue If a flame is not proven by the end of PFEP a safety shutdown occurs Main Flame Establishing Period MFEP After PFEP and ...

Page 105: ...maximum airflow capacity It is used when the space demands for make up air are not at a constant value due to exhaust fan cycling or environmental changes The standard Volumatic control option allows the air handler s discharge damper to modulate which in turns delivers the required airflow Methods of control for this option are by a manual damper position controller standard with this option Spac...

Page 106: ...oss the burner Low Air Volume Operation When switched to the low speed position the blower motor switches to low speed providing low Air Volume operation The burner profile motor closes the burner profile blades to provide the correct pressure drop across the burner for proper burner combustion As the profile motor closes its motor end switch opens putting the Maximum Fire Potentiometer located in...

Page 107: ... unoccupied cycles operated by an occupied unoccupied switch It includes a line voltage room thermostat shipped loose and an occupied unoccupied switch mounted on remote panel During the unoccupied cycle the air handler remains off until the room thermostat calls for heat At that time the air handler goes to a standard daytime sequence until the thermostat is satisfied 20 6 2 Night Setback with El...

Page 108: ...ch mounted in the air handler s control panel 20 7 5 Post Purge Timer and Relay This option allows the supply fan on the equipment to run for a timed period adjustable 1 to 100 minutes after burner shutdown It includes timer mounted on air handler 20 7 6 Pre Purge Timer and Relay This option allows the supply fan on the equipment to run for a timed period adjustable 0 1 to 15 minutes before allowi...

Page 109: ...e air from the heated space require the use of a room carbon dioxide sensor which is set to maintain a CO2 concentration below 5 000 ppm Shipped loose for field installation 20 7 17 Carbon Monoxide Detector This is a ship loose sensor that monitors the CO levels in the space It can either sound an alarm and or control the function of the air handler in the event its threshold set point is exceeded...

Page 110: ...tory calibrated to a base resistance so that component replacement will not upset the system calibration If the temperature control system should require field calibration refer to the provided temperature control amplifier product information sheet 21 1 1 System Components For Series 14 Temperature Selectors These are non temperature sensing controls which are used to select the supply air temper...

Page 111: ...es as its temperature increases The sensor is located such that the averaging tube protrudes into the discharge duct NOTE This is a field installed device and location is critical Make sure this sensor in mounted in the area of ductwork that has the most amount of air moving through it Recommended distance from air handler is 6 to 16 feet Amplifier This is a solid state control that receives its i...

Page 112: ...distance from air handler is 6 to 16 feet Amplifier This is a solid state control that receives its input signal from the temperature selectors and discharge sensor From this it produces the control voltage signal that is sent to the metering valve to control the discharge temperature of the unit The amplifier is supplied with 24 volts AC and is located inside the remote control panel Besides sign...

Page 113: ...lifier also sends a signal to the LED display located between the temperature selectors This signal is used to illuminate the LED displaying the average temperature the discharge sensor is seeing The amplifier for the MP2 system designated AMO2 allows for up to 8 separate programs to be entered and stored while the standard MP2 amplifier only allows one program to be entered Auxiliary Multifunctio...

Page 114: ...f air required for proper combustion for all of the firing rates WARNING Failure to follow these instructions can result in death electric shock injury or property damage Burn Hazard Allow heater to cool before service Tubing may still be hot after operation Explosion Hazard Leak test all compo nents of gas piping before operation Gas can leak if piping is not installed properly Do not high pressu...

Page 115: ...pilot gas tube is ignited by this arc The arc will be a brilliant electric blue in color See Page 109 Figure 90 The gas supplied to the pilot gas tube should be 3 1 2 wc for natural gas and between 9 to 11 wc for propane or LP The difference between the two fuels is that a restricting orifice is installed in the propane or LP pilot gas tube The pilot assembly can be used on propane or LP without a...

Page 116: ... or main flame It will be glowing bright red along at least 50 of its length See Page 109 Figure 90 FIGURE 91 Spark Rod Dimensions NOTE For the flame rod to produce this signal its position in relation to the grounding rod pilot and main flame is critical The flame rectification module of the flame safeguard control converts this signal to a D C voltage This voltage is the value that is used to mo...

Page 117: ... the amplifier in the control where it is processed to energize or hold in the flame relay FIGURE 92 Ultra Violet Sensor The flame rectification module of the flame safeguard control converts this signal to a D C voltage This voltage is the value that is used to monitor the pilot and the main flame of the burner For the flame safeguard control to recognize this signal the value of the voltage must...

Page 118: ...e More than one disconnect switch may be required to disconnect electric from equipment Equipment must be properly grounded Severe Injury Hazard Do not enter equipment while in operation Equipment may start automatically Do not operate with door open Installation operation and service must be done by a trained technician only DANGER Failure to follow these instructions can result in death electric...

Page 119: ...have filters installed to prevent particulate matter from entering the heater If not supplied by the Pro cess Heater then the installer must supply them These filters must be approved by the authority having jurisdiction of the installation 3 The return air duct system must be installed with doors panels or other means for access to facilitate inspection maintenance cleaning and access to fire pro...

Page 120: ...Heater s airflow comes with either Manual or motorized profile dampers Process Heaters that deliver up to and including 20 000 CFM may be supplied with manual burner profile dampers These models are limited to a CFM reduction of 50 of the maximum ventilating air capacity of that particular model Process Heaters supplied with motorized burner profile dampers may be reduced to a CFM reduction of 20 ...

Page 121: ... Summer Off Winter switch Three system indicating lights Blower Burner and Flame Failure Maxitrol M Series temperature set point with digital temperature indicator f A B 1 THE N O AUXILIARY CONTACT OF A PROCESS EXHAUST FAN S SHOULD BE CONNECTED BETWEEN TERMINALS 1 AND 1 UNLESS THE PROCESS HEATER IS DIRECTLY CONNECTED TO THE SYSTEM TO MAIN POWER f f f FUSE F2 FUSE F3 CONTROL TRANSFORMER SUMMER OFF ...

Page 122: ... Operation Paint Mode Switch in Summer position for fan only or Winter position for fan and burner Process Heater s discharge damper opens to 100 open position Exhaust fan starts and after a timed delay the supply fan comes on In the winter position temperature based on paint temperature set point Booth lights operated by on off switch 3 Operation Dry Mode Activate switch to either Summer or Winte...

Page 123: ...ides fine tune adjustment of exhaust fan speed to maintain booth pressure 3 Operation Dry Mode Activate switch to either Summer or Winter position Turn Dry Cycle Start Timer to desired time activates the dry cycle Spray gun solenoid and booth lights are shut off Purge timer is activated purging booth with 100 ventilation air operating as if in paint mode Process Heater s discharge damper re positi...

Page 124: ... gun solenoid and booth lights are shut off Purge timer is activated purging booth with 100 ventilation air operating as if in paint mode After purge cycle Process Heater s dampers re position to 10 ventilation air 90 return air for Dry cycle Exhaust fan speed reduces down to 10 airflow Temperature based on Dry temperature set point When Dry cycle is completed cool down cycle is activated Booth li...

Page 125: ...e exhaust fan revert to 100 airflow position operating as if in paint mode Process Heater and exhaust fan shut down after cool down cycle FIGURE 104 WRP 4 23 4 6 WRP 4R Remote Control Station 90 10 Recirculating Cure System Auto Balance 1 Description NEMA1 hinged control panel Summer Off Winter switch Three 3 system indicating lights Blower Burner and Flame Failure Spray gun interlock Dry Purge Ti...

Page 126: ...ure Purge Timer Digital Cure Timer Cool Down timer Maxitrol M Series temperature set point Spray gun interlock Booth balancing pot for exhaust fan variable frequency drive Booth pressure gauge Dwyer 4 Magnehelic monitors booth pressure 2 Operation Paint Mode System ON Push Button energizes system starting paint mode Burner is activated through Heat Auto On Switch In On Position Burner energizes In...

Page 127: ...cle Exhaust fan speed reduces down to 10 airflow Temperature based on Cure temperature set point When Cure cycle is completed cool down cycle is activated Booth lights remain off During cool down cycle the Process Heater and exhaust fan revert to 100 ventilation air operating as if in paint mode Process Heater and exhaust fan shut down after cool down cycle FIGURE 106 WRP 5 SYSTEM OFF CUTE ON CUTE...

Page 128: ...hese instructions can result in death electrical shock or injury Explosion Hazard Leak test all compo nents of equipment gas piping before operation Gas can leak if piping is not installed properly Do not high pressure test gas piping with equipment connected Carbon Monoxide Hazard Do not recirculate air from the heated space over burner Air supply to burner must be from outside Falling Hazard Use...

Page 129: ...00 ppm 24 2 Mechanical Refer to appliance rating plate for minimum outside air requirements during recirculation operation Before installation check that the local distribution condition nature of gas and pressure and the current state of adjustment of the appliance are compatible If filters are not installed via inlet hood or filter section an air strainer must be installed on the inlet of the ai...

Page 130: ...djustments are made and with the burner and blower both on 5 If applicable compare all variable frequency drive VFD programming parameters with specifications provided on electrical drawing 24 4 Airflow The air flow switches are factory calibrated safety devices for burner air flow If an air flow switch does not close the problem may not be the air flow switch It could be an indication of an air f...

Page 131: ...ile blade and turn the blade on the shaft in the direction necessary to correct the pressure make changes in small increments Each profile assembly is done individually and equally tighten setscrews securely when done Turn the air leaving edge of blade toward the burner to increase pressure and away from burner to decrease pressure Check pressure over the full operating range of the unit when done...

Page 132: ... mode Set the dry temperature Series 94 or the second stage temperature setting Series MP to at least 100 over the ambient temperature After the burner has ignited and run for 30 seconds measure the discharge temperature Subtract the outside air temperature from the discharge temperature the difference is the temperature rise If the value is lower than required increase the gas flow If the value i...

Page 133: ...129 Figure 113 and rotating the regulator adjustment screw A clockwise rotation increases manifold pressure For air handlers equipped with less than 1 MBH gas trains the high fire gas pressure is set by adjusting the regulator upstream of the M611 valve See Page 131 Figure 115 Reconnect any wires that were used for adjustment 6 Low Fire Adjustment NOTE High fire gas pressure must be set BEFORE adj...

Page 134: ... 112 Pilot Pressure Tap PILOT GAS REGULATOR CONTROLSTHE AMOUNT OF GAS FLOWTOTHE BURNER S PILOTTUBE PILOT SHUT OFF COCK MANUAL SHUT OFFTHAT ISOLATES THE PILOT GAS ASSEMBLY FROM THE MAIN GAS SUPPLY PILOT PRESSURETAP PILOT SOLENOIDVALVE ALLOWS GASTO FLOWTO THE BURNER PILOT ...

Page 135: ...SECTION 24 START UP PROCEDURES 129 of 198 FIGURE 113 Maxitrol MR212 Valve T N E V R 2A0 4 1 12A06 R Low Fire Adjustment loosen locking screw before adjustment High Fire Adjustment ...

Page 136: ...TT SERIES INSTALLATION OPERATION AND SERVICE MANUAL 130 of 198 FIGURE 114 Regulator RV61 ...

Page 137: ...w recommended setting decrease the profile linkage range of travel without altering the full airflow position If above setting increase the profile linkage range See Page 125 Section 24 4 2 1 Recheck air pressure drops across burner on high and low airflow settings Minimum air damper position controller is factory set and should not be adjusted unless specifically directed to do so by the factory ...

Page 138: ... high speed Pressure drop across burner should remain stable Open interlock for high speed Take air pressure drop across burner profiles If below recommended setting decrease the profile linkage range of travel without altering the high speed position If above setting increase the profile linkage range See Page 126 Section 24 4 2 2 Recheck air pressure drops across burner on high and low speed set...

Page 139: ... be re commissioned to the start up procedure as outlined on Page 122 Section 24 DANGER Failure to follow these instructions can result in death injury or property damage Severe Injury Hazard Do not enter equipment while in operation Equipment may start automatically Do not operate with door open Installation operation and service must be done by a trained technician only Electrical Shock Hazard D...

Page 140: ...on and adjust if necessary Annual Fall Start Up Follow entire start up procedure at this time and check control settings and operation Cabinet Exterior After installation touch up scratches Periodic painting should be done there after as required The caulk around weather enclosures and over field joints should be inspected annually Re apply caulk as needed to maintain integrity Warning labels and ...

Page 141: ...elongate Replace the entire set if replacement is necessary See Page 134 Section 25 2 and Page 123 Section 24 2 2 Blower Bearing Lubrication The blowers use pillow block and flange bearings they should be re lubri cated every 3 000 hours of operation or 6 months whichever occurs first The recommended lubricant is Shell Alvania 2 or S3 grease To re lubricate the blower flange pillow block bearings ...

Page 142: ...ed grease Do not over grease Relubrication intervals are specified in the table above After relubricating allow motor to run for 10 minutes before replacing relief hardware NOTE In general it is not recommended to mix greases of different brands The mixing of different types of thickeners may destroy the composition and physical properties of the grease In the event that a different grease is requ...

Page 143: ... away from the motor To remove the blower pulley remove the bolts from the bushing and insert into the previously unused threaded holes of the bushing Carefully press the blower pulley off the bushing tightening the bolts evenly Loosen the Allen Head setscrew located on top of the keyway and slide the pulley bushing off the shaft To remove the motor first remove any guards and or covers around mot...

Page 144: ... locks the collar to the shaft Use a punch with a hammer to give the collar a hard strike to set the collar then tighten the setscrew down again Manifold Periodically check fuel control assembly and internal and external piping for leaks Relief vent lines to outdoors on fuel controls should be checked to ensure against blockage caused by insects or any other substance Clean as required All gas pip...

Page 145: ...ush Scrub both sides of the stainless steel burner plates to remove any soot or other build up which may be on the burner All of the burner plate holes must be clear so air can pass through them unrestricted The holes in the burner plate allow air to mix with the gas in increasing amounts as the flame gets longer 7 After you ve cleaned the burner plates inspect them for cracking Cracks occurring b...

Page 146: ...Port Drill Size HMA 2A Natural Gas Propane 1 8 42 Dampers Check linkage when applicable and tighten set screws as required All moving parts of dampers should be cleaned and then thoroughly lubricated with light molybdenum oil in aerosol can Dampers furnished with stainless steel side seals should also have the seals lubricated generously Dampers should then be manually operated several times until...

Page 147: ...WARNING Use only genuine WEATHER RITE replacement parts per this installation operation and service manual Failure to follow these instructions can result in death electric shock injury or property damage Explosion Hazard DANGER Electrical Shock Hazard Fire Hazard Model Description Part Number Quantity TT112 BEARING 81900060 2 SHAFT 77017001 1 WHEEL 82000000 1 TT115 BEARING 81900060 2 SHAFT 770170...

Page 148: ... SDS138 1 3 8 82200490 SDS158 1 5 8 82200510 SDS1716 1 7 16 82200500 SF 1 438 1 7 16 14130500 SF 1 688 1 11 16 14263800 SF 2 938 2 15 16 82200900 SF11116 1 11 16 82200830 SF11516 1 15 16 82200840 SF158 1 5 8 82200850 SF21116 2 11 16 14173900 SF218 2 1 8 82201000 SF2316 2 3 16 82200860 SF238 2 3 8 14071000 SF2716 2 7 16 82200870 SF278 2 7 8 82200880 SH 75 3 4 14220000 SH 1 188 1 3 16 82200420 SH 1 ...

Page 149: ...3 16 82105080 1B X 9 4 PD SDS 82100220 2B X 11 0 PD SK 82100560 2B X 12 4 PD SK 82100570 2B X 13 6 PD SK 82100580 2B X 15 4 PD SK 82100590 2B X 16 0 PD SK 82100600 2B X 18 4 PD SK 82100610 2B X 20 0 PD SF 82100620 2B X 23 0 2 125 14143000 2B X 25 0 SF 82100630 2B X 3 4 PD SH 14228901 2B X 4 2 PD SH 82100360 2B X 4 4 PD SH 82100370 2B X 4 6 PD SDS 82100380 2B X 4 8 PD SDS 82100390 2B X 5 2 PD SDS 8...

Page 150: ...82101220 4B X 12 4 PD SK 82101230 4B X 13 6 PD SK 82101240 4B X 15 4 PD SF 82101250 4B X 16 0 PD SF 82101260 4B X 18 4 PD SF 82101270 4B X 20 0 PD SF 82101280 4B X 25 0 PD 82101290 4B X 30 0 PD 82101300 4B X 38 0 PD 82101310 4B X 5 2 PD SD 14100400 4B X 5 6 PD SD 14188400 4B X 5 8 PD SD 82101100 4B X 6 0 PD SD 82101110 4B X 6 2 PD SD 82101120 4B X 6 4 PD SD 82101130 4B X 6 6 PD SD 82101140 4B X 6 ...

Page 151: ...2190 2B X 6 0 7 4 1 5 8 82102200 2B X 7 0 8 4 1 3 8 14154300 2B X 8 0 9 4 1 3 8 82102230 2B X 8 0 9 4 1 5 8 82102240 2B X5 0 6 4 1 5 8 82102030 3B X 4 0 5 4 1 5 8 82102290 3B X 4 5 5 9 1 3 8 82102310 3B X 4 5 5 9 1 5 8 82102320 3B X 4 5 5 9 1 7 8 82102321 3B X 4 9 5 9 1 1 8 82102300 3B X 5 0 6 4 1 5 8 82102350 3B X 5 5 6 9 1 3 8 14153800 3B X 5 5 6 9 1 5 8 82102390 3B X 5 5 6 9 1 7 8 82102400 3B X...

Page 152: ...33689465 B 066 33689466 B 067 33689467 B 068 33689468 B 069 33689469 B 070 33689470 B 071 33689471 B 072 33689472 B 073 33689473 B 074 33689474 B 075 33689475 B 076 33689476 B 077 33689477 B 078 33689478 B 079 33689479 B 080 33689480 B 081 33689481 B 082 33689482 B 083 33689483 B 084 33689484 B 085 33689485 B 086 33689486 B 088 33689488 B 089 33689489 B 090 33689490 B 091 33689491 B 092 33689492 B...

Page 153: ...7 BX 88 33689588 BX 90 33689590 BX 93 33689593 BX 95 33689595 BX 96 33689596 BX 97 33689597 BX 98 33689598 BX 99 33689599 BX 100 33689500 BX 103 33689501 BX 105 33689505 BX 108 33689508 BX 113 33689513 BX 116 33689516 BX 117 33689517 BX 120 33689520 BX 128 33689528 BX 133 33689533 Description Part Number 2 POSITION SPRING RETURN 120 V 83400010 2 POSITION 120V 133 2 SPDT 14266201 24V 2SPDT 0 10VDC ...

Page 154: ...M GM2SPDT 14283702 DES FOR SM GM 1SPDT 14283700 DES NM MOTORS 2SPDT 14283703 CRANKARM FOR FOOT MOUNT ACTUATORS 14160800 COVER TRANSFORMER 120VOLT TO 24VOLT 11136204 ACTUATOR POSITIONER PANEL MOUNT 14321550 AUXILIARY SWITCH PACKAGE 14321551 FOOT MOUNT KIT DIRECT DRIVE ACTUATOR 14321560 Description Part Number ELECTRODE FLAME ROD 14123203 ELECTRODE SPARK ROD 14123204 PILOT ASSEMBLY FLAME ROD NAT GAS...

Page 155: ...ED PROOF OF CLOSURE VALVE BODY 2 82585261 MOTORIZED PROOF OF CLOSURE VALVE BODY 2 5 82585361 MOTORIZED VALVE BODY 1 82580171 MOTORIZED VALVE BODY 1 25 82580181 MOTORIZED VALVE BODY 1 5 82580191 MOTORIZED VALVE BODY 2 82580201 MOTORIZED VALVE BODY 2 5 82580211 MOTORIZED VALVE BODY 3 82580221 PILOT REGULATOR 325 3 X 3 8 14036300 MAIN REGULATOR LESS THAN 1 MBH x 1 82600030 MANUAL SHUT OFF VALVE 3 8 8...

Page 156: ...UAL 150 of 198 HIGH GAS PRESSURE SWITCH 83100070 IGNITION CABLE PER FOOT 81400400 IGNITION CABLE BOOT 81150420 IGNITION CABLE SNAP FITTING 81150440 FIREYE ULTRA VIOLET SCANNER 83500022 HONEYWELL ULTRA VIOLET SCANNER 15159701 PILOT OFF TIMER 14197700 ...

Page 157: ... FUSE FOR M4RT1 CHASSIS 14204902 Description Part Number Rotary 63 1 AMPS 14320505 Rotary 1 1 6 AMPS 14320506 Rotary 1 6 2 5 AMPS 14320507 Rotary 2 5 4 AMPS 14320508 Rotary 4 6 3 AMPS 14320510 Rotary 6 10 AMPS 14320514 Rotary 9 14 AMPS 14320516 Rotary 13 18 AMPS 14320520 Rotary 17 23 AMPS 14320521 Rotary 20 25 AMPS 14320522 Rotary 24 32 AMPS 14320532 Toggle 63 1 AMPS 14320205 Toggle 1 1 6 AMPS 143...

Page 158: ...20818 95 120 AMPS 14320819 110 140 AMPS 14320820 Description Part Number ROOM OVER RIDE THERMOSTAT OPTIONAL 83200052 NIGHT THERMOSTAT OPTIONAL 83200052 BURNER ON OFF OUTDOOR THERMOSTAT OPTIONAL 83200002 BURNER ON OFF OUTDOOR THERMOSTAT OPTIONAL 83200001 DISCHARGE SERIES 14 55 90 DEGREE 10948400 AMPLIFIER SERIES 14 10938310 DISCHARGE SENSOR SERIES 14 83200140 ROOM CONTROL SERIES 44 55 90 DEGREE 110...

Page 159: ...perator Yellow 14178306 Pushbutton Switch 22 5mm Operator Green 14178307 Pushbutton Switch 22 5mm Operator Red 14178308 Pushbutton Switch 22 5mm Operator Red Mushroom Head 14178309 Selector Switch 22 5mm 3 Position Center Off 14135700 Selector Switch 22 5mm 2 Position 14135800 Contact Block 22 5mm Normally Open 14132601 Contact Block 22 5mm Normally Closed 14132602 Process Electro Mechanical Timer...

Page 160: ... Poly Flat Panel 20 x 20 14074201 3 16 x 20 14074203 3 Optional Fresh Air Hood Mounted Permanent 2 x 16 x 25 82400150 2 2 x 20 x 25 82400170 2 TT118 Permanent 2 x 20 x 25 82400170 6 Disposable 2 x 20 x 25 82400080 6 30 Pleated 2 x 20 x 25 82402860 6 30 Poly Flat Panel 20 x 25 14074202 6 TT212 Permanent 2 x 20 x 20 82400160 9 Disposable 2 x 20 x 20 82400070 9 30 Pleated 2 x 20 x 20 82402870 9 30 Po...

Page 161: ...l Description Size in Part Number Quantity TT230 Permanent 2 x 20 x 20 82400160 6 2 x 20 x 25 82400170 30 Disposable 2 x 20 x 20 82400070 6 2 x 20 x 25 82400080 30 30 Pleated 2 x 20 x 20 82402870 6 2 x 20 x 25 82402860 30 30 Poly Flat Panel 20 x 20 14074201 6 20 x 25 14074202 30 TT233 Permanent 2 x 20 x 20 82400160 56 Disposable 2 x 20 x 20 82400070 56 30 Pleated 2 x 20 x 20 82402870 56 30 Poly Fl...

Page 162: ...esult in death electrical shock or injury Falling Hazard Use proper safety equipment and practices to avoid falling Do not use any part of equipment as support WARNING Failure to follow these instructions can result in death injury or property damage Burn Hazard Allow equipment to cool before service Internal compo nents of equipment may still be hot after operation Explosion Hazard Turn off gas s...

Page 163: ...owered by a single phase motor refer to the motor rating plate for reversing instructions 27 2 Supply Fan PROBLEM POSSIBLE CAUSE SOLUTION Blower motor does not run Damper limit switch not closed or inoperative Repair or replace switch Motor thermal over loads tripped For tripped condition reset Fuses blown or missing Replace External power source lacking Have incoming power lines checked Motor ino...

Page 164: ...et dial higher Replace stat High gas pressure switch Manual reset Verify gas pressure Optional Low gas pressure switch Manual reset Verify gas pressure Flame control defect Replace Burner Lockout Failure to ignite pilot or main flame Flame control failure Reset the flame control module at the unit and proceed to the next step observing the unit to indicate at which step lockout condition occures N...

Page 165: ...inals Set the temperature to the minimum dial setting The DC voltage should read 0 volts The DC voltage should gradually increase to at least 20 volts as you slowly rotate the dial to the maximum dial set ting If these voltages are obtained the valve function can now be checked out 2 The operation of the Valve with regard to volt age is as follows from 0 volts to approximately 5 volts the modulati...

Page 166: ...ation stabilizing the flame DO NOT adjust unless necessary because decreasing the sensitivity will increase the temperature DROOP of the system 27 5 3 Series 14 Temperature Calibration NOTE The components of this system are individually calibrated and are not part of a matched set It is necessary to place an accurate temperature measuring device as near the discharge air sensor as possible Set the...

Page 167: ...SECTION27 TROUBLESHOOTING 161 of 198 ...

Page 168: ...g 11 Open circuit in TS114 TS10765 Discharge or Inlet Air Sensor Circuit or wiring 12 Jumper not connected across amplifier terminals 2 and 3 F Continuous High Fire electronics ok 13 Foreign object holding valve open 14 Plunger jammed G Incorrect Maximum Fire 15 Inlet pressure too low 16 Incorrect outlet pressure adjustment of Pressure Regulator H Erratic or Pulsating Flame 17 Hunting 18 Erratic a...

Page 169: ...ure drop of the valve see Maxitrol capacity chart 16 Read manifold pressure using manometer and compare with recommen dation of equipment manufacturer 15 Increase inlet pressure if possible 16 See valve adjustments in Section 19 5 17 Adjust sensitivity control counter clockwise 18 Connect test resistor as described in Preliminary Circuit Analysis in Maxitrol product information sheet Turn TD114 se...

Page 170: ...ugh full range NOTE From 0 5 volts heater should be at by pass or low 5 15 volts heater should respond with various input rates beyond 15 volts heater is at maximum input If proper operation is observed continue procedure to check operation of sensing and selecting components If proper operation is not observed see Field Service Checklist to test M or MR valves and connecting wiring 13 With proper...

Page 171: ...ature 1 Install a thermometer or other temperature measuring device at a point adjacent to the tip of the Discharge Air Monitor 2 Disconnect wires from terminals 4 5 Con nect 12K resistor across terminals 4 5 3 Turn the calibrating potentiometer B until the reading of the thermometer adjacent to the Discharge Air Monitor agrees with the maxi mum setting of the Discharge Air Temperature Selector Cl...

Page 172: ...r Temperature 14 Improper TS144 location 15 Incorrect discharge air temperature calibrations G Continuous High Fire electronics ok 16 Foreign material holding valve open 17 Plunger jammed H Continuous High Fire electronics problem 18 Open circuit in TS144 I Incorrect High Fire 19 Inlet pressure too low 20 Incorrect outlet pressure adjustment J Continuous Maximum Discharge Air Temperature 21 Faulty...

Page 173: ...ge air temperature 15 Follow procedures outlined in PRELIMINARY CIRCUIT ANALY SIS Sections IV in Maxitrol product information sheet 14 Move TS144 to location where average temperature can be sensed 15 If proper temperatures are not observed refer to temperature calibration procedures in Maxitrol product information sheet 16 Remove button Plate and inspect valve and seat 17 Inspect plunger should b...

Page 174: ...erature Table 43 Resistance Temperature Table Approximate controller display temperature with 1100 to 1800 ohms resistance across terminals amplifier 8 and 9 amplifier selector 1 and 2 27 7 1 Series 94 Temperature Calibration Occasionally the set point that is indicated on the dial does not match the LED display This is usually a indication that calibration is required To calibrate the set point c...

Page 175: ...SECTION27 TROUBLESHOOTING 169 of 198 ...

Page 176: ...TT SERIES INSTALLATION OPERATION AND SERVICE MANUAL 170 of 198 27 7 2 Series 94 Field Service Checklist ...

Page 177: ...SECTION27 TROUBLESHOOTING 171 of 198 ...

Page 178: ... and fast and may be turned off Ss slow Sm medium or Sf fast is displayed during the time the Soft Start is active This feature is comprehensive to all Set Points NOTE Global Setting for MP2 system Max Valve VDC This feature limits the maximum voltage applied to the modulator It has a setting range of 7 to 25 VDC This feature is comprehensive to all Set Points NOTE Global Setting for MP2 system Ma...

Page 179: ... the user by flashing a character in the lower right hand corner of the display when the desired accumulated hours for the Process have been reached It has a setting range of 1 to 999 hours The feature is useful in maintaining maintenance requirements Timer 2 Timer 2 logs the hours of operation for a Process It will log up 999 hours at which time it will automatically reset to zero The hours can b...

Page 180: ... is used to fine tune a particular application Calibration shifts the Bandwidth range up or down from the factory set mean Each application is different with variances in burners and appliances It can be necessary to change the midpoint of the modulation range to have the Process Temperature and the actual sensed temperature match For sensed temperatures consistently displaying lower than the Set ...

Page 181: ... See MP2 or MP2 Select Information Selecting READY Power up READY is displayed Requires a momentary switch closure to move the controller to the first process After last manual process of a program After momentary switch closure to move out of the last process controller defaults to the READY position After last timed process of a program expires Controller defaults to the READY position Selecting...

Page 182: ...999 hrs Timer 2 View Hours Clear Hours Diagnostic Menu Max Proc Temp Max Temp Process 1 8 60 F 15 C to 240 F 115 C Min Proc Temp 60 F 15 C to 240 F 115 C Calibration Calibration Process 1 8 10 F 5 6 C to 10 F 5 6 C Monitor On Off Looping Mode Ready First Process F C Mode Software Version Buttons Description Press once to initially enter programming mode Press once during programming to return to t...

Page 183: ...ross the 8 terminals Press and release once to switch to the next Process or to move the controller from the READY position to the First Process Press twice or hold for 10 seconds to abort a timed process Display Description STORED Will appear on the screen to confirm entry accepted T Indicates a timed process M Indicates a manual process Controller in hte READY position 0 VDC Controller operating...

Page 184: ...ocess Operation and Diagnostics Menus Press once Table 47 Process Menu Programming Table 48 Operation Menu programming Controller in the READY position 0 VDC Controller operating in any of the 8 processes making up a Program 24 VDC 2W max 1 Scroll to the Processes Menu press Process Temperatures 2 Scroll to Temperatures press 3 Temp Set Point Process scroll to Set Point press 4 Set Point Temp Proc...

Page 185: ...ing press 3 Ramping Process scroll to Set Points press 4 Ramping Process set Ramp Rate Off 60 to 900 Deg Hr press 5 Stored will flash 4 times to confirm entry 6 Repeat steps 2 5 for Set Points 92 8 Timers TM02 required 2 Scroll to Timers press 3 Timer Process scroll to Set Point press 4 Timer Process scroll to Timer 1 or Timer 2 press 5 Timer 1 T1 Proce scroll to View Hours Clear Hours or Set Alar...

Page 186: ... Min Proc Temp press 3 Min Proc Temp set Temp value 60 F 15 C to 240 F 115 C press 4 Stored will flash 4 times to confirm entry Calibration 2 Scroll to Calibration press 3 calibration Process scroll to Set Point press 4 Cal Proc set Temp value 10 F 5 6 C to 10 F 5 6 C press 5 Stored will flash 4 times to confirm entry 6 Repeat steps 2 5 for Set Points 2 8 Monitor 2 Scroll to Monitor press 3 Monito...

Page 187: ...med Process will remain in the Process indefinitely until Button 1 is pushed and released or TB1 is momentarily latched Pushing and releasing Button 1 or the momentary latching of the TB1 will cause the MP2 System to proceed to the next Process If the last Process of a program is untimed pushing and releasing Button 1 or the momentary latch ing of TB1 will cause the MP2 system to proceed to the se...

Page 188: ...mproperly installed 1 Install with arrow on valve pointing in direction of gas flow B Continuous low fire electronic problem 1 Short circuit or no voltage to the amplifier 1 Prove the power source by checking for 24V AC at amplifier 2 Open circuit in TS194 Q Dis charge Air Sensor or wiring 2 Check TS194 Q for open circuit See Temperature Sensor Function of Pre liminary Circuit Analysis 3 Faulty MP...

Page 189: ...late and inspect valve and seat 2 Plunger jammed 2 Inspect Plunger should be smooth clean and operate freely in solenoid sleeve Clean or replace plunger if nec essary Do not use lubricants of any type G Incorrect high fire 1 Inlet pressure too low 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 s...

Page 190: ...ve DC voltage across modulator terminals If erratic or unstable DC voltages are obtained the MP2 may be faulty Replace If erratic operation continues after replacement consult Maxitrol Company I Incorrect discharge air temperature 1 Incorrect wiring 1 Check wiring diagrams in MP2 Installation Guide and correct if neces sary 2 System out of calibration 2 If sensed temperature thermometer next to TS...

Page 191: ... cable type is correct Replace with correct cable if necessary 4 Loss of program 4 Perform remedy for possible cause 1 and 3 above If Ready remains replace or consult Maxitrol Company M Control resets 1 Momentary switch wiring is run next to high voltage switching cir cuits causing induced voltages 1 Temporarily wire momentary switch externally or disconnect external momentary switch wiring and us...

Page 192: ...o M Service Guide Page 1 LOCKOUT MESSAGE OP CTRL INTRLCK PTFI FLAME LINE FREQUENCY NOISE FLAME FAIL PTF1 FAULT UNKNOWN AMPLIFIER COUNT FAIL FLAME FAIL MTFI FALSE FLAME IDLE INTRLCK OPEN INTRLCK CLOSED CHASSIS OPTO FLAME FAIL AUTO CHECK CHASSIS CHECK PROGRAMMER CHECK AMPLIFIER AMPLIFIER AUTO CHECK CHECK BLOWN FUSE CHECK SCANNER ...

Page 193: ...t the 120 volt AC supply has its neutral leg earth grounded at the supply floating isolation transformers can cause prob lems 5 Confirm that the ignition transformer s secondary winding is solidly earth grounded The grounding method is usually through the transformer case Dirt paint loose mounting hardware etc can all be factors 6 There may be a problem with transients in the main power supply If ...

Page 194: ...e connections 2 Reset and sequence the Relay Module 3 Check the 7800 power supply and make sure that frequency and voltage meet specifications 4 Check the backup power supply as appropriate Code 1 2 AC Quality Problem Excessive noise or device running on slow fast or AC line dropout detected Code 2 1 Unexpected Flame Signal Flame sensed when no flame is expected during STANDBY or PURGE 1 Check tha...

Page 195: ...ted properly 2 Inspect the purge card and the connector on the relay module for any damage or contami nants 3 Reset and sequence the relay module 4 If the fault code reappears replace the purge card 5 Reset and sequence the relay module 6 If the fault code persists replace the relay module Code 4 2 Wiring Problem Internal Fault Pilot ignition valve terminal main valve ignition or Main Valve 2 was ...

Page 196: ...al Faults Relay Module Self Test failure 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 check for electrical noise being copied into the relay module through the external loads or possibly an electrical grounding issue 4 If the fault persists replace the rela...

Page 197: ...are correct Place a check next to line items completed or enter data WEATHER RITE TT SERIES START UP Check all nuts bolts and fasteners to ensure they are tight Check all door seals and latches Confirm the latches are adjusted for proper tension Check sheaves setscrews and bearing collars Make sure they are tight Check lifting brackets to make sure they are tight and secure before lifing air handl...

Page 198: ...TT SERIES INSTALLATION OPERATION AND SERVICE MANUAL 192 of 198 ...

Page 199: ...ions 21 4 2 1 and 21 5 Open main shut off valve visually inspect the burner to make sure it is not over firing SERIES 14 and SERIES 44 To set up the high fire see Sections 21 4 2 1 and 21 5 SERIES 94 and SERIES MP2 To set up the high fire see Sections 21 4 2 2 and 21 5 Turn the airflow adjustment screw clockwise until the burner circuit shuts off for the supply airflow switch opposite for the volu...

Page 200: ... Customer Signature Operation of the balancing gauge to maintain positive pressure Location and operation of safety disconnect switch Use lockout tag out procedures The above start Up checklist has been completely and accurately filled out and reviewed with the customer Name and position of individuals trained Name Position Documentation The customer has a copy of the operations and maintenance ma...

Page 201: ...al maintenance history The data plate and or serial number are removed defaced modified or altered in any way The ownership of the WEATHER RITE TT Series is moved or transferred This warranty is non transferable Weather Rite LLC is not permitted to inspect the damaged equipment and or component parts READ YOUR INSTALLATION OPERATION AND SERVICE MANUAL If you have questions about your equipment con...

Page 202: ...TT SERIES INSTALLATION OPERATION AND SERVICE MANUAL 196 of 198 ...

Page 203: ...SECTION 28 THE WEATHER RITE TT SERIES WARRANTY 197 of 198 ...

Page 204: ...TT SERIES INSTALLATION OPERATION AND SERVICE MANUAL 198 of 198 ...

Page 205: ...nce and safety Weather Rite LLC recommends that a qualified contractor conduct at a minimum annual inspections of your WEATHER RITE equipment and perform service where necessary using only replacement parts sold and supplied by Weather Rite LLC Air handlers are approved for installation up to 2000 610 m For installations at elevations above 2000 610 m consult factory Further Information Application...

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