Installation & Operation Guide Industrial Direct Fired Heaters Horizontal / Vertical and Single / Twin Blowers Re-Circulating Systems Static Pressure Controller – Potentiometer FOR YOUR SAFETY FOR YOUR SAFETY If You smell gas: 1. Open windows 2. Don’t touch electrical switches 3. Extinguish any open flames 4.
TABLE OF CONTENTS WARRANTY ............................................................................................................................... 4 INSTALLATION........................................................................................................................... 4 Gas ........................................................................................................................................... 11 Electrical ...........................................................
WARRANTY This equipment is warranted to be free from defects in materials and workmanship, under normal use and service, for a period of 12 months from date of shipment.
4. 5. 6. 7. 8. 9. position onto adequate supports. Refer to the manufacturer’s estimated weights. Consider general service and installation space when locating the unit. Locate the unit close to the space it will serve to reduce long, twisted duct runs. Do not allow air intake to face prevailing winds. Air flow switch may trip in high winds. Situate the unit above ground or at roof level high enough to prevent precipitation from being drawn into its inlet.
FIGURE 1: SIZE 10, 12, 15, & 18 FIGURE 2: NO SPREADER BARS FIGURE 3: WITH SPREADER BARS FIGURE 4: ACCESSORIES CAUTION!! WARNING!! These are unbalanced loads Lift equipment gently Do not jerk Spreader bars must be used and should extend past the edges of the equipment to avoid damage to the casing.
Curbs The unit must have adequate structural support or the equipment or building could be damaged. The curb and unit must be leveled or the unit may leak or be damaged. Use gasket and caulk between the curb and unit. Use shims if necessary to level the unit. Screw or weld the unit’s base to the curb to avoid damage to the equipment. WARNING!! The unit must have adequate structural support or the equipment or building could be damaged.
Split Units 1. Apply weather-proof gasket to the seam of the vertical or horizontal unit 2. Use provided fasteners to secure the seam of the unit using the provided pre-punched holes a. Horizontal units internal channels and a formed frame b. Vertical units have angles on the outside of the casing FIGURE 1: HORIZONTAL SPLIT ASSEMBLY 3. 4. 5. 6.
Shipped Loose Intake or Discharge Dampers In some cases an intake or discharge damper may be shipped loose. This may be requested by the customer or can be required because of larger units shipping size restrictions. Follow these instructions to attach and wire the shipped loose damper. Factory mounted dampers may be attached on the unit and will not require assembly or field wiring. 1. Attach the damper to the intake or discharge using gasket, caulk, and #10 sheet metal screws 2.
Ductwork Sizing Chart Single Blower Ductwork Sizing Chart Dual Blowers Blower Size Duct Size (Inches) Duct Length (Inches) Blower Size Duct Size (Inches) Duct Length (Inches) 10 14 x 14 30 222 77 x 28 66 12 16 x 16 36 225 88 x 32 75 15 20 x 20 45 227 96 x 36 81 18 24 x 24 54 230 104 x 38 90 20 26 x 26 60 233 116 x 44 99 22 30 x 30 66 236 122 x 44 108 25 32 x 32 75 27 36 x 36 81 WARNING!! 30 38 x 38 90 33 44 x 44 99 36 44 x 44 108 Failure to undersi
Gas Gas piping must be installed to conform with local building codes, or in the absence of local codes, the National Fuel Gas Code, ANSI Z223.1 (NFPA 54) – latest edition. In Canada, gas piping must be installed in accordance with CAN/CGA-B149.1 for natural gas units and CAN/CGA-B149.2 for propane units. supply piping system at test pressures equal to or less than ½ PSI, the heater must be isolated from the gas supply piping system and its individual manual shutoff valve closed. 8.
Gas Connection Diagram Electrical Before connecting power to the heater, read and understand this entire section. Wiring diagrams are furnished with each fan by the factory, and are attached to the door of the unit. WARNING!! Disconnect power before installing or servicing fan. High voltage electrical input is needed for this equipment. This work should be performed by a qualified electrician. Electrical wiring must be done in accordance with local ordinances and the National Electric Code, ANSI/NFPA70.
9. If necessary, the original wire supplied with the heater may be replaced with type TW wire or the equivalent. Remote Control Panel For units with the optional remote control panel, a terminal strip inside the panel matches the terminals in the heater unit. This diagram shows an example of the field wiring for a unit with a 401M remote panel. Consult the as built wiring print supplied with the equipment.
Re-Circulating Damper Control Options The Re-Circulating system is for controlling the amount of make-up air being brought into a building. It can be set from a minimum 20& fresh air, and 80% return air to a maximum of 100% fresh air, and 0% return air. The Re-Circulating dampers can be controlled by three different options. Manual Positioning Control (Potentiometer) The dampers can be control at a remote location by a manual potentiometer to any position from 20% to 100% fresh air.
Static Pressure Controller Installation Instructions Avoid locating the front of the static pressure controller in sun light or other areas with high ambient light or corrosive levels. Bright light shining on the photocells can cause false actuation of the load relays. The static pressure controller should be zeroed out before attaching the low and high pressure hoses. The zero adjustment is located between the minimum and maximum dials.
SEQUENCE OF OPERATIONS Description of Operation Designed for indoor or outdoor installation, the Direct Fired Gas Heaters draw fresh outside air over a gas-fired burner. The unit may be equipped to fire with natural or propane gas. Units are designed for modulated firing of the burner, based on the discharge-air temperature or room temperature requirement. Only outside air passes over the burner, with return air bypassing the burner. Sequence of Operation – 80/20 Static Pressure Controller 1.
6. When airflow switch (PS-01) is proven, the flame relay (RE-07) is energized through the hightemperature limit control (TS-04), the optional low- and high-gas pressure switches (PS-03 & PS-04), and the burner ON/OFF intake air stat (TS-06), if equipped. The pilot valve (VA-03) opens, and the ignition transformer (TR-03) energizes 7. After the flame rod (SN-02) proves flame, the main valves (VA-01 & VA-02) open, and the ignition transformer de-energizes 8.
START-UP PROCEDURE 80/20 Check for signs of damage. Do not operate if damage exists and contact your manufactures sales representative. Units are easier to fix before the equipment is installed. Check all installation clearances. Clearance from Combustibles Clearance for Serviceability Top: 6” Sides: 6” Base: 0” Unit: 24” Service Accesses: 48” Check that the unit has been set level and secured. Unit must have adequate structural support or the equipment or building may be damaged.
Turn the blower service switch ON. The (optional) intake or discharge damper motor will start to open. Once the damper is 70% open the damper motor internal end switch will close and energize the blower motor starter. Check that the motor amp draw is less than the FLA (full load amps) of the blower motor. The fan RPM may need to be reduced to decrease motor amps. Opening the driver pulley decreases RPM and motor amps. Closing the driver pulley increases RPM and motor amps.
Close the burner gas shut off valve This will allow the unit to fire the pilot only and will be opened at a later time CLOSE VALVE Set the Burner Intake On Off Switch is set above the outside air temperature SET DIAL 10 DEGREES ABOVE OUTDOOR TEMP Turn the burner service switch ON BURNER SERVICE SWITCH The Fireye Flame Safety Control energizes the ignition transformer and pilot gas valve After the pilot flame is established, the main gas valves will open At this time the pilot will be the only flame in
Setting High Fire – Discharge Temp Method Open the Burner Gas Shut Off Valve OPEN VALVE Measure the intake air temperature. Add the intake air temperature to the units nameplate design temperature rise. This result will be the desired high fire discharge temperature. Example: Intake Temp 70 F Design Temp Rise 72 F Discharge Temp 142 F GAS TYPE: NATURAL MAX. TEMP. RISE: 140 F DESIGN TEMP. RISE: 72 F MAX. DISCHARGE TEMP.: 80 F Use the Maxitrol Amplifier to override the heater into high fire.
Setting High Fire – Manifold Pressure Method GAS TYPE: NATURAL MAX. TEMP. RISE: 140 F DESIGN TEMP. RISE: 72 F MAX. DISCHARGE TEMP.: 80 F Turn the burner service switch ON Open the Burner Gas Shut Off Valve OPEN VALVE Use the Maxitrol Amplifier to override the heater into HIGH FIRE high fire.
Setting Low Fire Use the Maxitrol amplifier to override the heater into low fire.
AIR BALANCING The Direct-Fired Gas, make-up heater requires the correct air flow velocity across the burner. The burner profile opening creates a pressure drop which increases the air velocity across the burner. The air flow switch monitors the pressure difference, and will open the burner circuit if pressure difference is not correct. The air flow switches have low and high pressure settings. The pressure drop should not be near the minimum and maximum of the air flow switch.
If the pressure drop is too low, in fresh and return air mode, add more blank-off panels to the burner profile opening and bypass fresh air and return air damper, which will increase the pressure drop. (There must be at least 2 inches of area minimum around the burner.) If the correct air flow pressure drop is still not achieved adjust the blower drives to increase the blowers RPM.
TEMPERATURE CONTROL SYSTEMS 401M • • • The 401M replaces building-exhaust air with tempered make-up air. A discharge-sensing controller that compensates for intake air temperature changes modulates the burner flame. A manual, remote SUMMER/OFF/WINTER selector switch controls the unit’s operation. o Summer: blower only operation. o Winter: blower and burner operation. 402M • • • • The 402M is used primarily in door-heater applications.
SC10 Signal Conditioner • • When computer of other process controls are specified instead of standard electronic controls, the signal conditioner provides compatibility with modulator / modulator-regulator valves. This system requires a customer supplied 4 to 20 milliamp or 0 to 10 DC voltage signal from a building control system. UNIT COMPONENTS M4RT1 Flame Safety Control The first system to understand is the Flame Safety Control.
Air Flow Switch Air Flow Switch There are both high and low airflow switches contained within one housing measuring the pressure drop across the burner. This is to insure that there is proper airflow (.15 in. w.c. to .95 in. w.c.) across the burner and proper combustion at all times. Both switches are wired in series and have single pole double throw (one common contact, one normally open contact, and one normally closed contact) switches that are ‘switched’ by air pressure.
2 9 4 1 8 1 5 6 3 7 1 1 1 1 1 1 1 1 ELECTRICAL VESTIBULE 1. 2. 3. 4. 5. 6. 7. 8. 9. IGNITION TRANSFORMER INTAKE AIR THERMOSTAT FLAME SFAETY CONTROL MODULATING AMPLIFIER BLOWER SERVICE SWITCH BURNER SERVICE SWITCH CONTROL TRANSFORMER FREEZE CONTROL HIGH TEMPERATURE LIMIT 10. 11. 12. 13. 14. 15. 16. 17. 18.
5. MODULATING GAS VALVE 6. PILOT SHUT OFF VALVE 7. PILOT REGULATOR 8. PILOT GAS VALVE 9. 80/20 DAMPER ACTUATOR TROUBLESHOOTING The following tables list causes and corrective actions for possible problems with direct fired heater units. Review these lists prior to consulting the manufacturer.
Burner Troubleshooting Chart Problem Pilot does not light/stay lit Potential Cause Main gas is off Air in gas line Dirt in pilot orifice Gas pressure out of range Pilot valve is off Leaking pilot orifice fitting Excessive drafts Safety device has cut power Dirty flame sensor Remote panel in “Vent” mode No spark at igniter Main burner does not light (Pilot is lit) Defective valve Loose valve wiring Defective pilot sensor Shut-off valve closed Defective flame safety controller Pilot fails as main gas valve
Remote Panel Troubleshooting Chart Light Indication No lights Condition Power not available to Remote Panel Proper heating operation Possible Cause Bad voltage to unit Main Disconnect in “OFF” position Circuit breaker tripped Bad main transformer No problem Manual/Off/Auto switch in “OFF” position (3-position Remote Panels only) Improper damper function Low Temperature Thermostat timed out (option) No problem Manual/Off/Auto switch in “OFF” position (2-position Remote Panels only) Heat/Vent switch in “VE
Troubleshooting Flowcharts Nothing Happens Is Overload tripped on starter? YES Reset & measure FLA of motor. Is it higher than rating? YES Adjust or change Pulley Blower runs but there is no heat YES Adjust or Replace Adjust pulley to achieve proper airflow.
Maxitrol Preliminary Circuit Analysis Series 14 System The basic Series 14 system consists of an amplifier, a discharge-air sensor and mixing tube, a remotetemperature selector, and a modulating valve or a modulator-regulator valve. Series 14 Preliminary Wiring Testing Procedures: • Disconnect the discharge-air sensor and replace with a 10,000-Ohm, 1/4-watt test resistor at Terminals 3 & 4. • Connect a dc-volt meter on the modulator-regulator or modulator-valve terminals.
Maxitrol Series 14 Troubleshooting Symptom No Gas Flow Continuous low fire (electronics problem) Continuous low fire (electronics OK) Incorrect minimum fire Possible Cause Modulating valve improperly installed Short circuit or no voltage to the amplifier Field Test Arrow on side of valve should point in direction of gas flow Check for 24-V at amplifier terminals 7 & 8 Remedy Install properly Open circuit in TD114 remote temperature selector or wiring Check wire connections between amplifier terminals
Symptom Continuous high fire (electronics OK) Possible Cause Foreign object holding valve open or plunger jammed Incorrect maximum fire Inlet pressure too low Erratic or pulsating flame Incorrect discharge air temperature Field Test Inspect: plunger should be smooth and clean, and operate freely in the solenoid valve. Read pressure at inlet to modulating valve using a manometer with unit operating at high fire.
Maxitrol Preliminary Circuit Analysis Series 44 System The basic Series 44 system consists of an amplifier, a discharge-air monitor with mixing tube, a selectrastat, and a modulating valve or a modulator-regulator valve. Series 44 Wiring for Preliminary Testing Procedures: • • • • • • • • Turn the test potentiometer to 2,000-Ohm minimum resistance. The dc voltage should read 0-V. Slowly turn the test potentiometer to maximum resistance or 12,000-Ohms.
Maxitrol Series 44 Troubleshooting Symptom No gas flow Continuous low fire (electronics problem) Continuous low fire (electronics OK) Incorrect minimum fire Possible Cause Modulating valve installed improperly No voltage to amplifier Field Test Arrow in side of valve should point in direction of gas flow.
Symptom Incorrect minimum or maximum discharge air temperature Possible Cause Improper TS144 location Field Test Compare sensed temperature at TS144 with average discharge air temperature Remedy Move TS144 to location where average temperature can be sensed Incorrect discharge air temperature control calibration Refer to the preliminary circuit analysis section Continuous high fire (electronics problem) Open in TS144 circuit Continuous high fire (electronics OK) Foreign material holding valve open
Flame Safety Service Guide (Airflow LED may or may not be illuminated) 40
Flame Safety Service Guide (continued) (Airflow LED may or may not be illuminated) 41
To guarantee trouble free operation of this heater, the manufacturer suggests following these guidelines. Most problems associated with fan failures are directly related to poor service and maintenance. WARNING!! DO NOT ATTEMPT MAINTENANCE ON THE HEATER UNTIL THE ELECTRICAL SUPPLY HAS BEEN COMPLETELY DISCONNECTED AND THE MAIN GAS SUPPLY VALVE HAS BEEN TURNED OFF. General Maintenance 1. Fan inlet and approaches to ventilator should be kept clean and free of any obstructions. 2.
2 Weeks after Start-Up 1. Belt tension should be checked after the first two weeks of fan operation. Belts tend to stretch and settle into pulleys after an initial start-up sequence. Do not tighten the belts by changing the setting of the motor pulley. This will change the fan speed and may damage the motor. To re-tension belts, turn the power to the fan motor OFF. Loosen the fasteners that hold the blower scroll plate to the blower. Rotate the motor to the left or right to adjust the belt tension.
JOB INFORMATION Job Name Address City State Zip Phone Number Fax Number Contact Purchase Date TECHNICIAN INFORMATION Service Company Address City State Zip Phone Number Fax Number Contact Start-Up Date Refer to the start-up procedure in this manual to complete this section. Name Plate and Unit Information Model Number Serial Number Motor Volts Motor Hertz Motor Phase Motor FLA Motor HP Blower Pulley Motor Pulley Belt Number Gas Type Min. Btu/Hr Max.
