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SECTION VIII - MAINTENANCE SCHEDULE AND LUBRICATION REQUIREMENTS

5. Quarterly

a. Complete the monthly maintenance schedule.
b. Inspect all drives for proper belt tension and wear.
c. Check the alignment of the sheaves and adjust if

necessary.

d. Inspect all bearings set screws for tightness and lubri-

cate bearings if necessary.

e. Check the

ame and spark rod wiring and connections.

f. Check the

ame and spark rods. Replace if necessary.

g. Inspect the burner carefully. Clean and adjust if nec-

essary.

h. Check voltages and amp draw on main fan motor.
i. Check the operation of all safety controls individually.
j. Check the operation of the automatic gas shut off

valves and check them for leakage at the pressure
test ports provided.

k. On vertical units inspect burner clean out and drain if

necessary.

6. Off Season or Yearly

a. Complete the monthly and quarterly maintenance

schedule.

b. Inspect all fan wheels and housings. Clean if necessary.
c. Check that all fan wheels, sheaves, and couplings are

securely set on the shaft.

d. Inspect all bearings and alignment. Adjust if necessary.
e. Inspect all V-belts, sheaves, and coupling inserts.

Replace if necessary.

f. Inspect all electrical components, connections and

terminals. Clean and tighten where necessary.

g. Test ignition spark. Adjust gap if necessary.
h. Clean ignition electrodes and check for cracks.
i. Test

ame safeguard relay and replace components if

necessary.

j. Inspect all regulators, relief valves, motorized valves,

solenoid valves, vent valves, manual shut off valves
and safety shut off valves. Check their operation and
clean as necessary.

k. Ensure all vents to the atmosphere are clean and free

from obstruction.

l. Inspect and clean all drip legs in the fuel line.
m. Lubricate fan motor as directed by motor manufac-

turer.

n. Inspect fan motor wiring for loose connections.
o. Lightly oil all door latches.
p. Check that cabinet is weathertight, replace door gas-

kets and recaulk as necessary.

q. Check all nuts and bolts for tightness.

NOTE: Keep screened air intakes clear of obstruc-
tions at all times.

WARNING: Failure to comply with the general
safety information may result in extensive
property damage, severe personal injury or
death.

Periodic maintenance is essential to the ef

cient

operation and extended service life of this equipment.
Failure to provide maintenance as recommended may
void the equipment warranty.

A. Maintenance Schedule

1. Daily

a. Check gauges, monitors, instruments and equipment

settings.

2. After 8 hours of operation

a. Check that fan belts are tight and sheaves are

aligned. The fan belts can be checked every 30 days
after the

rst 60 days of new belt run-in. CAUTION:

Do not overtighten belts.

b. Check set screws and bolts on the fan, bearings,

couplings, and burner assembly.

c. Check gas pressure at regulator.

3. After 48 hours of operation, check bearings for any
unusual vibration or excessive temperature.
4. Monthly

a. Check all valves, piping and connections for leaks.
b. Check the

ame signal and safety lockout (RE-02).

c. Check the fuel pressure in the fuel supply line to each

heater.

d. Check the burner manifold pressure at full

and low

re. At low

re setting, be sure there

is a continuous

ame along the entire burner

length without any blowout spots.
e. Clean the

ame sensor.

f. Inspect

lters. Clean or replace as necessary.

g. Inspect the main fan bearings, lubricate if necessary.

See Section VIII on bearing maintenance.

h. Check all dampers, damper actuators and linkages.

Adjust and tighten if necessary.

i. Ensure that there are no obstruction blocking the

air supply to the heater or the air discharge from the
heater.

j. Inspect the area and make sure that no combustible

or hazardous material has been stored within the
clearances as shown on the unit nameplate.

k. Check and clear all air sensing tubes and

ttings. CAUTION: Remove tubes from switches,

transducers, and

ow station before using

compressed air to blow through tubing.
l. Test ignition spark. There should be a

continuous spark for 10 seconds with last gas
cock turned off.

Содержание WDF

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

Страница 2: ...on company when the claim is filed They will give you disposition instructions Packing We comply with the packing requirements of the transportation companies and your bill of lading proved that everything was in good condition when shipped That bill of lading contract requires them to deliver in perfect condition SECTION I FOREWARD As is the case with any fine piece of equipment care must be take...

Страница 3: ... and critical components Rotate the fan s monthly Prior to beginning installation of a unit that has been in storage for weeks or months the unit and its compo nents should be closely inspected Shipments are made F O B Dallas Texas by flat bed truck The unit is securely strapped tied and blocked to prevent shipping damage All shipments are checked by an inspector before they are accepted by the ca...

Страница 4: ...writers National Electrical Code and local governing bodies The following recommendations are not intended to supplant any requirements of federal state or local codes having jurisdiction Authorities having jurisdiction should be consulted before instal lations are made Local codes may require additional safety controls and or interlocks All installations in airplane hangers must be in ac cordance...

Страница 5: ...g and positioning will assure a water tight curb unit installation Re check approval prints prior to installation Be sure that there are no obstructions to ducting and that proper planning has been exercised in connection of piping and or electrical services The curb assembly may be bolted or welded to either trusses or roof decking however connection to roof trusses is recommended The curb is des...

Страница 6: ...les prévus pour résister à une chaleur d au moins 105 C F Field Piping Gas Piping All gas piping must be in accordance with the require ments outlined in the National Fuel Gas Code ANSI Z223 1 It is required that a ground union be installed adjacent to the manifold for easy servicing A drip leg and or filter should be provided upstream of the unit s inlet gas connection An additional shut off must...

Страница 7: ...voltage drop Check the VA rating of control circuit transformer to determine maximum load 3 Mount and wire remote control panel thermostats temperature sensors and any other field installed controls as indicated on the unit control wiring diagram 4 Connect all wires to the appropriate field wiring terminals and any shielded or twisted wires as indicated on the unit control diagram 5 Field wiring s...

Страница 8: ...m duct work is installed and free from obstructions 11 Check that fans turn free in housing 12 Check that the area around the unit is clear of flammable vapors or containers of flammable liquids 13 Check that all piping connections particularly unions are tight Check all gas piping for leaks using a soap bubble solution The most common types of problems found relative to the gas train itself is fo...

Страница 9: ...will enable the fans To also enable the fans go to Unit Modes and enter AUTO this mode has four different functions that control the fans and unit operation They are a Time Clock Heating and Cooling Night Setbacks and signal from an external source to an auxiliary digital input To disable the fans go to Unit Modes and enter OFF NOTE A BACview or PC is required to change Unit Modes For a more detai...

Страница 10: ...ire for approximately 10 seconds before modulating up The reading should be at least 0 5 microamps If the read ing is too low slowly turn the low fire adjustment on the modulating valve in or out until satisfactory readings are obtained When adjusting low fire there should be a continuous flame along the entire burner length without any blowout spots Install manometer at test port on the last tee ...

Страница 11: ...s to a lower temperature setting while the unit is operating on high fire and observing cutoff The controls should be reset to settings shown below Make sure all the safeties and controls are working properly Suggested Control Settings Refer to Digital Control System user manual for default settings TS 02 Space Temperature Sensor Customer Discretion KP 01 Keypad Display Module Customer Discretion ...

Страница 12: ...e is sensed during a purge period when no flame should be present the control will remain in purge with the gas valve off until the false flame disappears If the gas valve is found to be powered when it should be off or not powered when it should be on the ignition control will enter lockout with all outputs off Reset is accomplished by cycling the power off for a minimum of 5 seconds The Red LED ...

Страница 13: ...gnition control 1 Check power source 2 Check and replace 3 Close or connect customer interlock 4 Enable the fan 5 Check time clock night setback thermostat and field installed controls for proper settings 6 Reset freeze stat by interrupting power Check for proper setting and burner operation 7 Check for power at damper motor and that end switch has been wired correctly to the N O normally open con...

Страница 14: ...lenoids 5 Type of gas natural LP supplied different from factory required type Note components may change 6 Flame detection system not sparking or sensing flame see spark rod diagram P 001117 7 No voltage output terminals of ignition control 8 Main gas valve relay open 1 For DDC System 2 For RTC RE 26 1 Defective or misadjusted transducer PT 15 2 Transducer PT 15 wired incorrectly 3 Transducer PT ...

Страница 15: ...1 signal conditioner provides signal conversion for a high impedance 2 10VDC signal source to drive a 24VDC solenoid The control should be powered by an isolated 24VAC transformer to drive up to a 5A dc solenoid Power Status LED A solid green LED indicates power and normal operation A slow blinking green LED indicates power but the 10 second start up delay has not completed A fast blinking green L...

Страница 16: ...fier RE 26 terminals 7 8 2 Inspect 3 Check item B1 Check for 2 10 VDC input signal from UC 01 at terminals 1 2 Check for 0 20 VDC output signal to gas valve at terminals 5 6 4 Check DC Voltage on AO 1 1 Measure resistance across modulator terminals with connecting wires detached 2 Inspect Plunger should be installed to operate freely in solenoid sleeve 1 See valve adjustments in Section X 2 Close ...

Страница 17: ...plus pressure drop of the valve 2 Read manifold pressure using manometer and compare with the pressure stated on the specification plate 1 Check setpoint on Unit Enable Potentiometer MP 15 2 Check Discharge Air Temperature Sensor TS 03 and wiring See Thermistor curve 3 Check setpoint with BACview or PC 1 Measure resistance across modulator terminals with red lead wires disconnected 2 Inspect wirin...

Страница 18: ...of valve should point in direction of gas flow 1 Remove wires connected to amplifier terminals and measure resistance MR212 60 80 ohms M611 45 55 ohms 2 Inspect plunger should be installed to operate freely in solenoid sleeve 3 Disassemble valve for inspection of internal parts 1 Check for 24V AC at amplifier RE 26 terminals 7 8 2 Inspect 3 Check item B1 Check for 2 10 VDC input signal from UC 01 ...

Страница 19: ...t 1 Open circuit in Space Temperature Sensor TS 02 or Discharge Air Temperature Sensor TS 03 1 Short in modulator coil circuit 2 Short circuit between amplifier and modulator valve 1 Incorrect Maximum Heating Discharge Temperature Setpoint 2 Incorrect Minimum Heating Discharge Temperature Setpoint 3 Incorrect space setpoint 4 Insufficient burner capacity G Continuous High Fire Electronics OK H Con...

Страница 20: ... are energized and condensing unit or evaporative cooler is not on C Incorrect Space Temperature 1 Enable the cooling mode 2 Check auxiliary circuit wiring and contact 3 Adjust the air flow and external static pressure to match the unit rating plate DO NOT ADJUST SWITCHES 4 Change to correct setpoints See Digital Control User Manual 5 See Digital Control System User Manual 1 Check and or replace 2...

Страница 21: ...tside Air Profile Damper To calibrate the Flow Station Pressure Transducer PT 15 1 Remove the tubes at the Low and High pressure fittings 2 The voltage at COM and OUT should be O VDC If not adjust Z do not adjust S 3 Make sure the Low and High fittings are clean do not insert any sharp objects into the pressure fittings make sure the static pressure sensing pitot tubes and all tubing is also clean...

Страница 22: ...ve disconnected the sensing tubes and get the burner running in high fire Your differential pressure should have dropped If it is near the low switch trip point you need more air Some adjustments can be made by repositioning the burner profile plates If the high switch is open you can open the profile plates If the low switch is open you can close the profile plates Remember to keep the distance b...

Страница 23: ... 4 6020 1 24 RS4 7020 1 36 RS1 2 3 8060 1 47 RS2 3 9060 1 57 RS1 3 10060 1 65 RS3 11060 1 73 RS1 2 12080 1 80 RS2 13080 1 87 RS1 14080 1 92 NONE 15080 1 98 UNPLUGGED NA 3 30 IN 3 JUMPER RS 04 MIXED AIR TEMP RE 56 RS 03 SAFETY CKT STATUS RE 09 RS 02 FLAME FAILURE SW 72 RS 01 100 OA or 100 OUTPUT IN 4 RE 27 RS 04 BURNER STATUS RE 65 RS 03 FAN STATUS RE 12 RS 02 CLOGGED FILTER SW 09 RS 01 AUXILIARY U...

Страница 24: ...kets and recaulk as necessary q Check all nuts and bolts for tightness NOTE Keep screened air intakes clear of obstruc tions at all times WARNING Failure to comply with the general safety information may result in extensive property damage severe personal injury or death Periodic maintenance is essential to the efficient operation and extended service life of this equipment Failure to provide main...

Страница 25: ... rear end fan housing must be removed to expose the grease plugs 2 Pillow Block Bearings Pillow block bearings are used on supply blower s Bearings have been prelu bricated with a number 2 lithium base grease Relu brication should be done with a similar grease using a low pressure grease gun Wipe all grease fittings clean before adding grease Grease should be added slowly in small amounts at frequ...

Страница 26: ...o this end of the shaft 10 Slide the shaft through the next blower wheel hub and add another bearing Continue this procedure until the shaft is through all of the blower wheels 11 Place a bearing on each end of the shaft 12 Replace the old shims with new 13 Bolt the bearings in place and reattach the grease lines When installing a Sleevlock bearing see note at bottom of page 14 Adjust the shaft so...

Страница 27: ...blowers are used for ventilation and heating D Belt Tensions and Adjustments Belt tension is adjusted during the initial run in and test periods at the factory However the belts are run as slack as possible to prevent excessive damage to the bearings yet tight enough to prevent slippage It is necessary therefore to tighten all belts during the first few months of operation and to check for proper ...

Страница 28: ... on either side of the mixing plates should be removed with a wire brush Check visually that no holes in the mixing plates are blocked If any burner ports are plugged even partially clear them with a piece of wire See Maintenance of Gas Ports WARNING Do not enlarge burner ports or performance may be drastically affected If any mixing plates are loose or missing fasteners tighten replace as necessa...

Страница 29: ...adequate once the initial piping debris is removed The operating conditions of the burner will determine how frequently maintenance is actually required P001117 Mestek Line Burners Use of an electric drill motor is not suggested unless both Pin Vise and Drill can be chucked up in a vari speed drill unit Use caution because it is easy to snap the bits off in a port when using a drill motor Removal ...

Страница 30: ... WITH DDC MR212 High Fire Manifold Adjustments Note Low fire may need to be set first to get the burner to light off properly 1 Disconnect the plug where the Temperature Sensors TS 01 and TS 03 are wired to the unit control module UC 01 A minimum of 15vdc is required at terminals 5 and 6 on electric relay RE 26 This causes the valve to call for continuous high fire Caution The unit will shut down ...

Страница 31: ...e voltage Above approximately 15 volts DC the Valve should be delivering full flow to the heater and the unit should be on full fire If the DC voltage is obtained on the Valve terminals but the heater does not respond as described the problem can be isolated to the valve itself or to the gas control manifold of the heater If the proper voltages are not obtained the problem can be isolated to the e...

Страница 32: ...y must be ad dressed separately The heater inlet shall be located in accordance with applicable building code provisions for ventilation air Field constructed intake accessories should be prop erly designed to minimize the entry of snow and rain All ventilation air to the heater shall be ducted directly from the outdoors If in doubt regarding the application consult the heater manufacturer ETL lab...

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