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Direct Gas Make-Up Air

Typical Pilot System with Combined Shut-off Valve and Regulator

This is a typical gas train. The gas train in your unit may be different.

Burner Differential

Pressure Sensor

(Airflow Switch)

Modulating

Valve

to Burner

Combination Shut-Off

Valve/Regulator

(Optional) Low Gas

Pressure Switch

Low Gas Pressure

Test Port

Gas Connection

High Gas Pressure

Test Port

Burner Manual

Shut-Off Valve

(Optional) High Gas

Pressure Switch

Pilot Line to Burner

Pre-Start: Direct Gas-Fired Heating

Gas Train Identification

Ignition Control Identification

Commercial Pilot

Typical ignition control for commercial pilot.
• A 24V Commercial Pilot System is used with

6-inch burners

• A 120V Commercial PIlot System is used with

12-inch or greater burners.

Industrial Pilot

Typical ignition control for industrial pilot.
• All Industrial Pilot Systems are 120V

Содержание XDG

Страница 1: ... wheel is critical It must be free to rotate without striking or rubbing any stationary objects 3 Motor must be securely and adequately grounded 4 Do not spin fan wheel faster than the maximum cataloged fan rpm Adjustments to fan speed significantly affects motor load If the fan RPM is changed the motor current should be checked to make sure it is not exceeding the motor nameplate amps 5 Do not al...

Страница 2: ...emperature Control Identification 26 27 High Low Gas Pressure Switches es 27 UV Scanner 27 Start Up Direct Gas Fired Heating All Units 28 29 120V Industrial Pilot System 12 inch burner 30 120V Commercial Pilot System 12 inch burner 31 24V Commercial Pilot System 6 inch burner 32 Final Checks 33 Optional Features Variable Air Volume 34 35 Recirculation Operation 36 Recirculation Arrangements 37 Sta...

Страница 3: ...on Remove any accumulations of dirt water ice or snow and wipe dry before moving to indoor storage To avoid condensation allow cold parts to reach room temperature Leave coverings loose to permit air circulation and to allow for periodic inspection The unit should be stored at least 3 in 89 mm off the floor Clearance should be provided to permit air circulation and space for inspection Outdoor The...

Страница 4: ...mendations for ease of servicing All deviations must still adhere to clearance to combustibles requirements All deviations from the service clearance recommendations are at the discretion of the end user as this may impede component removal Reference the Start Up Optional Features Other PDX Cooling Module section in this Installation Operation and Maintenance Manual for further clearance requireme...

Страница 5: ...2 5 57 22 5 57 63 160 H12 MF 16 8 17 22 8 58 55 140 31 79 28 2 72 83 211 26 1 66 32 8 83 83 211 H22 25 5 65 25 5 65 72 183 25 5 65 25 5 65 72 183 25 5 65 25 5 65 72 183 H22 MF 27 5 70 33 6 85 86 218 36 8 94 39 1 99 107 272 38 7 98 25 5 65 89 226 H32 31 5 80 31 5 80 89 226 31 5 80 31 5 80 89 226 31 5 80 31 5 80 89 226 H32 MF 32 9 84 42 107 105 267 39 8 101 46 9 119 122 310 42 1 107 31 5 80 103 261 ...

Страница 6: ...perimeter of the weatherhood to prevent water penetration and drafts into the building Indoor Unit Mounting Floor Mounted 1 Install Unit Use a crane and a set of spreader bars hooked to the factory lifting lugs to lift and locate the unit in place The use of all lifting lugs and a set of spreader bars is mandatory when lifting the unit It is recommended that any shipped loose modules be installed ...

Страница 7: ...ply Air Ductwork Arrangement DB only Sealant Ductwork Installation Outdoor Unit Mounting Complete Rooftop Installation 5 Assemble and Attach Shipped Loose Modules Using sheet metal screws assemble optional shipped loose modules Fasten the cover seams and vertical panels on each module securely Some weatherhoods may ship disassembled Detailed assembly instructions ship with the weatherhood If an op...

Страница 8: ...ion and Maintenance Manual for proper duct sizes The use of a duct adapter is recommended on a downblast DB arrangement to align the ductwork with the supply unit The duct adapter is only a guide and is not to be used as a support for the ductwork Exhaust Supply 1 inch Inside Flange Combination Extension Supply Ductwork by Others Exhaust Ductwork by Others Ductwork Installation 4 Apply Sealant App...

Страница 9: ...to the supply unit will allow for easier installation of options NFPA 96 requires the exhaust fan to be hinged Follow instructions included with the exhaust fan Installing Supply Unit Complete Combination Installation Installation Outdoor Unit Mounting 8 Assemble and Attach Shipped loose Modules Using sheet metal screws assemble optional shipped loose modules Fasten the cover seams and vertical pa...

Страница 10: ...e see page 11 Unit may be fastened to slab through lifting lugs Sans text used in the TSU IOM Lifting Lugs 4 Intake Spreader Bar 1 Slab Construction Recommended Size is 1 ft wider and longer than total unit size Recommended Material is concrete at least 4 thick Slab should be set level on a sufficient bed of gravel for proper drainage 2 Install TSU Unit Use a crane and spreader bar to prevent dama...

Страница 11: ...e base unit along the top and down both sides Fasten at the top through the cover flanges To fasten the sides the media may need to be removed To remove the media first remove the access panel on the evaporative module and disconnect the evaporative pump s The media will now slide out With the media removed you can access the side fastening points inside the evaporative cooling module With all the...

Страница 12: ...following instructions and wiring diagrams Complete wiring diagrams are attached on the inside of the control center door s All wiring must be done in accordance with the latest edition of the National Electrical Code NFPA 70 and any local codes that may apply In Canada wiring must be done in accordance with the Canadian Electrical Code The equipment must be properly grounded Any wiring running th...

Страница 13: ...h a wall mounted CO2 sensor The CO2 sensor is intended to prevent the build up of CO2 in the space It must be wired as indicated on the unit wiring diagram to command the unit to 100 outside air in the event CO2 rises above the alarm setting If a microprocessor is included with this unit reference the supplemental Microprocessor Controller for Make Up Air Reference Guide for more information Fire ...

Страница 14: ...al Microprocessor Controller for Make Up Air Reference Guide for more information Maxitrol Room Temperature Sensor Requires wiring to be run in separate conduit or run with shielded cable Room Override Thermostat Requires wiring to be run in separate conduit or run with shielded cable Unit Controller Room Temperature Sensor Requires wiring to be run in separate conduit or run with shielded cable R...

Страница 15: ...ment CGA B149 and Provincial Regulations for the class Consult authorities having jurisdiction before installations are made All piping must be clean and free of any foreign matter Foreign material entering the gas train can damage the valves regulators and burner Do not connect the unit to gas types other than what is specified and do not connect the unit to gas pressures that are outside of the ...

Страница 16: ...ter line from freezing If they cannot be installed below the roof an alternative method must be used to protect the lines from freezing CAUTION Provisions must be taken to prevent damage to the evaporative cooling section during freezing conditions The sump drain lines and supply lines must be drained prior to freezing conditions or an alternate method must be used to protect the lines and media S...

Страница 17: ...rain line to the sump overflow connection Install the 3 4 in normally open solenoid Valve C between the sump drain connection and the drain line A trap must be provided for proper unit drainage Single Pass Connect an unobstructed drain line to the sump drain and overflow connections A trap must be provided for proper unit drainage 6 in min 0 254 cm sec 6 in min 0 254 cm sec Drain Trap Optional Eva...

Страница 18: ... equalized the factory installed equalizer line can be left as is Distributor Access Panel Retainer Ring Nozzle Distributor General Installation Expansion Valve by others Liquid Line Thermal Nozzle Suction Header Coil Distributor Equalizer Line Suction Line Remote Sensing Bulb Straps Suction Connection 5 Mount the TXV Sensing Bulb by others Mount the TXV sensing bulb to the horizontal run of the s...

Страница 19: ...tem Coils are generally plumbed with the supply connection located on the bottom of the leaving air side of the coil and the return connection at the top of the entering air side of the coil This arrangement provides a counter flow heat exchanger and positive coil drainage Return Connection Cold Supply Connection Entering Air Leaving Air Guidelines for the installation of chilled water cooling coi...

Страница 20: ...his must be supplied by others 3 Setting the Desired Building Pressure The Photohelic pressure gauge is used to set the desired building pressure The pressure is set by adjusting the upper and lower pressure limits A typical positive pressure setting is 0 0 in wg 0 0 kPa for the lower and 0 10 in wg 0 02 kPa for the upper pressure setting Duct Pressure Control The optional microprocessor controlle...

Страница 21: ...et belt driven housed centrifugal fans The impeller is constructed with shallow blades that scoop the air In some instances Models VSU or TSU units use two forward curved fans with a common shaft Backward Curved Plenum Fans Backward curved plenum fans are single width single inlet fans The impellers are unhoused with blades that curve away from the direction of rotation These fans throw the air ra...

Страница 22: ...y fan must always be supplied with a Variable Frequency Drive VFD due to the direct drive arrangement on the supply fan Before proceeding further identify if this is a constant volume or Variable Air Volume VAV unit A VAV unit will have a bypass damper located adjacent to the burner Reference the Start Up Direct Gas Fired Heating Optional Features Variable Air Volume section in this Installation O...

Страница 23: ...tors can be used 4 Motor Check Measure the motor s voltage amps and RPM Compare to the specifications Motor amps can be reduced by lowering the fan RPM or increasing system static pressure Additional starters and overloads may be provided in the make up air control center for optional external exhaust fans Exhaust fan motor voltage must match unit nameplate voltage Exhaust fan overloads must be se...

Страница 24: ...ure Test Port Gas Connection High Gas Pressure Test Port Burner Manual Shut Off Valve Optional High Gas Pressure Switch Pilot Line to Burner Pre Start Direct Gas Fired Heating Gas Train Identification Ignition Control Identification Commercial Pilot Typical ignition control for commercial pilot A 24V Commercial Pilot System is used with 6 inch burners A 120V Commercial PIlot System is used with 12...

Страница 25: ...lves Regulator Airflow Typical Pilot System with Separate Modulating Valve and Regulator Typical Pilot System with Combined Modulating Regulator Burner Differential Pressure Sensor Pilot Solenoid Pilot Regulator Burner Gas Pressure Test Port Burner Manual Shut Off Valve Safety Shut Off Valves Pilot Gas Pressure Test Port Modulating Regulator Valve Airflow Optional High Gas Pressure Switch Optional...

Страница 26: ...0 F 32 C Maxitrol 44 Series Amplifier This system is used to maintain a room temperature set point when a call for heat is active There are varying versions of this amplifier but they will always include at least one shipped loose accessory Room Override Control Remote Selector Dial Room Temperature Sensor Remote Selector Dial Selectrastat Maxitrol 44 Series Maximum discharge temperature setting T...

Страница 27: ...controller If this is the case reference the supplemental Microprocessor Controller for Make Up Air Reference Guide for more information Typically the SC Series amplifier is wired to an owner supplied Building Management System which provides the signal to vary the burner firing rate Note The SC Series amplifier also limits the minimum and maximum discharge air temperatures Reference the unit spec...

Страница 28: ...ration and Maintenance Manual for the high and low pressure switch location The purpose of the high and low gas pressure switches is to automatically shut down the burner if the inlet gas pressure is too low for the burner to safely light or if the manifold pressure is too high for the burner to operate properly 3 Energize the unit control circuits field wiring shown on diagram with dashed lines E...

Страница 29: ...probes If burner baffles have been adjusted this process may need to be repeated until the proper pressure is achieved This adjustment will change the air quantity delivered by the unit and therefore the air quantity delivered should be rechecked Reference the Supply Fan Start Up section in this Installation Operation and Maintenance Manual for more information 7 Set the Low Fire Time Delay Identi...

Страница 30: ...e acceptable flame signal In some cases reducing pilot gas pressure can increase flame signal 3 Set maximum fire rating Open main hand valve and then set maximum firing rate to the design temperature rise found on the direct gas nameplate located on the outside of the unit on the control center side Send unit to high fire by removing the wire connected to terminal 3 of Maxitrol 14 or 44 Series amp...

Страница 31: ...pilot flame signal Close main hand valve Flame current must be measured with pilot valve lit but no main gas flowing Set meter to μA DC scale Locate flame signal terminals on the pilot ignition control place red lead on terminal and black lead on terminal The signal must be above 1 μA DC Adjust pilot gas pressure up or down if necessary to achieve acceptable flame signal In some cases reducing pil...

Страница 32: ...g temperature rise temperature rise discharge temperature inlet temperature adjust combo valve regulator to achieve desired temperature rise Start Up Direct Gas Fired Heating 24V Commercial Pilot System 6 inch burner 4 Set the minimum firing rate Set the minimum firing rate to achieve a small ribbon of continuous blue flame across the burner Disconnect one of the wires going to the modulating valv...

Страница 33: ... on the optional components Reference the Reference Control Center Layout section in this Installation Operation and Maintenance Manual for location of optional components Heating Inlet Air Sensor Typical setting 60 70ºF 15 56 21 11ºC Cooling Inlet Air Sensor Typical setting 75ºF 23 89ºC Building Freeze Protection Typical setting 5 minutes 35ºF 7 22ºC Dirty Filter Switch Typical setting Settings v...

Страница 34: ...start up For kitchen applications the drive may be located in the kitchen or in the unit The VAV option is recommended when a building s exhaust volume may vary This option enables the make up air volume to track the exhaust volume providing only the amount of make up air required Control strategies include 2 speed and modulating options Before the unit is left in service test the variable air vol...

Страница 35: ...ons in supply airflow and no adjustments to the burner profile are necessary Reference the Start Up Direct Gas Fired Heating All Units section in this Installation Operation and Maintenance Manual for more information about measuring burner pressure differential and adjusting burner baffles Before making any adjustments to the burner baffles on a variable air volume unit check the burner pressure ...

Страница 36: ...switch on the remote control panel to each position and confirm that the return air damper adjusts accordingly The damper actuator may take a few minutes to open or close Modulating Options Potentiometer Control A modulating spring return actuator is used to control the return air amounts The return air damper modulates from fully open to fully closed based on a signal from a remote potentiometer ...

Страница 37: ...h air is allowed to bypass the burner the burner pressure differential will be too low If too little air is allowed to bypass the burner the burner pressure differential will be too high Reference the Start Up Direct Gas Fired Heating All Units section in this Installation Operation and Maintenance Manual for more information about measuring burner pressure differential and adjusting burner baffle...

Страница 38: ...ate flow is not achieved If too much water is flowing to the media the flow can be adjusted using the manual ball valve If flow adjustments are made verify that sufficient water is still being supplied to the media to keep the entire pad wet during normal operation Excessive water flow can result in water carryover problems Insufficient water flow can result in mineral build up Bleed Off Valve Ove...

Страница 39: ... system in the module is a complete sealed unit with compressed R 410A refrigerant It consists of one or two compressors evaporator and condenser coils and all other necessary components Reference the supplemental Packaged DX Module Installation Operation and Maintenance Manual for more information Start Up Optional Features Other Dirty Filter Switch To adjust the switch the unit must be running w...

Страница 40: ...mally open and normally closed high and low gas pressure contacts PS4 and PS3 which are both closed if gas pressure is within the set range Power passes to normally open and normally closed airflow switches PS2 which are closed if there is proper airflow across the burner Power passes to terminal TH on the flame safeguard FSG Flame safeguard checks for proper airflow and completes verification of ...

Страница 41: ...ized power passes through the normally open cooling relay RC contacts and the normally open auto drain relay RA contacts to the evaporative cooling pump s P1 The evaporative cooling pump s are energized and cooling begins Drain Time Period When the run time period expires the auto drain relay RA and the auto drain valves VS VD are de energized The drain time period begins When the auto drain relay...

Страница 42: ...ly fan relay RF contacts are closed This creates a run command for the VFD The run command allows the VFD to pass power to the supply fan M1 The supply fan M1 will operate at the speed commanded by the external signal provided by others The external signal provided by others will send a 2 10 VDC or a 4 20 mA signal to the VFD analog input terminal A 2 VDC or 4mA signal will command the VFD to mini...

Страница 43: ...r limit switch DL1 closes Power passes to and energizes supply starter relay RF Power passes to normally open fan contact RF which is energized and closed Power reaches and energizes supply fan An external source will provide a 2 10 VDC or 4 20 mA signal to the recirculation damper actuator to control recirculation damper position Sequence of Operation Building Pressure Recirculation Control Power...

Страница 44: ...mperature overridden to a maximum value to provide the maximum amount of heat to the space When the call for heating from the space thermostat ends the unit will be turned off Night Setback Variable Volume Control During occupied hours the variable volume sequence of operation is the same as that described in the Optional Variable Volume section During unoccupied hours the unit is off until there ...

Страница 45: ...nded Bearing Lubrication Schedule in months Fan RPM Bearing Bore Size inches 1 2 1 11 8 11 2 15 8 17 8 115 16 23 16 27 16 3 250 6 6 6 6 6 500 6 6 6 5 4 750 6 5 4 3 3 1000 5 3 2 1 1 1250 5 3 2 1 1 1500 5 2 1 1 0 5 2000 5 1 1 0 5 0 25 Suggested initial greasing interval is based on 12 hour per day operation and 150 F 48 9ºC maximum housing temperature For continuous 24 hour operation decrease greasi...

Страница 46: ...g Air Entering Air 45º 15º Media Orientation Motors Motor maintenance is generally limited to cleaning and lubrication where applicable Limit cleaning to exterior surfaces only Removing dust and grease build up on the motor assures proper motor cooling Grease motors supplied with grease fittings in accordance with the manufacturer s recommendations Do not allow water or solvents to enter the motor...

Страница 47: ... tool Do not enlarge burner ports when clearing a blockage as performance could be affected Replace or tighten any loose or missing fasteners on the mixing plates Always use appropriate fasteners Inspect and clean the flame rod or UV scanner Occasional replacement of the flame rod and spark rod may be necessary to ensure optimum unit performance Gas Train Check the gas connections joints and valve...

Страница 48: ... amp draw and correct as necessary Damper limit switch D1L not closed Damper stuck closed or actuator failed Repair damper interference or replace actuator Exhaust fan contactor not powered Close or wire exhaust switch reset exhaust overload or replace faulty exhaust contactor 24 VAC across A2 and A1 on the supply contactor ST1 Yes No RF relay failure Check for loose connection or bent relay pins ...

Страница 49: ...t Yes No Reverse fan rotation Reference Supply Fan Start Up Filters dirty or clogged No Yes Clean or replace filters Reference Maintenance General Filters Belt slipping or broken No Yes Replace or tighten belt Reference Maintenance General V Belt Drives Fan speed too low No Yes Adjust drives as needed Reference Supply Fan Start Up section System static losses too high No Yes Reduce losses by impro...

Страница 50: ...als 104 and 101 Yes No High limit HLC1 tripped Reset replace high limit HLC1 Investigate cause of high limit trip 115 VAC between terminals 106 and 101 Yes No Optional high low gas pressure switch es PS3 and PS4 tripped Correct gas pressure and reset Reference Pre Start Direct Gas Fired Heating All Units Is alarm light blinking on the flame safeguard FSG No Yes Record the flash code from the alarm...

Страница 51: ...rr from flame rod threads touching flame rod Remove burr Flame rod or flame rod porcelain cracked or deteriorated No Yes Replace flame rod 120 VAC or more on terminal S on flame safeguard amplifier Yes No Check wiring in flame safeguard subbase Correct any wiring issues Flame safeguard FSG or flame safeguard amplifier faulty Replace flame safeguard or flame safeguard amplifier 1 25 VDC or higher o...

Страница 52: ...eset Reference Start Up Direct Gas Fired Heating 115 VAC between terminals 107 and 101 Yes No Airflow switch PS2 holding for proper airflow Correct airflow across burner Reference Pre Start Direct Gas Fired Heating All Units Green light flashing or illuminated on flame safeguard Yes No Check wiring to flame safeguard Correct any wiring issues Flame safeguard FSG faulty Replace flame safeguard 115 ...

Страница 53: ... and on flame safeguard amp Yes No Pilot pressure too low Increase pilot pressure Check wiring to flame safeguard Correct any wiring issues Flame safeguard FSG or flame safeguard amplifier faulty Replace flame safeguard With a flame signal of 1 0 micro amps or higher the green flame light should be illuminated and steady 115 VAC between terminals 110 and 101 Yes No Check wiring to flame safeguard ...

Страница 54: ... holding for proper airflow Correct airflow across burner Reference Pre Start Direct Gas Fired Heating All Units Pilot flame visible through sight glass No Yes Skip to question that reads Steady green light illuminated on flame safeguard FSG Inlet gas pressure between the minimum and maximum values shown on the direct gas label Yes No Correct the inlet gas pressure Pressure drop across the burner ...

Страница 55: ...p Yes No Pilot pressure too low Increase pilot pressure Check wiring to flame safeguard Correct any wiring Issues Flame safeguard FSG or flame safeguard amplifier faulty Replace flame safeguard With a flame signal of 1 0 micro amps or higher the green flame light should be illuminated and steady 24 VAC between terminals 37 and 21 Yes No Check wiring to flame safeguard Correct any wiring issues Fla...

Страница 56: ...ector DIP switch to Integral to allow the onboard set point to control the discharge temperature If this is set to Integral Is the Selector DIP switch set to Remote Yes No Set the Selector DIP switch to Remote to allow the remote dial to control the discharge temperature Is the LFST switch set to 10 Sec Yes No Set the LFST DIP switch to 10 Sec to allow the main portion of the burner to ignite at l...

Страница 57: ...burner to ignite at low fire Turn the remote dial to the setting that matches the ambient temperature where the dial is located Remove the wires from terminals 4 and 5 on the Maxitrol Amplifier AMP Check resistance between the two wires Is the resistance in the range of 5500 6500 ohms Yes No Remote temperature dial TS3 wired incorrectly Correct wiring Remote temperature dial TS3 faulty Replace rem...

Страница 58: ...inlet gas pressure to above the minimum input for maximum output value Modulating valve MOD stuck Tap valve gently to loosen Modulating valve MOD faulty Replace modulating valve Reconnect wires to Terminals T1 and T2 Analog input signal connected to terminals 5 and 6 Yes No Connect analog signal Is the J3 jumper set to 0V Start Yes No Set the J3 jumper to 0V Start to allow the main portion of the ...

Страница 59: ...rence Blower Start Up Fan Interlock ST1 or RF open Refer to Troubleshooting Supply Fan Line voltage at primary side of TR3 Yes No Transformer fuses FU7 blown Check and replace blown fuse s 115 VAC between terminals 102 and 101 Yes No Transformer secondary fuses FU8 blown Check and replace blown fuse s Transformer TR3 wired incorrectly Refer to wiring diagram on transformer and correct wiring Trans...

Страница 60: ...me ranges on auto drain timer set correctly Yes No Set time ranges to the values shown on the ladder diagram Auto drain timer in drain mode No Yes Wait for the drain mode timer to expire usually 10 minutes 24 VAC between terminals 8 and 61 Yes No Auto drain timer TC wiring issue Inspect and correct wiring issue Auto drain timer TC faulty Replace auto drain timer Evaporative cooling module sump fil...

Страница 61: ...it breaker If circuit breaker continues to trip inspect circuit for improper wiring or grounding Single pass transformer TR2 failed Replace cooling transformer 24 VAC between terminals 8 and 61 Yes No Cooling relay RC failure Check for loose connections or bent relay pins repair or replace relay Water flowing to media Yes No Manual ball valve closed Open and adjust ball valve Single pass valves VS...

Страница 62: ...ght when pressure drop is above field adjustable set point 14 Inlet Air Sensor optional outdoor air stat that automatically controls the heating and or cooling based on outdoor air temperature 15 Remote Temperature Selector optional allows for remote temperature set point 16 Heat Relay allows power to pass to heating controls 17 Heating Terminal Block provides wiring access to heating controls 18 ...

Страница 63: ..._ CFM kPA Optional Accessories o Heating Inlet Air Sensor _________ Actual Setting Typical setting 60º 70ºF 15 6º 21 1ºC o Cooling Inlet Air Sensor _________ Actual Setting Typical setting 75ºF 23 9ºC o Building Freeze Protection Typical setting 5 minutes 35ºF 1 7ºC o Dirty Filter Gauge _________ Actual Setting Typical setting varies Start Up Direct Gas Refer to Start Up Direct Gas Fired Heating s...

Страница 64: ...___________________ Date____________________Time______________ AM PM Notes ____________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ Date____________________Time______________ AM PM Notes _________________________...

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