Weather-Rite XT112 Installation, Operation & Service Manual Download | Manualshive

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NOT FOR RESIDENTIAL USE

CANADA: 100% OUTSIDE AIR ONLY

WARNING

Installation must be done by a contractor qualified
in the installation and service of gas-fired heating
equipment or your gas 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.

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

© 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 gas

supplier after leaving the building.

Follow the gas supplier’s

   instructions.
  8.  If you cannot reach your gas

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

™

XT-Series

Direct, Gas-Fired, Industrial

Air Handler

Installation, Operation &

Service Manual

XT112
XT115
XT118
XT125
XT130

P/N WR121100NA Re

v

F 2/17

1
2
3
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Summary of Contents for XT112

Page 1: ...321 Telephone 1 612 338 1401 Fax 1 616 784 0435 Toll Free 800 589 3691 www weather rite com 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 gas supplier after leaving the buildin...

Page 2: ......

Page 3: ...ís 800 589 3691 www weather rite com 2017 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 loc...

Page 4: ......

Page 5: ... Inlet Duct Work 35 14 2 Return Duct Work 35 14 3 Discharge Duct Work 35 SECTION 15 Gas Piping 36 15 1 Gas Manifolds 36 15 2 Gas Piping and Pressures 36 15 3 Gas Manifold Venting 36 15 4 Gas Piping 39 15 5 Pressure Test Ports 39 15 6 Line Pressure Test Leak Testing 39 SECTION 16 Electrical 40 16 1 Disconnect Fuse Sizing 41 16 2 Wiring and Electrical Connections 41 16 3 Remote Panel 41 16 4 Motor C...

Page 6: ... 2017 Weather Rite LLC Printed in the U S A ...

Page 7: ...drocarbons Recirculated 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 fresh air piece of equipment It is designed for indoor or outdoor installation with fresh outdoor air delivered to the bu...

Page 8: ... Rite LLC or your WEATHER RITE independent distributor to obtain replacement signs or labels 1 4 California Proposition 65 In accordance with California Proposition 65 require ments a warning label must be placed in a highly visible location on the outside of the equipment i e near equipment s serial plate To order additional labels please contact Weather Rite LLC or your WEATHER RITE independent ...

Page 9: ... tag on a wall near the heater e g thermostat or control system A copy of the wall tag P N 91040118 is illustrated on the back cover For an immediate solution you may affix this copy on the wall near the heater Know your model number and installed configuration Model number and installed configuration are found on the rating plate and in the Installation Operation and Service Manual 2 2 Corrosive ...

Page 10: ...nsible for supplying or arranging for the appropriate lifting equipment so that the air handler and accessories may be placed in a safe manner The qualified installer or service technician is responsible for having the appropriate equipment for the safe installation and start up of a direct fired air handler Tools required to commission the equipment include but are not limited to the following Va...

Page 11: ...ment and workstations Clearances to combustibles do not denote clearances for accessibility Minimum clearance for access is 48 122 cm Minimum clearance for accessibility applies to the control enclosure blower access panel and 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 temperatur...

Page 12: ...ended purge card of the appropriate duration to meet this requirement 3 3 Hardware Unless otherwise specified all hardware must be torqued to settings on Page 6 Table 1 Note Inlet hood opening shall not be installed with inlet opening facing into the prevailing wind direction in order to help prevent the possibility of moisture entrainment Table 1 Recommended Torque Settings Bolt Head Grade Markin...

Page 13: ...arages 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 air handler must be in accordance with ...

Page 14: ...Heat Output at Maximum Temperature Rise Btu h x 1000 Minimum Inlet Gas Pressure in wc mbar Manifold Size in NPT mm 0 0 25 0 50 0 75 1 00 0 0 50 1 00 NG LPG 1 000 1 700 XT 112 1 1 1 1 1 62 66 70 97 86 7 1 17 6 0 75 19 2 000 3 400 XT 112 2 2 2 2 2 60 66 70 194 173 7 1 17 6 0 75 19 3 000 5 100 XT 112 2 2 2 2 2 60 65 70 292 259 7 1 17 6 0 75 19 4 000 6 800 XT 112 3 3 3 3 3 62 65 70 389 345 7 1 17 6 0 ...

Page 15: ... 25 0 62 0 10 0 25 0 05 0 12 18 000 25 000 30 600 42 500 0 40 1 0 0 50 1 25 0 10 0 25 0 05 0 12 XT 130 27 500 30 000 46 772 51 000 0 35 0 87 0 75 1 87 0 10 0 25 0 05 0 12 32 500 40 000 55 200 68 000 0 40 1 0 0 85 2 12 0 10 0 25 0 05 0 12 Model Airflow Range Discharge Heads Splash Plate Inlet Discharge Damper in wc mbar in wc mbar in wc mbar in wc mbar XT 112 1 000 2 000 1 700 3 400 0 10 0 25 0 05 ...

Page 16: ...sories or packages that were shipped on the same skid inside the air handler or inside the control enclosure 3 Inspect the air handler to Verify that there is no damage as a result of shipping Ensure that it is appropriately rated for the utilities available at the installation site Verify that the lifting lugs are intact undamaged and secured to the air handler Ensure factory installed hardware i...

Page 17: ...he long axis Lift the air handler off the skid and place it on a flat clean dry surface Step 2 Remove the lifting lugs on the inlet end of the air handler and re install hardware Step 3 Use all four lifting lugs on the discharge end of the air handler to enable the air handler to be lifted into the upright position Step 4 Lift the air handler into upright position Step 5 Next refer to the applicab...

Page 18: ... 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 clearances to combustibles and clearance for access See P...

Page 19: ... perimeter of roof curb at bolted joints Top Mounting Flange Side Panel End Panel Inlet or Discharge Side panels are split Cross Brace Model Dimensions Weight Weight A B C D E lbs kg lbs kg XT 112 in 24 3 80 2 21 3 128 1 48 9 96 43 140 63 cm 61 7 203 7 58 7 325 5 121 8 XT 115 in 39 3 105 1 36 3 155 5 51 4 133 60 179 81 cm 99 8 267 0 96 8 395 1 128 1 XT 118 in 45 1 96 3 42 1 143 2 47 9 130 59 173 7...

Page 20: ...t metal screws supplied by others equally spaced on each side must be used to attach the air handler to the curb After the curb has been installed the air handler may be placed on the curb There must be a 1 8 3 cm x 2 5 1 cm neoprene closed cell adhesive back gasket supplied by others between the top of the curb and the base surface of the air handler to prevent moisture from leaking into the buil...

Page 21: ... bolt locations Place the leg on the inside of the corner and attach with the previously removed hardware Missing hardware needs to be added at each bolt location The required hardware is a 5 16 18 x 1 grade 5 bolt a 5 16 flat washer and a 5 16 18 grade 5 flange nut To attach the legs to a concrete slab the base of each leg is equipped with two 1 holes Studs capable of accepting 5 8 nuts must be i...

Page 22: ... and re install the hardware See Page 21 Figure 10 Lift the air handler on to the legs See Page 10 Section 6 1 for safe lifting practices Once the air handler is placed on the legs secure it with the provided attaching hardware recommended torque settings After placing the air handler on the legs seams between the mounting legs and the air handler must be properly caulked caulk provided by others ...

Page 23: ... the provided hardware 3 8 bolts nuts and lock washers Assemble the legs with the top upside down on a flat surface See Page 17 Figure 5 FIGURE 5 Step 1 Step 2 Attach the mounting feet to each leg using supplied hardware See Page 17 Figure 6 FIGURE 6 Step 2 ...

Page 24: ...ON OPERATION AND SERVICE MANUAL 18 Step 3 With the top frame upside down insert and attach the first two legs Note All legs are identical and not all the holes will be used on each leg See Page 18 Figure 7 FIGURE 7 Step 3 ...

Page 25: ...SECTION 9 UPRIGHT INSTALLATION 19 Step 4 Next attach the horizontal support s and repeat process for the other two remaining legs See Page 19 Figure 8 FIGURE 8 Step 4 ...

Page 26: ...TION AND SERVICE MANUAL 20 Step 5 Attach remaining support braces taking note of the support location to proper orient for your air handler s configuration See Page 20 Figure 9 FIGURE 9 Step 5 Control Side Filter Access Return Air ...

Page 27: ...azard 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 instructions can result in death injury or prop...

Page 28: ...ion Installation To install a filter section on an upright air handler that is mounted on legs the filter section must be installed in the leg assembly prior to placing the air handler See Page 16 Section 9 for proper leg mounting Place the filter section so that the outward flange is on the top side Set the filter section into the leg assembly Place foam tape supplied by others along the perimete...

Page 29: ...e missing contact your WEATHER RITE independent distributor 11 1 Inlet Hood Assembly FIGURE 12 Inlet Hood with Filter Racks 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...

Page 30: ... and mount with lag bolts provided by others The following hardware is supplied for the assembly of the inlet hoods 10 TEK self tapping screws 3 8 nuts bolts washers 3 16 rivets and foam gasket tape Step 11 2 Inlet Hoods with Filter Rack Assembly Step 11 2 1 Seal around the perimeter of the inlet of the air handler with the provided foam gasket tape Step 11 2 2 Mount the upper inlet hood right and...

Page 31: ...11 2 3 Attach the upper hood roof with the provided TEK screws along the left and right side and upper edge to the air handler Step 11 2 4 Attach the bottom filter rail for the upper inlet hood to the hood using the provided rivets ...

Page 32: ...ll be facing out with the bolts and wash ers provided and the upper edge of these sides to the lower portion of the upper hood with the TEK screws provided Step 11 2 6 Attach the bottom filter rail for the lower inlet hood and attach to the left and right side of the hood and to the air handler using the provided TEK screws ...

Page 33: ...SECTION 11 INLET HOOD 27 Step 11 2 7 Attach the lower hood roof with the provided TEK screws along the left and right side ...

Page 34: ...ided rivets Step 11 2 10 Caulk seam between air handler and inlet hood Step 11 2 11 Load filters into the inlet hood checking to see that each filter is in the proper orientation by ver ifying that the arrow on the side of the filter points in the direction of air flow All of the arrows should be point ing towards the air handler when installed in the proper orientation Once filters are installed ...

Page 35: ...ing in to the top of the inlet hood using the TEK screws provided Step 11 3 3 Attach the inlet hood to the filter section using the nuts bolts washers provided Bolt it to each corner of the filter section Use the provided TEK screws to attach the inner flanges to the right and left side of the filter section Step 11 3 4 Attach the rain gutters to both sides of the inlet hood using the provided riv...

Page 36: ...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 instructions can result in death injury or property damage ...

Page 37: ...andler covering the inlet opening The inlet damper has four outward turned flanges Based on air handler style damper may include upper and lower damper C E C D A B C C F NOTE 1 CONTRACTOR INSTALLER MUST MAKE APPROPRIATE ALLOWANCES FOR DUCT CONNECTIONS 2 NUMBER OF LOUVERS WILL VARY 3 MOUNTED DOWNSTREAM OF AIR HANDLER IN DUCT WORK DOES NOT MOUNT DIRECTLY TO AIR HANDLER FIELD WIRED TO PROVIDED TERMIN...

Page 38: ...et metal supplied by others may be required See Page 32 Figure 15 for the three way discharge head available FIGURE 15 Three Way Discharge Head 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 pr...

Page 39: ...plash plate start by threading a flanged nut onto each hanger rod Then slip each hanger rod down through a hole located in each corner of the splash plate Next feed a flanged nut onto the rod below the splash plate See Page 33 Figure 16 The hanger rods should be attached to the air handler in the same manner as the splash plate with a flanged nut on both sides of the air handler floor Adjusting th...

Page 40: ...AL 34 FIGURE 17 Mounting Hole Locations A B Blower Discharge Centerline Model A B XT 112 in 24 6 22 5 cm 62 5 57 1 XT 115 in 32 1 34 0 cm 81 5 86 4 XT 118 in 36 6 36 8 cm 93 0 93 4 XT 125 in 40 6 40 3 cm 103 1 102 3 XT 130 in 45 7 45 7 cm 116 0 116 0 ...

Page 41: ...Dh d Dh hydraulic diameter d round duct inside diameter Hydraulic duct diameter for rectangular ducts in inches Dh 2 H W H W Dh hydraulic diameter H rectangular duct inside height W rectangular duct inside width The air handler is not designed to support the weight of ductwork Ductwork must be constructed in a fashion that is self supporting Ductwork should be straight elbows should be minimal and...

Page 42: ...nt valves fitted on XL compliant manifolds must be piped to the atmosphere outside the structure and in accordance with applicable codes This is the responsibility of the installer 15 3 1 Main Gas Regulator Venting The main regulator used on 1 and larger manifolds must be piped to the atmosphere outside the structure This is the responsibility of the installer 15 3 2 Vent Line Installation The fol...

Page 43: ...anifolds Manual Gas Valve Burner Manual Gas Valve Main Combination Valve Manual Gas Valve Pilot Vent to Atmosphere FM and XL Manifold Union By Others NOTE Vent valves must be piped to the atmosphere outside the structure and in accordance with applicable codes Alternate Inlet Inlet By Others Combination Valve Manual Gas High Gas Pressure Regulator Optional Burner Modulating Valve With Pressure Reg...

Page 44: ...e Safety Shut Off Valve NOTE Vent valves must be piped to the atmosphere outside the structure and in accordance with applicable codes Alternate Inlet Inlet By Others Manual Gas High Gas Pressure Regulator Optional Valve Pilot Drip Leg Ps Modulating Valve With Pressure Regulator Manual Gas Valve Burner High Gas Pressure Switch Burner LOW GAS PRESSURE SWITCH Low Gas Pressure Switch Pilot Regulator ...

Page 45: ...the burner gas pressure during burner setup 15 5 1 Manifold Inlet Gas Pressure The pressure port for measuring manifold inlet pressure is located on the inlet side of the first safety shutoff valve Refer to the unit rating plate for the acceptable inlet gas pressure 15 5 2 Burner Gas Pressure A pressure tap is used to measure negative airflow at the burner and to set high fire gas pressure On air ...

Page 46: ...mote panel is not supplied Note Spark testing or shorting of the control wires by any means will render the transformers inoperative Each unit is equipped with a fused rotary disconnect The rotary disconnects are for copper wire only DANGER Electrical Shock Hazard Disconnect electric before service More than one disconnect switch may be required to disconnect electric from equipment Equipment must...

Page 47: ...iring between the remote panel and the air handler control enclosure is run in a single conduit the wire run can be as long as 100 30 m For longer wire runs consult the factory If the interconnection wiring between the remote panel and the air handler control enclosure is run in two conduits separating the shielded cable and the 120 V power supply for the remote panel the wire run can be as long a...

Page 48: ...oses it permits the flame safeguard relay to begin ignition This switch is factory set at 0 32 in wc 0 8 mbar The high velocity pressure switch will open if the airflow across the burner reaches its maximum allowable limit This switch is factory set at 1 40 in wc 3 5 mbar The pressure switch is a safety device which cannot be field adjusted or tampered with 16 6 3 Gas Pressure Switches Gas pressur...

Page 49: ... Page 79 Section 23 16 6 5 Discharge Temperature Sensor This device senses the discharge temperature of the air at the blower The discharge temperature sensor reports the discharge temperature to the temperature control amplifier which modulates the burner to the temperature set on the remote panel selector Should this system fail the manual high temperature limit switch will turn the burner off B...

Page 50: ...SERIES XT INSTALLATION OPERATION AND SERVICE MANUAL 44 FIGURE 25 Interconect Wiring 2 ...

Page 51: ...witch and the exhaust fan interlock If the air handler s discharge temperature falls to the predetermined low temperature limit setpoint after the 5 minute establishing period the air handler fan will be turned off If there is a failure of the exhaust fan to activate the field supplied airflow switch after the 5 minute establishing period the air handler fan will be turned off To reset the MUA exh...

Page 52: ...ariable frequency drive enclosure heater and or GFI 16 8 10 Service Receptacle Powered by Others Wired This option provides a service receptacle It includes ground fault interrupter GFI receptacle mounted on the interior or exterior of the control enclosure Power to the receptacle is supplied by the installer 16 8 11 Room Override Stat For use with Standard Discharge Control remote This option pro...

Page 53: ...into the space to satisfy the pressure setpoint Most installations require a setpoint of 0 02 in wc to 0 03 in wc to achieve adequate pressure control in the building space 5 16 diameter tubing connected to the positive pressure port of the switch must run to the inside of the building 5 16 diameter tubing connected to the negative pressure port of the switch must run to the outside of the buildin...

Page 54: ...tside air and 80 return air Constant Air Management AM Adjustable ratio of 20 outside air and 80 return air to 100 out side air and 0 return air Constant Building Pressure Controls Outside Return Air Ratio Variable Air Volume VAV 100 Outside Air Variable 50 100 Building Pressure Controls Air Volume Requirement MUA MAKE UP AIR All Models FR FIXED RETURN All Models VAV VARIABLE AIR VOLUME All Models...

Page 55: ... blower and burner operate continuously to provide heated air When the air handler is operating air is being discharged at the setpoint on the discharge temperature selection dial The burner flame modulates to maintain a constant discharge air temperature as selected on the temperature selection dial The unit disregards the thermostat setpoint while in this mode ON SUMMER Mode Only the blower oper...

Page 56: ...and varies the discharge air temperature to maintain the space temperature ON SUMMER Mode Only the blower operates continuously to provide unheated air The burner remains off regardless of temperatures on the temperature selection dial and thermostat FAN ON indicator Indicates that the air handler is supplying power to the blower motor via the M1 motor starter BURNER ON indicator Indicates that th...

Page 57: ...the safety shutoff is opened 115 VAC is applied to the Burner On light and T3 transformer the secondary side supplies 24 VAC to the temperature control amplifier The temperature control amplifier controls the modulating valve based on the discharge temperature monitor and also the room temperature monitor in the case of a DTC remote panel 17 3 1 Flame Control The flame control is a safety device a...

Page 58: ...D is illuminated When the flame sensor detects a pilot flame the signal is sent back to the safeguard control The electronic 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 sh...

Page 59: ... Purge timing Pilot Trial for Ignition PTFI timing and recycle or non recycle operation See Page 53 Figure 28 Purge Timing Jumpers JP1 through JP5 are used to select the purge timing for the M4RT1 The available purge timing selections are 5 7 30 60 and 240 seconds and any additive combination of those times Selecting two or more purge timing jumpers will result in a purge time period equal to the ...

Page 60: ...contact that powers up terminal 3 and terminal 4 in the safeguard control Terminal 3 powers up the equipment s pilot gas solenoid valve which opens allowing gas to flow Terminal 4 powers up the ignition module creating the spark at the burner This lasts for 10 seconds This cycle is called trial for ignition During this time period the PTFI LED is illuminated When the flame sensor detects a pilot f...

Page 61: ...or 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 pressure test gas piping with equipment conn...

Page 62: ...e 29 FIGURE 30 Spark Rod Dimensions 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 an orifice if this is the case then the pressure for LP is 2 0 w c Ignition w...

Page 63: ... not recessed more than 1 8 At this setting the flame rod will be enveloped by the pilot or main flame It will be glowing bright red along at least 50 of its length See Page 56 Figure 30 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 ...

Page 64: ...re 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 electrical s...

Page 65: ... space served by the Process Heater that can be used by personnel to enter the space must have door interlock switch or switches to shut down the Process Heater if in the bake cycle 2 On recirculation Process Heaters the return air duct from the served space must have filters installed to prevent particulate matter from entering the heater If not supplied by the Pro cess Heater then the installer ...

Page 66: ... the recirculation air is properly diluted during the bake cycle mode This is accomplished by ensuring the bypass feature of the ventilating air damper is not blocked by the installation or that the minimum position control of the ventilating air damper is functioning properly 19 3 Installer s Responsibility for Process Heaters Connected to Paint Booths 1 If the exhaust control system is not suppl...

Page 67: ...ns 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 proper safety ...

Page 68: ...s recommendations The normally closed contacts of this sensor must be wired in as per the CO2 interlock diagram maintaining the room concentration of CO2 below 5 000 ppm Select the CO2 interlock diagram based on air handler configuration and model See Page 43 Figure 24 With the AM and VAV package a temperature rise limiting resistor comes prewired When the air handler goes into full recirculation ...

Page 69: ...re all variable frequency drive VFD programming parameters with specifications provided on electrical drawing 20 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 flow problem incorrect blower rotation duct restrictions etc 20 4 1 Differential ...

Page 70: ...eading tem porarily leave the manometer attached to the 1 8 tap It will be used later to check high fire gas pressure 20 5 Gas Piping and Initial Pressure Settings 1 Perform a pressure test on all gas supply lines to the air handler per applicable codes Make sure to isolate all gas controls before pressure testing the system 2 Verify supply pressure does not exceed maxi mum rated gas pressure as s...

Page 71: ...e the control enclosure may need adjustment until recirculation temperature rise is obtained Return unit to normal operating conditions Reconnect any wires that were removed for adjustment 7 Maximum discharge temperature is 160 F 71 C for models approved to Z83 4 and Z83 18 see ETL Standard For models approved Z83 25 see ETL Standard the maximum discharge temperature is 200 F 93 C 8 Low fire adjus...

Page 72: ...ibration If the temperature control system should require field calibration refer to the provided temperature control amplifier product information sheet Table 18 Maximum Temperature Rise SC11 Signal Conditioner Set BMS to max fire or remove input wires from terminals 6 and 5 and connect a 9VDC battery to the signal conditioner Remove from terminal 1 on the signal conditioner Series 94 Disconnect ...

Page 73: ...ustment loosen locking screw before adjustment High Fire Adjustment Cap Modulator TOP VIEW cover removed Inlet Pressure Outlet Pressure Tap Tap Burner Pressure SIDE VIEW NOTE For high fire adjustment turn clockwise to increase manifold pressure turn counter clockwise to decrease manifold pressure ...

Page 74: ...GURE 36 M611 Valve FIGURE 37 Regulator XT 112 Low Fire Adjustment under cap Gas Inlet Gas Outlet NOTE Modulating only IN PSI 2 OFF ON Outlet Pressure Tap 1 8 NPT Inlet Pressure Tap 1 8 NPT Regulator Adjustment Below High Fire Adjustment Cap Gas Flow Gas Flow ...

Page 75: ...quipment gas piping before operation Gas can leak if piping is not installed properly Do not high pressure test gas piping with equipment connected 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 ...

Page 76: ...ck belts and adjust as required See Page 63 Section 20 2 2 Though belts were properly adjusted at the factory they will stretch after the first few hours of operation First 100 Hours of Operation Re check belt tension and adjust if necessary Annual Fall Start Up Follow entire start up procedure at this time and check control settings and operation See Page 61 Section 20 Cabinet Exterior After inst...

Page 77: ...on Blowers with spider bracket bearings are pre lubricated and do not require any re lubrication during their entire service life Blowers that use pillow block bearings should be re lubricated per the chart below The recommended lubricant is Shell Alvania 2 or S3 grease To re lubricate the blower pillow block bearings be sure that the grease fittings on the bearing housing or air handler cabinet w...

Page 78: ...ufacturer for grease capacity recommen dations as capacities vary by motor 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 greas...

Page 79: ... Page 63 Section 20 2 3 An annual inspection of the burner and components must be made to ensure proper and safe operation For the most part the burner is self cleaning However if the application is extremely dirty or dusty it may become neces sary to periodically clean the burner Inspect and clean the burner in accor dance with the following recommended procedures 1 To avoid damaging the valves d...

Page 80: ...inkages and check dampers for proper operation See Page 30 Section 12 Filters Filters should be checked for dirt restriction on a monthly basis or as required Replace filters with filters of equal specification when they appear dirty NOTE When using Weather Rite LLC supplied disposable polyester filters they must be inserted with the white media side facing the inlet of filter sec tion When using ...

Page 81: ...tices and equipment Equipment and accessories are heavy Failure to follow these instructions can result in death injury or property damage WARNING Cut Pinch Hazard Wear protective gear during installation operation and service Edges are sharp Failure to follow these instructions can result in injury Carbon Monoxide Hazard WARNING Use only genuine WEATHER RITE replacement parts per this installatio...

Page 82: ...125 XT 130 22993 Direct drive mod motor 2 10VDC 180 in lb XT 112 XT 115 XT 125 XT 130 28430 Ignition Control Module 07617 Flame Rod All models 07590 High Temperature Limit Switch 17071 Igniter All models 07640 Relay 15Amp 07165 Relay 8Amp 28560 Relay Socket 28561 DDC Controller All models 10244 Model XT 112 XT 115 XT 118 XT 125 XT 130 Manifold size 0 75 1 0 1 25 1 5 2 0 Safety shut off valve 36009...

Page 83: ...8 Starter 33810 33810 33810 33810 33810 33811 33812 33813 33814 33815 33816 33817 33818 Fuse 25128 25091 25092 25093 25094 25095 25096 25097 25099 25100 25101 25103 25106 Fuse Block 25130 25130 25130 25130 25130 25130 25130 25130 25131 25131 25131 25132 25132 230 3 60 1 1 5 2 3 5 7 5 10 15 20 25 30 40 50 Overload 28709 2878 28708 28711 28712 28713 28714 28716 28717 28718 28719 28720 28720 Starter ...

Page 84: ...713 28715 28717 28718 28719 Starter 33812 33813 33813 33815 33817 33818 33819 Fuse 25096 25097 25099 25100 25103 25108 25109 Fuse Block 25130 25130 25131 25131 25132 25906 25906 Description Part Number Description Part Number V BELT BX49 02557 V BELT BX126 04597 V BELT BX51 04448 V BELT BX128 04452 V BELT BX50 4XT 130 V BELT BX154 21290 V BELT BX53 42026 V BELT BX150 04471 V BELT BX89 04836 V BELT...

Page 85: ...ectrical 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 supply to equipmen...

Page 86: ...otor rating plate for reversing instructions 23 2 Motor and Blower PROBLEM POSSIBLE CAUSE SOLUTION Motor does not operate Main disconnect switch is OFF Turn disconnect to ON Blown fuse s in disconnect Replace fuse s Blown fuse s breaker tripped in control transformer Replace fuse s reset breaker with disconnect off Fan switch on Check wiring between remote panel and air handler Replace switch Opti...

Page 87: ...anual 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 occurs No PILOT flame No spark Check wiring from burner control...

Page 88: ...s A 1044 Amplifiers Series 44 Amplifiers are supplied on units equipped with DTC remote panels If problems persist after performing the troubleshooting procedure and the temperature control amplifier troubleshooting procedure contract the factory PROBLEM POSSIBLE CAUSE SOLUTION No main flame Manual shut off valve closed Open manual shut off valve Safety Shut Off Valve not operating Is there positi...

Page 89: ...in TS114 TS10765 Discharge or Inlet Air Sensor Circuit or wirin 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 air patterns or impr...

Page 90: ...ing plus pressure 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...

Page 91: ...4 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 amplifier 22 Open circuit in ...

Page 92: ...re 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 be smooth and cle...

Page 93: ...ts bolts and fasteners to ensure they are tight OK ____ Loose____ Specify 4 Check sheaves set screws and bearing collars Make sure they are tight OK ____ Loose ____ Specify 5 Compare voltage on unit rating plate to job site voltage Job Site Voltage ______ ____ _____ 6 Compare gas type and supply pressure on unit rating plate to job site gas supply Job Site Gas Type____ Supply Pressure_______ Explo...

Page 94: ...e setting 2 Record burner pressure with inlet manual gas valve off and blowers on ______________ in wc mbar Gas Piping and Initial Pressure Setting Page 39 Section 15 4 1 Perform a pressure test on all gas supply lines to air han dler per local codes OK _____ 2 Verify supply pressure does not exceed maximum rated gas pressure as stated on the rating plate OK_____ 3 Set the supply gas pressure at t...

Page 95: ...plate and or serial number are removed defaced modified or altered in any way The ownership of the WEATHER RITE XT 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 contact your installing professiona...

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