IOM-IFD-2 INSTALLATION, OPERATION AND MAINTENANCE MANUAL FOR THE IFD SERIES DUCT FURNACES COPY TO BE MAINTAINED IN A LEGIBLE CONDITION WITH THE DUCT FURNACE. READ THIS MANUAL CAREFULLY BEFORE INSTALLING AND OPERATING THIS FURNACE PLEASE GIVE MODEL NO. & SERIAL NO. WHEN CONTACTING THE FACTORY OR REPRESENTATIVE FOR INFORMATION AND/OR PARTS FOR YOUR SAFETY The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous.
CONTENTS 1.0 INTRODUCTION……………………………………………. 3 1.1 Notes…………………………………………………. 3 1.2 Caution………………………………………………. 3 1.3 Warranty…………………………………………….. 4 2.0 INSTALLATION………………………………………………. 5 2.1 Receiving and Storing……………………………. 5 2.2 Lifting and Handling………………………………. 5 2.3 Installation Clearances…………………………… 6 2.4 General Installation……………………………….. 7 2.5 Drains and Traps…………………………………... 7 2.6 Combustion Air Requirements………………….. 8 2.7 Exhaust Stack and Venting………………………. 8 2.8 Gas Installation…………………………………….. 9 2.
1.0 INTRODUCTION The following Owner's Manual for the Applied Air equipment outlines installation, operation and service requirements for IFD series of indirect gas fired duct furnace. The IFD series is ETL certified. Certification includes indoor models, high altitude applications, and a wide range of operational conditions. For more information on certification, please contact the Customer Service department at Applied Air Systems.
1.3 Warranty Applied Air warrants all Applied Air products to be free from defects in material or workmanship, under normal use and service, for a period of twelve (12) months from date of shipment, unless a start-up form is on file and accepted by Applied Air, in which case the warranty is twelve (12) months from date of start-up, or eighteen (18) months from date of shipment, which ever comes first. Warranty void if any of the following occur: 1.
2.0 INSTALLATION CAUTION The equipment installation shall conform with local building codes, or in the absence of local codes in accordance with the Installation Code for Gas Burning Appliances and Equipment, CAN1-B149 in Canada or Z223.1 in USA, and applicable Provincial/State Regulations; which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made.
2. NOTE: Hooks, jacks, slings, or chains must not be applied to the duct furnace casing or to any of its components. Every duct furnace is supplied with lifting lugs unless otherwise specified, use ALL lifting lugs on each duct furnace section. The lifting points must be at the center of gravity to assure that the duct furnace is level during hoisting and prior to setting. Lifting lugs are not to be used for permanently suspending the furnace. 3.
2.4 General Installation 1. It is the customer and installation personnel responsibility to determine if the duct furnace is equipped with all of the safety devices required for the particular application. Safety considerations include the accessibility of the equipment to non-service personnel, the provision of electrical lockout switches, maintenance procedures, and automatic control sequences. 2. Duct furnaces must be level.
2.6 Combustion Air Requirements 1. If the duct furnace is installed in furnace rooms, confined areas or low-leakage construction buildings, provisions must be made for combustion air. The duct furnace shall be located such that a negative pressure will not be created, which will starve the burner of combustion air. The combustion air vent piping should not be less than 24 Ga. galvanized steel, and not more than 50 feet nor less than 10 feet in length. 2.
7. The stack should be installed in such a manner that access to the appliance is not obstructed. Do not support the weight of the stack on the flue connection of the heating section. 8. Approved methods must be followed when putting the stack through walls, floors, roofs, etc. 9. Any exhaust stack shall have a minimum of at least 36" clearance to combustible material. 10.
2.9 Electrical Installation CAUTION Installations must be in accordance with the requirements of authorities having jurisdiction. Do not cut holes in the floor of outdoor model duct furnaces as the bottom of the duct furnace has been made waterproof. Wiring diagrams are included in the control cabinet of the duct furnace. The power requirements are indicated on the duct furnace rating plate. Authorities having jurisdiction should be consulted before installations are made.
3.0 OPERATING INSTRUCTIONS CAUTION Provincial and State regulations require that service mechanics must be licensed to work on combustion equipment. The duct furnace should not be started or serviced by unqualified personnel. Although many maintenance items do not require the service of a licensed mechanic, it is recommended that a licensed mechanic supervise any work done on the duct furnace by unlicensed personnel. Unqualified personnel should not be allowed to work unsupervised.
9. Set thermostat in "OFF" position and turn duct furnace control switch "ON" (manual). 10. Check all fan motors for correct rotation. nameplate wiring diagram). If incorrect, reverse rotation (see motor 11. Check the amperage draw of each motor. Refer to rating plate for Full Load Amps (FLA). If actual motor load is significantly different than rated, take corrective action. 12. Re-check voltage at duct furnace disconnect switch with the duct furnace running.
7. Frequently the cause for safety lockouts relates to gas pressures that are too high, and or combustion air dampers not set correctly. Cycle pilot several times to make sure that the combustion air and pilot gas pressure is sufficient to provide instant ignition, and a stable flame. Check to make sure the pilot flame signal is steady. Pilot regulator adjustment may be necessary if the adjustment of the needle valve does yield the required flame signal (if applicable). 8.
3.4 Shut-down Instructions EMERGENCY SHUT-DOWN • Set the disconnect switch to the "OFF" position • Close the main manual firing valve in the manifold on gas fired duct furnaces NOTE: The installer must clearly identify all emergency shut-off devices 1. De-energize the heating control, turning the burner off. 2. Close the Manual Firing Valve in the manifold on gas fired duct furnaces. 3.
3.6 Troubleshooting Refer to burner manufacturer’s IOM for additional troubleshooting information. Symptom Cause Remedy A. Burner motor does not operate. 1. 2. 3. Low or no voltage. Fuse(s) blown. Customer’s interlock not closed or connected. 4. Burner “Manual / Auto” switch in “Off” position. 5. Safety and limit circuits open. 6. Ignition control not closed. 7. Overload protection on motor or starter tripped. 8. Motor may be defective or incorrectly wired. 9. Burner relay not closed. 10.
E. If pilot does not light after prepurge has timed out and there is no voltage at flame safeguard relay output terminals. F. If there is no heat with pilot OK (if applicable) and voltage is present at flame safeguard relay output terminals. 1. See technical data sheets on flame safeguard relay. 1. Check wiring and replace if defective. 1. Manual gas shut-off valve closed. 1. 2. No gas on outlet side of regulator with proper inlet pressure. 2. 3.
3.7 Final Checks and Adjustments Detectable Carbon Monoxide (CO) With the gas input pressure established, the flue gas analysis can now be preformed. This is done at the stack. • • • • The following readings should be taken but not limited to: Fuel input too high Not enough burner air Restricted draft Flame impingement Excessive Stack Temperature CO2% Net Stack Temperature O2% Combustion Efficiency CO % • • • If necessary, make adjustments on burner air shutter. DO NOT change the fuel input rate.
4.0 MAINTENANCE If the duct furnace requires stopping to service, follow the section 3.0 on shutting the duct furnace down and starting up. 4.1 Recommended Maintenance NOTE: The following recommended maintenance schedule should be followed every 6 months unless otherwise specified below. It is highly recommended to schedule the maintenance of the equipment in the spring and fall as equipment demands are commonly most critical after these periods and serve as good prevention practice. 1.
• Inspect the flue for blockages. If excessive contamination is present, flush out the flue by removing the exhaust vent pipe and use a water hose to rinse out the contamination. Water and contaminants will wash out of the condensate drain. It may be advisable to temporarily disconnect the normal drain line to prevent a buildup of residue in the drain system when performing a flush out. • Clean the burner. • Do a flue gas analysis.
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