INSTALLATION, OPERATION AND MAINTENANCE MANUAL FOR WDF MODEL

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INSTALLATION, OPERATION AND MAINTENANCE MANUAL FOR WDF MODEL | Manualzz
IOMWDF-4
INSTALLATION, OPERATION AND
MAINTENANCE MANUAL FOR WDF MODEL
DIRECT GAS-FIRED HEATERS WITH DDC CONTROLS
ATTENTION: READ THIS MANUAL AND ALL LABELS ATTACHED TO THE UNIT CAREFULLY BEFORE
ATTEMPTING TO INSTALL, OPERATE OR SERVICE THESE UNITS! CHECK UNIT DATA PLATE FOR
TYPE OF GAS AND ELECTRICAL SPECIFICATIONS AND MAKE CERTAIN THAT THESE AGREE WITH
THOSE AT POINT OF INSTALLATION. RECORD THE UNIT MODEL AND SERIAL No.(s) IN THE SPACE
PROVIDED. RETAIN FOR FUTURE REFERENCE.
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.
POUR VOTRE SÉCURITÉ
L'utilisation et l'entreposage d'essence ou d'autres liquides ou produits émettant des vapeurs
inflammables dans des récipients ouverts à proximité de cet appareil est dangereux.
FOR YOUR SAFETY
If you smell gas:
1. Open Windows
2. Don’t touch electrical switches.
3. Extinguish any open flame.
4. Immediately call your gas supplier.
c
POUR VOTRE SÉCURITÉ
Si vous sentez une odeur de gaz :
1. Ouvrez les fenêtres.
2. Ne pas actionner d'interrupteur.
3. Éteindre toute flamme ouverte.
4. Appelez immédiatement votre
fournisseur de gaz.
WARNING: Improper installation, adjustment, alteration, service or maintenance can
cause property damage, injury or death. Read the installation, operating and maintenance
instructions thoroughly before installing or servicing this equipment.
AVERTISSEMENT : Une installation déficiente, de même qu'un mauvais réglage,
modification, entretien ou maintenance peuvent occasionner des dommages matériels, corporels voire causer la mort. Lire attentivement les instructions d'installation,
d'utilisation et d'entretien avant d'installer ou d'intervenir sur cet appareil.
WARNING
Install, operate and maintain unit in accordance with manufacturer's instructions to avoid
exposure to fuel substances or substances from incomplete combustion which can cause
death or serious illness. The state of California has determined that these substances
may cause cancer, birth defects, or other reproductive harm.
INSTALLER'S RESPONSIBILITY
Installer Please Note: This equipment has been test fired and inspected. It has been shipped
free from defects from our factory. However, during shipment and installation, problems such as
loose wires, leaks or loose fasteners may occur. It is the installer's responsibility to inspect
and correct any problems that may be found.
4830 Transport Drive, Dallas, TX 75247 Phone: 214-638-6010 Fax: 214-905-0806
www.ljwing.com
SECTION I - FOREWARD
Table of Contents
Section I: Foreword, Table of Contents,
and Important Notice .................................. 2
Section II: General Information .................................... 3
Section III: Installation ................................................. 4
Section IV: Pre-Start Up .............................................. 8
Section V: Unit Start Up ............................................... 9
Section VI: Unit Shut Down ....................................... 11
Section VII: Troubleshooting Guide ........................... 12
Section VIII: Maintenance Schedule
and Lubrication Requirements............... 24
Section IX: Mestek Burner ......................................... 29
Section X: Manifold and Valve Adjustments .............. 30
Section XI: Thermistor Curves................................... 31
Section XII: Replacement Parts................................. 32
Section XIII: Recirculating Units ................................ 32
As is the case with any fine piece of equipment, care
must be taken to provide the proper attention to the
operation and maintenance details of this machine.
This manual of instructions along with the Digital
Control System user manual has been prepared in
order for you to become well-acquainted with those
details, and in doing so, you will be able to give your
Direct Gas-Fired System the care and attention which
any piece of equipment needs and deserves.
It is the customer and installation personnel
responsibility to determine if the unit is equipped
with all of the safety devices required for the
particular application. Safety considerations
include the accessibility of the unit to non-service
personnel, the provision of electrical lockout
switches, maintenance procedures, and automatic
control sequences. Clearly mark all emergency
shutoff devices.
*IMPORTANCE NOTICE*
LJ Wing assumes no responsibility for loss or damage
in transit; therefore, you should protect yourself by
following these instructions:
Bill Of Lading
Save your bill of lading. It is a contract, and you will
need it, provided you have to file a loss or damage
claim. Remember, claims are outlawed after nine
months.
Loss In Transit
Before you sign for this shipment, check against the bill
of lading, also the transportation company’s delivery
ticket. Make sure that you get the exact total of articles
listed. Should the delivery ticket show more or less
items than are offered, then the carrier’s agent must
mark the difference on your freight bill before you sign.
Visible Damage In Transit
If anything is damaged, accept the shipment only if
the carrier’s agent places a notation on your freight
bill explaining the nature and extent of damage. Upon
inspection of article, make claim to the delivering
carrier.
Concealed Damage In Transit
Sometimes transit damage is not noticed until the
goods are unpacked. In such cases, notification to
the carrier must be made within fifteen (15) days of
receipt of shipment. In such cases, save the packages
and packing material, then notify the transportation
company at once, and request an inspection. When
the inspector calls, have him make out and leave a
“concealed” bad order report. He is obliged to give one
to you. Insist on it.
Disposition Of Damaged Atticles
Never return damaged articles to us. They are the
property of the transportation 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.
–2–
SECTION II - GENERAL INFORMATION
A. Purpose
The purpose of this manual is to present a guide for
proper installation, maintenance, and operation of the
Direct Gas-Fired System, and supplement, but not to
replace, the services of qualified field service personnel to supervise the initial start-up and adjustment
of the unit. Persons without previous experience with
large commercial and industrial heating equipment
should not attempt the initial adjustment and checkout
procedure which is essential before such installations
may be considered ready for operation. This manual
should be made readily available to all operating personnel as an aid in troubleshooting and proper maintenance.
B. Shipping
Base Direct Gas-Fired units are shipped completely
assembled where shipping limitations allow. Optional
inlet hoods, filter and/or damper sections, or other
large accessories are assembled and shipped mounted and wired whenever possible within limitations
of shipping and handling. Any optional accessories
shipped separately are shipped as assembled sections. Any wired accessories which have been disassembled for separate shipment require no additional
conduit or wire for field reassembly. All wire leads will
be tagged for ease of reconnection in the field.
Shipments are made F.O.B. Dallas, Texas by flatbed 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 carrier. Parts that are shipped unmounted are
noted on the bill of lading. These parts, where feasible,
are packaged and shipped with the units. Upon receipt
of shipment, all units should be checked against the
bill of lading to insure all items have been received. All
equipment (and any optional accessories) should be
checked carefully for physical damage in the presence
of the carrier’s representative. If parts are missing or
damage has occurred, a claim should be filed immediately with the carrier.
All Direct Gas-Fired units are given a complete operations test and control circuit checkout before shipment.
Copies of the wiring diagram, piping diagram and
bill of material are included with each unit shipped. If
correspondence with the factory is necessary, please
provide the unit model and serial number.
C. Optional Factory Service
Periodic service on any piece of mechanical equipment is necessary for efficient operation. A nationwide
service support network is available to provide quick
and dependable servicing of make-up air, heating,
ventilating, or air handling types of equipment. Factory
start-up service is also available which includes the
presence of a service engineer to supervise the initial
start-up and adjustment of the equipment and provide
instructions for the owner’s maintenance personnel in
proper operations and maintenance. Consult factory
for quotations on start-up or periodic service.
If the unit and/or accessories cannot be installed
immediately, they should be stored in a clean dry
environment. If this is not possible and the unit
must be stored outdoors, it should be protected
from the weather with tarpaulins or plastic
coverings. Do not assume that simply covering a
unit will keep insects, dust and condensation out
of the unit 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 components should be closely inspected.
–3–
SECTION III - INSTALLATION
During transit, unloading and setting of the unit, bolts
and nuts may have become loosened, particularly
in the pillow block ball bearing assemblies in the fan
section. It is recommended that all nuts and set screws
be tightened. Turn fan shaft by hand to make certain
that blower does not rub against blower housing, and
that bearing set screws are tight. If units are not set
immediately, cover all openings that might be exposed
to the weather.
FOR CANADIAN INSTALLATIONS ONLY
1. All installations must conform with local building
codes, or, in the absence of local codes, with
current CAN/CGA-B149-Installation Codes For
Gas Burning Appliances and Equipment.
2. All electrical connections must be in accordance with Canadian Electrical Code, Part 1,
CSA Standard C22.1.
This equipment must be installed and wired in accordance with regulations of the National Board of
Fire Underwriters, 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 installations are made. Local codes may require additional
safety controls and/or interlocks.
Open the cover on the electrical control box located on
the unit. Inspect all wire terminals and wiring terminations to ensure that all connections are tight.
If units are not set immediately, cover all openings that
might be exposed to the weather.
Rotate fans monthly.
RIGGING AND MOUNTING DATA - DIRECT FIRED UNITS
All installations in airplane hangers must be in accordance with current ANSI/NFPA No. 409. All installations in public garages must be in accordance with
current NFPA No. 88A and NFPA No. 88B.
SPREADER
BAR
SPREADER
BAR
A
CAUTION: Do not install heating system in corrosive
or flammable atmospheres! Premature failure of, or
severe damage to the unit will result!
CAUTION: Heating system must not be installed in
locations where air for combustion would contain
chlorinated, halogenated or acidic vapors. If located
in such an environment, premature failure of the
unit will occur!
B
A
B
LIFTING LUGS
PROVIDED IN ONE
OF TWO LOCATIONS
A - USE WHEN LIFTING OVER 3,000 LBS.
B - USE WHEN LIFTING UNDER 3,000 LBS.
A. Handling the Equipment
The Direct Gas-Fired unit has been designed for
rigging and handling through the use of special lifting
lugs installed on the sides of each unit. As explained
previously, the basic unit is designed for shipping in
one piece where shipping limitations allow. Some
optional accessories may require field mounting.
08/16/07
The Direct Gas-Fired unit has been designed for
rigging and handling through the use of special lifting
lugs installed at each corner of unit. When unloading
and setting the unit, use the lifting lugs provided or
move the equipment on rollers. Hooks, jacks, or chains
must not be used around the casing, main control
panel or exterior mounted controls.
–4–
C000539A
WARNING: To insure that a proper unit lift is
made, lift unit approximately 24 inches and
verify proper center of gravity lift point. To avoid
dropping of unit, reposition lifting point if unit
is not level. Failure to properly lift unit could
result in death or serious injury or possible
equipment or property-only damage.
B. Locating the Unit
Prior to locating the unit, authorities having jurisdiction should be consulted before installations are made.
Approval permits should be checked against the unit
received.
On Direct Gas-Fired units, which recirculate room air,
outside ventilation air must be provided in accordance
with the information shown on the heater nameplate.
All ventilation air to the heater must be ducted directly
from the outside. See Section XIII.
Use extreme caution in handling the curb. Proper
handling 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.
If in doubt regarding the application of this appliance,
consult the factory.
The curb assembly may be bolted or welded to either
trusses or roof decking; however, connection to roof
trusses is recommended. The curb is designed to carry
the weight of the unit. Additional support is required for
certain applications.
Locate the unit exactly level. Special attention should
be given to the duct, electrical, and fuel connection
points. Install duct work with adequate flexible connections to isolate vibration from the duct work. All duct
work should have taped or caulked seams. Duct work
should be properly sized so as not to inhibit airflow.
This information should be cross-checked with the
position of support beams and stand pipes to insure
that clearance dimensions coincide with those of the
unit. The minimum clearance to combustible material
must be maintained as listed in Table 1.
Placement of the curb is critical in squareness and
leveling. Shims for leveling must be applied to the
curb; application of shims to the unit will tend to
destroy the sealing effect after installation. Make sure
sealing tape is in place before unit is set. Be careful
not to allow gaps where two pieces of sealing tape
meet. A bubble level must be used in the leveling
process. Measure across diagonals to check for
squareness. Allowable tolerance is 1/4" difference
between diagonal measurements. Double-check
approval prints before setting the unit.
Table 1
Minimum clearance to combustible material,
also consult local codes and regulations.
Clearances to Combustible Material
Vertical Units
Horizontal Units
Front*
39 inches
36 inches
Rear
6 inches
6 inches
Right
6 inches
6 inches
Left
6 inches
6 inches
Top
12 inches
12 inches
Floor
Zero
6 inches
*Consider control side as front of unit.
**Optimum clearance for shaft removal would be
equivalent to cabinet width.
Upon completion of setting the curb, apply roofing
material and flashing as required. On outdoor curb
mounted installations, flash and seal the roof curb to
prevent leakage. The cross section of factory provided
curb is formed to accept wood nailing strip and insulation provided by others.
Make a visual inspection to insure no damage has occured to the unit during installation.
C. Curb Mounted Units
Outdoor units can be supplied with an optional roof
curb. The curb greatly facilitates installation thereby
reducing installation costs. All connections to the unit:
duct, piping, electrical power and control wiring can
be made through the roof opening. The curb may be
shipped prior to unit shipment. All curbs are shipped
un-assembled from the factory.
D. Location of Accessories
Where applicable, standard or optional accessories will
be placed inside the fan section of the unit for shipment,
and must be removed and installed by the mechanical
or electrical contractor.
Remotely located discharge or inlet dampers must be
equipped with an end switch and interlocked to insure
maximum design opening before starting and running
circuits may be energized.
Field constructed intake accessories should be properly
designed to minimize the entry of rain and snow.
Adequate building relief must be provided, so as to not
over-pressurize the building, when the heater is
operating at its rated capacity. This can be accomplished by taking into account, through standard
engineering methods, the structure’s designed infiltration rate, by providing properly sized relief openings,
by interlocking a powered exhaust system, or by a
combination of these methods.
–5–
F. Field Piping
E. Electrical Connections
WARNING: Open all disconnect switches and
secure in that position before wiring unit.
Failure to do so may result in personal injury or
death from electrical shock.
WARNING: Controls must be protected from
water. Do not allow water to drip on the ignition
system.
NOTE: Before installing any wiring, check the unit
rating plate for supply power voltage and minimum
ampacity.
Gas Piping
All gas piping must be in accordance with the requirements 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 be
located external of the unit’s enclosure. The location of
this valve must comply with all local codes. A 1/8 inch
N.P.T. plugged tapping, accessible for test gauge connection, must be installed immediately upstream of the
gas supply connection to the unit.
All electrical connections must conform to the current
edition of: ANSI/NFPA No. 70 National Electrical Code
and applicable state and local codes; in Canada, to the
Canadian Electrical Code, Part 1 CSA Standard C22.1
and applicable provincial and local codes.
WARNING: To avoid equipment damage or
possible personal injury, disconnect gas piping
to this unit until a supply line pressure/leak test
has been completed. Connecting the unit before
completing the pressure/leak test may damage
the unit gas valve and result in a fire hazard.
Since shipment of unit may require disassembly after
factory check and test, reconnection of some electrical
devices will be required in the field. Connect electrical
wires (supplied in factory furnished conduit) to appropriate terminals. All leads are tagged to facilitate field
connections. See wiring diagram provided with equipment. Complete all wiring to any optional accessories
as shown on unit bill of material and electrical wiring
diagram as required before applying voltage to the unit.
On vertical units there is a factory installed “Burner
Cleanout” pipe located on the opposite end of the gas
piping compartment. This is a clean out to drain any
condensate that may have collected in the line burner.
Entry location for all field-installed and control wiring is
through the control panel.
WARNING: DO NOT connect supply gas to this
pipe.
If optional disconnect is not furnished with heater, the
field provided disconnect must be of the proper size
and voltage. Refer to unit rating plate for minimum
circuit ampacity and voltage. The disconnect must be
installed in accordance with Article 430 of the current
edition of ANSI/NFPA No. 70 National Electrical Code.
The gas line should be supported so that no strain
is placed on the unit. Pipe compounds which are not
soluble to liquid petroleum gases should be used on
threaded joints.
Check the supply voltage before energizing the unit.
The maximum voltage variation should not exceed
± 10%. Phase voltage unbalance must not exceed 2%.
NOTE: Should any original wire supplied with the
heater have to be replaced, it must be replaced
with wiring material having a temperature rating of
at least 105° C.
REMARQUE : Dans le cas où un quelconque des
câbles livrés avec l'unité devait être remplacé, il
doit être remplacé avec des câbles prévus pour
résister à une chaleur d'au moins 105° C.
DANGER: Never use an open flame to detect
gas leaks. Explosive conditions may exist which
would result in personal injury or death.
Refer to the heater’s rating plate for determining the
minimum gas supply pressure for obtaining the maximum gas capacity for which this heater is specified.
Une tuyauterie adéquatement dimensionnée doit être
posée jusqu'à l'unité. Veuillez noter que la pression de
la tuyauterie d'alimentation en gaz doit correspondre
à celle spécifiée sur la plaque d'identification, lorsque
l'unité fonctionne à plein rendement.
Refer to the heater’s rating plate for determining the
maximum supply pressure to the heater.
The appliance and its individual shutoff valve must
be disconnected from the gas supply piping system
during any pressure testing of that system at test
pressures in excess of 1/2 PSIG.
–6–
The appliance must be isolated from the gas supply
piping system by closing it’s individual manual
shutoff valve during any pressure testing of the gas
supply piping system at test pressure equal to or
less than 1/2 PSIG.
Correctly sized piping must be run to the unit.
Please note that gas line pressure must be
as shown on specification plate when unit is
operating at full input. The high-pressure regulator
and relief valve should be, if possible, mounted
at least 5 to 10 feet upstream from the appliance
regulator on the unit (if possible).
Building Pressure Transducer Piping (PT-13)
Pipe the high side to location inside the building that
will not be affected by air movement. Pipe the low side
to the atmosphere, positioned so it will not be affected
by the wind and not exposed to the elements. Be sure
that all tubing is clean and clear of any debris before
installing tubes on the transducer.
disconnect switch.
2. Field wiring is typically indicated on the wiring
diagram as dashed lines. When running any field
wiring for control circuit be sure wire is sized for
a maximum 10% 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 shall have a temperature rating of at
least 105°C. The minimum size of the supply cable
circuit shall be sufficient for the maximum ampacity
of the heater.
L'installation éléctrique d'utilisateur aura une
température qui évalue d'au moins 105°C. La
minimum de source du circuit de câblage sera
suffisante pour le ampacity maximum de l'appareil
de chauffage.
H. Locating Temperature Controls
The room or outdoor sensors should be mounted
where they will not be subjected to direct impact of
the heated air or radiant heat from the sun. It is also
recommended that thermostats, especially those with
mercury bulb contacts, be mounted on a vibration free
surface. The side of building columns away from the
heater or interior walls are usually the location best
suited for mounting thermostats.
Flow Station Transducer Piping (PT-15)
Pipe the high side to the upstream connection and
low side to the downstream connection of the Airflow
Station as shown in Drawing # C000643 below. Be
sure that all tubing is clean and clear of any debris
before installing tubes on the transducer.
G. Field Wiring and Remote Control Installation
1. Connect the power lines to the line side of
the power distribution block or optional main
Controls with outdoor sensors require that the outdoor
sensor be shielded from direct radiation from the sun. Unit
mounted sensors are factory located and mounted.
AIRFLOW STATION LAYOUT
HEATER
CASING
RA DAMPER
NOTE: RUN TUBE CONNECTIONS
TO TRANSDUCER (PT-15) IN
UNIT CONTROL ENCLOSURE
LOW PRESSURE
TUBE CONNECTION
STATIC PRESSURE
SENSING TUBE
HIGH PRESSURE
TUBE CONNECTION
TOTAL PRESSURE
SENSING TUBE
BULLET
AIRFLOW STATIO N
AMPLIFIER WING
(SHEET METAL STRIP)
EXTERIOR INSULATION
FIELD PROVIDED WHEN
MOUNTED OUTDOORS
C000643
–7–
SECTION IV - PRE START-UP
Do not attempt start-up without completely reading
and understanding this manual, along with the
Digital Control Sysem user manual.
A. Pre Start-Up
The owners representative or equipment operator
should be present during start-up to receive instructions on care and adjustments of the equipment.
All equipment has been factory tested, adjusted,
metered and inspected to meet conditions set at
the time the order was placed. Only minimal
adjustments should be required. All information
in this service manual is typical. All products are
semi-custom and changes may occur.
Suggested Tools and Instruments
Volt/Ohm Meter
Thermometer
Tachometer
Ammeter
Manometer (0-10" W.C.)
Microammeter
Standard Hand Tools
D.C. Volt Meter
Gas Pressure Gauge (0-35 lbs.)
BACview 6
CAUTION: Line side of disconnect may be energized.
Follow proper “lockout/tagout” procedures.
NOTE: All servicing and adjustments of the Direct
Gas-Fired unit should be performed by a qualified
service engineer.
Perform a visual inspection, internally and externally,
to make sure no damage has occured and that
everything is secure. This inspection is very important
and should be completed with greatest care given to
detail. A good pre-start inspection will insure against
possible unit damage on start-up and will save
valuable analysis time.
1. Check that the physical condition of the unit
exterior is acceptable.
2. Check that the insulation inside of unit is properly
secured.
3. Remove all shipping blocks, brackets and bolts
from supply fan base with optional isolation base.
4. Check all wiring for loose connections and tighten
if necessary.
5. Inspect all fan and motor bearings and lubricate if
necessary.
9. Check thermostat(s) for normal operation.
10. Check that system 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 foreign material within the gas piping. This
will interfere with the proper operation of the gas
train components and burner. Purge all air from
gas lines per gas codes.
14. Check that all accessories requiring field wiring
have been properly installed.
15. Check burner for proper location and alignment.
16. Check that filters, filter stops, accessories and ship
loose items are installed correctly.
17. Check that vent lines (if applicable) are run to
atmosphere on gas regulators and pressure
switches for indoor units. Vent lines should
terminate outside the building, with a turndown
elbow and bug screen. Note that some units will
use vent limiters and vent lines are not required.
If vent lines are even partially plugged, this will
interfere with proper venting of pressure control
devices.
18. Check that all manual gas shut-off valves are closed.
19. When failure or malfunction of this heater creates a
hazard to other fuel burning equipment, (e.g. when
the heater provides make-up air to a boiler room),
the heater is to be interlocked to open inlet air
dampers or other such devices.
20. Motor overload relay setting should match the
motor’s nameplate full load amperage.
21. Check that dampers and linkages are free to move,
and that linkages are tight.
22. The unit may require that a Return Airflow Station
be field installed. Be sure all tubing connections
are in the correct location as shown in drawing
#C000643.
23. Check to ensure all manual reset safety devices
have been reset and limits are in the normal
operating position.
24. If inlet duct is attached to the heater, a purge
timer must be provided and set to purge 4
times the inlet duct volume.
CAUTION: DO NOT RUPTURE GREASE SEALS.
6. Inspect pulleys and belts for tightness, tension and
alignment. Do not overtighten belts.
7. Check set screws on all bearings, pulleys, fans and
couplings for tightness.
8. Check voltage supplied to disconnect switch; the
maximum voltage variation should not exceed
± 10%. Phase voltage unbalance must not exceed 2%.
Purge time in seconds = 4 x L x W x H x 60
SCFM
L = duct length in feet, W = duct width in feet,
H = duct height in feet, SCFM = rating plate air
throughput.
Refer to the electrical schematic for the proper
circuit placement. Purge timer P/N 65.0711.00.
–8–
SECTION V - UNIT START-UP GENERAL
To disable the fans go to “Unit Modes” and enter
[OFF].
Before attempting to start the heater read and
understand the the sequence of operations
electrical schematic, ignition module, control
components, gas train, burner and the Digital
Control System user manual.
NOTE: A BACview or PC is required to change Unit
Modes. For a more detailed control sequence see
the (Digital Control System User Manual).
WARNING: During installation, testing, servicing
and trouble shooting of this product, it may
be necessary to work with live electrical
components. Have a qualified licensed
electrician or other individual who has been
properly trained in handling live electrical
components to perform these tasks. Failure to
follow all electrical safety precautions when
exposed to live electrical components could
result in death or serious injury.
Turn main disconnect switch on and Enable fans.
Damper opens (if applicable). After end switch has
proven damper is open, the blower fan turns on.
(see operating modes in Digital Control System user
manual)
Disable the fans. Check supply blower for proper
rotation.
NOTE: To change rotation of the blower, simply
interchange any two (2) of the line leads of the
motor starter for three (3) phase motors. On single
phase motors refer to motor nameplate.
Make sure all manual gas valves are closed.
Make sure all doors and service panels have been
closed or replaced.
Enable the fans. Check for proper blower rpm. Check
that all motor amp draws do not exceed rating plate
ratings and overloads are set to motor rating plate
amps.
Turn main disconnect switch off. Check the incoming
line voltage to match unit rating plate rating. If voltage
is over ±10% of nameplate rating or phase voltage
unbalance is over 2%, notify contractor or power
company.
Check all dampers for proper operation, and linkage
does not bind, see “Sequence of Operation”, and
Digital Control System user manual for damper control
modes.
Fans Are Enabled And Disabled By The Following:
MDT And MRT Standard:
By rotating the remote “Temperature Setpoint” knob
(MP-15).
Clockwise will enable the fans.
Counterclockwise will disable the fans.
Disable the fans.
MRT-PRO With Smart Room Sensor:
To enable the fans and place the unit in the Occupied
Mode press the “Manual On” button on the face of
the (TS-02) MRT-PRO room sensor. Pressing the
“Warmer” button will add 30-minute increments of
time for a total of 9-hours of operating time. To disable
the fans and place unit in the Unoccupied Mode press
and hold down the “Manual On” button. Alternately
pressing the “Manual On” button will also decrease
the amount of operating time until it reaches zero and
turns the fan off.
MRT Expert or VDT Expert With A BACview (KP-01):
To enable the fans go to “Unit Modes” and enter
[MANUAL], this mode 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.
NOTE: Before attempting to light the main burner
you need to review Section X for proper Manifold
and Valve Adjustments. A BACview 6 or PC will be
required to change setpoints.
Check the gas supply pressure by replacing the plug
fitting on the gas line with a pressure gauge having
appropriate range, and opening the manual gas
valve. Check that the pressure reading is within the
specified range on the rating plate.
NOTE: To adjust gas pressure on supply lines
where a regulator has been installed (to reduce the
inlet pressure to rating plate maximum pressure),
remove dust cap of main gas regulator and turn
adjusting screw clockwise to increase pressure or
counter-clockwise to decrease pressure.
Connect a DC Microammeter between SENSE
terminal and flame rod sensing wire.
–9–
Open first main gas shut-off valve slowly. Reset highlow gas pressure switches (if applicable). Check main
gas line for leaks using soap solution.
Install manometer at test port on the last tee of the
burner manifold, or MR valve test port.
Slowly open last manual gas shut-off valve.
Heat is Enabled By The Following:
Enable the fan and burner. Unit will run for 5 seconds
before valve opens and burner lights if all safeties and
limits are in normal operating mode.
MDT And MRT Standard:
To enable the heat, rotate the “Temperature
Setpoint” knob (MP-15) clockwise to the desired
setpoint above the actual air temperature. The
allowable temperature range is 55o to 90oF.
NOTE: This is a direct spark ignition burner. Low
fire may need to be adjusted first in order to light
the burner.
MRT-PRO With Smart Room Sensor:
To enable the heat, press the “Warmer” or “Cooler”
button on the face of the remote MRT-Pro room sensor
(TS-02) to the desired room setpoint. Each push of the
button changes the temperature setpoint by 1o F. The
setpoint can be changed a maximum of + 10oF from
the default of 65oF. Changing the heating setpoint
also changes the cooling setpoint.
MRT Expert or VDT Expert With A BACview (KP-01):
To enable the heat for MRT Expert scroll through
the “Setpoints” menu in the BACview and enter the
desired room Heating Occupied and Unoccupied
Setpoints. For VDT Expert enter the desired Heating
Discharge Air Setpoint.
Energy Savings Modes:
There are 3 Energy Savings Modes that could
disable the burner.
Adjust high fire pressure reading (from manometer) to
match Normal Manifold Pressure firing rate shown on
unit rating plate.
Refer to Valve Adjustment instructions in Section X
for setting high and low fire gas pressure settings.
The high fire setting must be made before adjusting
low fire. Adjust the high fire setting according to the
Maxitrol Valve Adjustment instructions in Section X.
The high fire setting must not exceed the pressure
stated on the rating plate.
When adjusting low fire, there should be a
continuous flame along the entire burner length
without any blowout spots. Burner must hold in low
fire for approximately 10 seconds before modulating up.
Check flame signal with burner cycling through full firing
range.
NOTE: A BACview or PC is required to change
Setpoints. For a more detailed control sequence,
see the Digital Control System Users Manual.
Cycle burner several times to insure smooth light off.
Low fire may need to be readjusted.
Setting Main Flame
CAUTION: You will have approximately three (3)
minutes before the unit shuts down on Freezestat
( L o w D i s c h a r g e Te m p e r a t u r e , i f y o u h a v e
disconnected plug wires TS-01 and TS-03). Referred
to in Section X.
There should be a continuous spark for ten (10)
seconds with the last gas cock turned off and the
ignition control (RE-02) should lock out.
Check main gas lines for leaks.
Main flame is now set. Make sure burner modulates
and turn thermostat to the desired setting.
NOTE: 3 OR 4 TRIALS MAY BE NEEDED TO
PURGE AIR FROM GAS LINE.
United Technologies Electronic Controls Spark
Ignitor (RE-02)
Watch microammeter carefully. Burner must hold in low
fire 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.
– 10 –
Safety Controls Check All
A. Ignition Control (RE-02) – Close last manual gas
valve before main burner. Operate unit in Heat mode.
The ignition control must lock out within approximately
15 seconds.
B. High Temperature Limits and Firestats – These limit
controls are not adjustable and are checked at the
factory. Reset the button(s) to be sure they are ready
for operation. Contact factory if these switches fail to
reset.
C. Gas Pressure Switches – The low pressure switch
will trip out and must be reset before resuming operation when the inlet gas valve is turned off during
operation. The high pressure switch may be checked
out by reducing the setting of its trip point to unit operating pressure. It should then trip out and shut off the
burner. Return the adjustment to its original setting and
reset to resume operation.
D. Air Pressure Switches – The high air pressure
switch is checked by removing the sensing tube
from the entering air side of the burner and gently
blow into the switch connection. Switch operation
will shut off the burner. Recycle is automatic when
the sensing tube is replaced. The low air pressure
switch is checked by removing the sensing tube from
the leaving air side of the burner. Switch operation
will shut off the burner. Recycle is automatic when
the sensing tube is replaced. Do not adjust air flow
switches.
Suggested Control Settings
(Refer to Digital Control System user manual for default settings)
TS-02
KP-01
MP-05
MP-15
PS-04
PS-07
PS-12
PT-13
FL-02
Space Temperature Sensor ..... Customer Discretion
Keypad/Display Module ........... Customer Discretion
Damper Control Potentiometer ... Customer Discretion
Unit Enable Potentiometer ....... Customer Discretion
Low Gas
Pressure Switch .........................................1.0" W.C.
High Gas
Pressure Switch ........ 125% above burner firing rate
Clogged Filter Switch ............Adjust to field condition
Building Pressure Transducer .. Adjust to field condition
High Temperature Limit (Manual) ................... 185° F
Cooling is Enabled By The Following:
MDT And MRT Standard:
To enable the cooling, rotate the “Temperature
Setpoint” knob (MP-15) clockwise to the desired
setpoint below the actual air temperature. The
allowable temperature range is 55o to 90oF.
MRT-PRO With Smart Room Sensor:
To enable the cooling, press the “Warmer” or
“Cooler” button on the face of the remote MRT-Pro
room sensor (TS-02) to the desired room setpoint.
Each push of the button changes the temperature
setpoint by 1o F. The setpoint can be changed
a maximum of + 10oF from the default of 73oF.
Changing the cooling setpoint also changes the
heating setpoint.
E. Adjustable temperature and limit Controls – The
limit controls are checked by adjusting control
settings 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:
MRT Expert or VDT Expert With A BACview (KP-01):
To enable the cooling for MRT Expert scroll through
the “Setpoints” menu in the BACview and enter the
desired room Cooling Occupied and Unoccupied
Setpoints. For VDT Expert enter the desired Cooling
Discharge Air Setpoint.
Make sure all the safeties and controls are working
properly.
Energy Savings Mode:
Energy Savings Mode 4 can disable the cooling.
NOTE: The cooling outputs are protected by an
anti-cycle timer which has a 3 minute off/3 minute
on delay. A BACview or PC is required to change
Setpoints. For a more detailed control sequence,
see the Digital Control User Manual.
SECTION VI - UNIT SHUTDOWN
A. Extended Shutdown —
1. Disable the heating and cooling for 30 seconds,
then disable the fan.
2. Close all manual gas valves.
3. Open the main electrical disconnect switch.
B. Emergency Shutdown ONLY —
1. Open the main electrical disconnect switch.
2. Close the main manual gas valve.
– 11 –
SECTION VII - TROUBLE SHOOTING
This equpipment has been electrically and fire tested
prior to shipment. However, during transit control
setpoints can change, and wiring can come loose. Do
not assume controls are defective until all associated
setpoints and wiring are checked.
Check Safety Shutdown Performace
WARNING: Fire or explosion hazard. Can
cause property damage, severe injury or death.
Perform the safety shutdown test any time work
is done on a gas system.
NOTE: Read steps 1 through 7 before starting, and
compare to the safety shutdown or safety lockout
tests recommended for the intermittent ignition
module. Where diffferent, use the procedure
recommended for the module.
1. Turn off the last manual gas cock.
2. Adjust setpoint above room temperature to call for
heat.
3. Watch for ignition spark following prepurge. See
ignition module specifications.
4. Time the length of the spark operation. See the
ignition module specifications.
5. After the module locks out, open the manual gas cock
and make sure no gas is flowing to the main burner.
6. Reset the ignition control relay (RE-02).
7. Operate system through one complete cycle to
make sure all controls operate properly.
If you do not have the optional BACview 6 (KP-01)
keypad display it will be difficult to troubleshoot
any alarm that may occur on the unit. To reset
most alarms on the I/O Zone 583 Controller (UC-01)
without a BACview 6 keypad display, simply turn
the power off and back on at the unit disconnect.
If you have a BACview 6 keypad display the alarm
can be reset remotely or at the I/O Zone 583
Controller.
The following is a simplified list of possible problems
and typical causes and remedies. However, it does
not cover all possibilities, and is intended as a guide
only. You might also need to reference the Digital
Control System User Manual for additional troubleshooting and diagnostics.
United Technologies Electronics Control Operation
of the Series 1016-400 Direct Spark Ignition
Control (RE-02)
On a call for heat a five second pre-purge is initiated.
Upon completion of the pre-purge, the gas valve and
60Hz spark are energized. When flame is detected,
the control enters the steady state heating condition.
Steady state heating will continue until the call for heat
is satisfied.
If ignition is not achieved within 15 seconds, the control
shuts off the gas and locks out. If the trial for ignition has
been accomplished without ignition, the control shuts off
all outputs and enters lockout. Reset is accomplished
by cycling the power off for a minimum of 5 seconds. If
flame is lost once it has been established, the control will
shut off the gas valve within 0.8 seconds and locks out.
If flame 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 Diagnostics codes are:
Steady Off:
No power or control hardware fault
Steady On:
Power applied, control OK
1 Flash:
Burner failed to light
2 Flashes:
Flame was established but then went out.
3 Flashes:
Control hardware fault detected
– 12 –
WARNING: Many of the steps listed on the
following pages require electrical cabinet and
blower access while the unit is powered. High
voltage and moving parts are present, and these
steps should be performed by qualified service
personnel. If any of the controls requiring
manual reset were at fault this is an indication
of a problem with the system that should be
investigated.
SECTION VII - TROUBLESHOOTING continued
Fan and Heat Mode
Symptom
A. If blower does not
operate.
Cause
1. Low or no voltage.
2. Fuse(s) blown.
3. Customer interlock not closed or
connected.
4. Fan is disabled.
5. Time clock, night setback
thermostat, or field installed
controls open.
6. Freeze protection tripped. (low
discharge temperature)
Remedy
1.
2.
3.
4.
5.
6.
7.
7. Damper motor not operating, its
end switch not making, or the
damper is binding.
8.
8. Overload Protection on motor
starter tripped.
9. Belts loose or broken.
10. Bearings seized.
11. Motor may be burned or
incorrectly wired.
12. Blower motor overheating.
13. DO-1 on UC-01 not energized.
14. Door switch open.
B. If there is no voltage at
ignition control (RE-02)
input terminal and the
fan is enabled.
1. Heat mode is disabled.
2. Auxiliary switch on starter not
closed (ST-01).
3. Air flow switches open.
4. Outside air temperature higher
than Heating Economizer
Setpoint.
5. High temperature limit thermostat
open.
6. High-low gas pressure switch
open. (If applicable)
7. Field purge timer open.
(If applicable)
8. DO-2 on UC-01 not energized.
C. If the ignition control
(RE-02) goes into safety
shutdown (lockout).
1. See technical cut sheet on
ignition control.
9.
10.
11.
12.
13.
14.
Check power source.
Check and replace.
Close or connect customer interlock.
Enable the fan.
Check time clock, night setback
thermostat and field installed
controls for proper settings.
Reset freeze stat by interrupting
power. Check for proper setting
and burner operation.
Check for power at damper
motor and that end switch has
been wired correctly to the N.O.
(normally open) contact. Check
that the linkage is clear and not
binding.
Push reset button on starter and
check amps.
Turn power off and check belts.
Check and replace.
Turn power off and check motor
and wiring.
Check burner firing rate.
See Digital Control System User
Manual.
Close door. Check and/or replace.
1. Enable the heating mode.
2. Check auxiliary circuit wiring and
contact.
3. Adjust the air flow and external
static pressure to match the
rating plate (Do not adjust switch
setpoint).
4. Check stat for proper setting.
5. Reset control and correct problem before restarting.
6. Check gas pressure and reset
switch.
7. Check for power or replace if
necessary.
8. See Digital Control System User
Manual.
1. Determine the cause of (lockout).
Recycle power.
(Refer to Digital Control System User Manual for additional troubleshooting suggestions)
– 13 –
SECTION VII - TROUBLESHOOTING continued
Heat Mode continued
Symptom
D. If burner does not light
after prepurge has
timed out (5 seconds)
and voltage is present
on ignition control input
terminals.
E. Burner will not respond
to temperature.
Cause
1. Manual shut-off valve closed.
2. Inlet gas pressure lower than
required gas pressure
3. No gas through main gas regulator
with inlet gas pressure ok.
4. No gas through main gas
solenoids.
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. Slowly open valve.
2. Increase gas pressure.
1. For DDC System.
1. See Digital Control System User
manual.
2. Refer to following troubleshooting
guide for RTC controls.
2. For RTC RE-26.
F.
Mixing Box with Airflow
Station dampers not
functioning properly. See
Sequence of Operation
for damper control.
Remedy
1. Defective or misadjusted
transducer (PT-15).
2. Transducer (PT-15) wired
incorrectly.
3. Transducer (PT-15) tubing not
installed correctly.
4. Building Pressure Transducer
(PT-13), Damper Control
Potentiometer defective or not
calibrated.
5. Building Pressure Transducer
(PT-13), Damper Control
Potentiometer not wired correctly.
6. Building Pressure Transducer
(PT-13), Damper Control
Potentiometer not installed
correctly.
7. Unit Control Module (UC-01)
defective.
8. Unit Control Module (UC-01) not
wired correctly.
9. Damper motor defective.
10. Dampers binding and/or loose.
3. Clear obstruction in vent orifice/
line or replace if defective.
4. Check for correct installation and
voltage. Correct or replace.
5. Replace with factory required
type of gas.
6. Flame Rod - assure rod is in
flame, check wiring and flame
rod.
7. Check wiring or replace ignition
control.
8. Check for power, replace if
necessary.
1. Check and/or replace. See
section on troubleshooting PT-15.
2. Check wiring.
3. Install correctly. See section on
airflow station layout.
4. Check and/or replace
components. See section on
trouble shooting PT-13.
5. Check wiring.
6. Install correctly. See section
on trouble shooting PT-13 and
manufacturer’s cut sheet.
7. Check and/or replace. Contact
Factory.
8. Check wiring.
9. Check and/or replace.
10. Check and repair.
(Refer to Digital Control System User Manual for additional troubleshooting suggestions)
– 14 –
TROUBLESHOOTING GUIDE FOR AMPLIFIER (RE-26)
The SC-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.
Span Override Switch - When terminals 3 & 4 are
shorted together the span setting is ignored forcing the
ratio to 100%.
Start Up Delay - The unit will pause for 10 seconds
after power is applied to begin driving the output.
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 LED indicates the the inpput
signal is out of range or may be reversed.
– 15 –
TROUBLESHOOTING GUIDE
Modulating Discharge Temperature (MDT or VDT EXPERT) Controls
Portions reproduced with permission from Maxitrol® Company
Symptom
Possible Cause
A. No Gas Flow
with DO-2
on UC-01
energized.
1. Modulating valve
improperly installed.
1. Arrow on side of valve should
point in direction of gas flow.
1. Install properly.
B. Continuous Low
Fire (Electronics
Problem).
1. Short circuit or no
voltage to the amplifier
(RE-26).
2. Jumper not connected
across amplifier (RE-26)
terminals 3 & 4.
3. Faulty amplifier (RE-26).
1. Check for 24V AC at
amplifier (RE-26) terminals
7 & 8.
2. Inspect.
1. Prove the power source.
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.
3. If item B1 checks out and
modulating voltages are
still not obtained, amplifier
(RE-26) may be assumed
faulty. Replace.
1. Short circuit or open
circuit in Modulator Coil.
1. Measure resistance across
modulator terminals with
connecting wires detached.
2. Plunger missing,
jammed or improperly
installed.
2. Inspect. Plunger should be
installed to operate freely in
solenoid sleeve.
1. Replace modulator head
if not approximately 45-55
ohms for M611 Valve and
60-80 ohms for MR212
Valve.
2. Clean or replace plunger if
necessary.
D. Incorrect
Minimum Fire
Erratic or
Pulsating Flame.
1. Incorrect by-pass
metering valve
adjustment.
2. Excessive negative
burner pressure.
1. See valve adjustments in
Section X.
1. Adjust to proper minimum
fire.
2. Close main gas supply and
measure manifold pressure
with blower operating.
Reading should be less than
1.5" w.c. negative pressure.
2. If reading is greater than 1.5"
negative pressure, check
for clogged filters or other
inlet air restrictions. Consult
factory for other solutions.
E. Continuous High
Fire (Electronics
Problem).
1. Open circuit in Outside
Air Temperature Sensor
(TS-01) or Discharge
Air Temperature Sensor
(TS-03) circuit or wiring.
1. Check Outside Air
Temperature Sensor
(TS-01) or Discharge Air
Temperature Sensor (TS-03)
for open internal circuit. See
Thermistor curve.
1. Replace Outside Air
Temperature Sensor (TS-01)
or Discharge Air Temperature
Sensor (TS-03
F. Continuous High
Fire (Electronics
OK).
1. Foreign object holding
valve open.
2. Plunger jammed.
1. Remove bottom plate and
inspect valve and seat.
2. Inspect. Plunger should
be smooth and clean and
operate freely in solenoid
sleeve.
1. Clean seat. Clean valve or
replace if necessary.
2. Clean, or if necessary,
replace plunger.
4. No output voltage on
UC-01.
C. Continuous Low
Fire (Electronics
OK).
Field Test
Remedy
2. Correct the wiring.
4. Contact Factory.
(Refer to Digital Control System User Manual for additional troubleshooting suggestions)
– 16 –
TROUBLESHOOTING GUIDE
Modulating Discharge Temperature (MDT or VDT EXPERT) Controls continued
Symptom
G. Incorrect
Maximum Fire.
Possible Cause
1. Inlet pressure too low.
2. Incorrect outlet pressure
adjustment of Pressure
Regulator.
H. Incorrect
Discharge Air
Temperature
1. Unit Enable Potentiometer
(MP-15) not set correctly.
2. Discharge Air
Temperature Sensor
(TS-03) not reading
correctly.
3. The Heating Discharge
Air Setpoint on
VDT-EXPERT Control
System is not set
correctly.
I. Burned out
Transformer.
1. Short circuit in
modulator coil.
2. Short circuit between
amplifier and modulator
valve.
Portions reproduced with permission from Maxitrol® Company
Field Test
Remedy
1. Read pressure at inlet to
modulating valve using
a manometer with unit
operating at full fire.
Pressure should be equal
to the sum of outlet pressure
setting plus pressure drop
of the valve.
2. Read manifold pressure
using manometer and
compare with the pressure
stated on the specification
plate.
1. Increase inlet pressure if
possible.
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. Change to correct setpoint
setting.
1. Measure resistance across
modulator terminals with red
lead wires disconnected.
2. Inspect wiring.
1. Replace modulator head if
less than 40 ohms.
2. See valve adjustments in
Section X.
2. If readings are not correct,
replace Discharge Air
Temperature Sensor (TS-03)
or repair wiring.
3. Change to correct setpoint.
See Digital Control System
User Manual.
2. Correct wiring if short is
found.
(Refer to Digital Control System User Manual for additional troubleshooting suggestions)
– 17 –
TROUBLESHOOTING GUIDE
Modulating Room Temperature (MRT, MRT-PRO or MRT-EXPERT) Controls
Symptom
Possible Cause
Portions reproduced with permission from Maxitrol® Company
Field Test
Remedy
A. No Gas Flow with
DO-2 on UC-01
energized.
1. Valve improperly
installed.
1. Arrow on side of valve
should point in direction
of gas flow.
1. Install properly.
B. Continuous Low
Fire (Electronics
OK).
1. Open circuit in
modulator coil.
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. If proper resistance values
are not observed, replace
modulator head or repair
wiring.
1. Check for 24V AC at
amplifier (RE-26) terminals
7 & 8.
2. Inspect.
1. Prove the power source.
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.
3. If item B1 checks out and
modulating voltages are
still not obtained, amplifier
(RE-26) may be assumed
faulty. Replace.
1. See Valve Adjustments
Section X.
2. Close main gas supply and
measure manifold pressure
with blower operating.
Should be less than 1.5" w.c.
negative pressure.
1. Adjust to proper low fire.
2. Plunger missing,
jammed or improperly
installed.
3. Ruptured main or
balancing diaphragm.
C. Continuous Low
Fire (Electronics
Problem).
1. Short circuit or no
voltage to the amplifier
(RE-26).
2. Jumper not connected
across amplifier (RE-26)
terminals 3 & 4.
3. Faulty amplifier (RE-26).
4. No output voltage on
UC-01.
D. Incorrect
Low Fire.
E. Continuous
Minimum
Discharge Air
Temperature.
F. Incorrect
Maximum
or Minimum
Discharge Air
Temperature.
1. Incorrect by-pass metering
valve adjustment.
2. Excessive negative
burner pressure.
1. Incorrect room
temperature.
1. Maximum or minimum
heating discharge
temperature setpoint
not set correctly.
2. Clean or replace plunger if
necessary.
3. Replace diaphragm if
ruptured.
2. Correct the wiring.
4. Contact Factory.
2. If greater than 1.5" negative
pressure, check equipment
for clogged filters and other
inlet air restrictions. For other
solutions, consult factory.
1a. Check Outside Air Sensor
(TS-01),Space Temperature
Sensor (TS-02) and
Discharge Air Sensor
(TS-03) for correct readings.
See Thermistor curve.
1b. Check Space Temperature
Sensor (TS-02) setpoint.
1c. Check Heating Occupied
and/or Unoccupied setpoint.
1a. Replace Sensors if reading is
incorrect or correct wiring.
1. Install a BACview 6 or PC.
1. Change to correct setpoints.
1b. Change to correct setpoint.
1c. Change to correct setpoint.
(Refer to Digital Control System User Manual for additional troubleshooting suggestions)
Control circuits external to MRT Controls can cause burner malfunction.
Always check manual valve to be certain gas is on, and check limit controls for normal operation.
– 18 –
TROUBLESHOOTING GUIDE
Modulating Room Temperature (MRT, MRT-PRO or MRT-EXPERT) Controls continued
Symptom
Possible Cause
Portions reproduced with permission from Maxitrol® Company
Field Test
Remedy
G. Continuous High
Fire (Electronics
OK).
1. Foreign material
holding valve open.
2. Plunger jammed.
1. Remove bottom plate and
inspect valve and seat.
2. Inspect - plunger should be
smooth and clean and operate
freely in solenoid sleeve.
1. Clean, replace valve and/or
seat if necessary.
2. Clean, or if necessary,
replace plunger.
H. Continuous High
Fire (Electronic
problem).
1. Open circuit in Outside
Air Temperature
Sensor (TS-01), Space
Temperature Sensor
(TS-02) or Discharge
Air Temperature Sensor
(TS-03)
1. Measure resistance per
Thermistor Curve.
1. If readings are incorrect,
replace Outside Air
Temperature Sensor (TS-01),
Space Temperature Sensor
(TS-02) or Discharge Air
Temperature Sensor (TS-03)
or repair wiring.
I. Incorrect High
Fire.
1. Inlet pressure too low.
1. Read inlet pressure at
valve, using a manometer
with heater operating at full
fire. Pressure should be at
least equal to the sum of:
outlet pressure setting and
pressure drop of the valve
plus 1.0" w.c.
2. Read outlet pressure using
manometer and compare
with the pressure stated on
the specification plate.
1. Increase inlet pressure
if possible or change to
larger valve. Consult factory
about possibility of using
special spring to reduce
pressure drop on selected
installations.
2. Incorrect outlet
pressure adjustment.
2. See Valve Adjustments
-Section X.
J. Continuous
Maximum
Discharge Air
Temperature.
1. Open circuit in Space
Temperature Sensor
(TS-02) or Discharge
Air Temperature Sensor
(TS-03).
1. Measure resistance per
Thermistor Curve.
1. If readings are incorrect,
replace Space Temperature
Sensor (TS-02) or Discharge
Air Temperature Sensor
(TS-03) or repair wiring.
K. Burned out
Transformer.
No Voltage to
Amplifier.
1. Short in modulator
coil circuit.
1. Measure resistance per
item B1.
2. Short circuit between
amplifier and modulator
valve.
2. Inspect wiring.
1. If proper resistances are not
observed, replace modulator
head or repair wiring.
2. Correct wiring if short is
found.
L. Incorrect Space
Temperature.
1. Incorrect Maximum
Heating Discharge
Temperature Setpoint.
1. Check to see if heater is
delivering at Maximum
Heating Temperature
Discharge Setpoint.
2. Check to see if heater
is delivering at Minimum
Discharge Setpoint.
2. Incorrect Minimum
Heating Discharge
Temperature Setpoint.
3. Incorrect space setpoint. 3a. Check Unit Enable
Potentiometer (MP-15)
Setpoint.
3b. Check Heating Occupied
and/or Unoccupied setpoint.
4. Insufficient burner
4. Check to see if heater is
capacity.
operating at high fire.
1. If desired temperature is
not reached, increase
Maximum Heating Discharge
Temperature Setpoint.
2. If desired Space Temperature
is not reached, increase
Minimum Heating Discharge
Setpoint.
3a. Change to correct setpoint.
3b. Change to correct setpoint.
4. If desired Space Temperature is not reached with
heater at high fire, it may be
undersized. Consult Factory.
(Refer to Digital Control System User Manual for additional troubleshooting suggestions)
Control circuits external to MRT Controls can cause burner malfunction.
Always check manual valve to be certain gas is on, and check limit controls for normal operation.
– 19 –
TROUBLESHOOTING GUIDE
Cooling Mode
Symptom
Cause
Remedy
A. There is no voltage at cooling relays
(RE-34) (RE-35) and/or (RE-33) and
the fan is enabled.
1. Cooling mode is disabled
2. Auxiliary switch on starter (ST-01)
is not closed.
3. Air flow switches open.
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.
4. Cooling Changeover and/or
Economizer Setpoints not set
correctly.
5. DO-3 and/or DO-4 are not
energized.
B. Cooling relays (RE-34) (RE-35)
and/or (RE-33) are energized and
condensing unit or evaporative
cooler is not on.
C. Incorrect Space Temperature.
5. See Digital Control System User
Manual.
1. Cooling relays (RE-34) (RE-35)
and/or (RE-33) contacts are not
closed.
2. Cooling relays (RE-34) (RE-35)
and/or (RE-33) contacts are not
wired correctly.
3. Compressors or evaporative pump
not running.
1. Check and/or replace.
1. Incorrect Maximum Cooling
Discharge Temperature Setpoint.
1. Decrease Maximum Cooling
Discharge Temperature Setpoint.
See Digital Control System User
Manual.
2. Decrease Minimum Cooling
Discharge Temperature Setpoint.
See Digital Control System User
Manual.
3. Change to correct setpoints.
See Digital Control System User
Manual.
4. Change to correct setpoint settings.
See Digital Control System User
Manual.
5. If desired Space Temperature is
not reached and cooling is at full
capacity, it may be undersized.
6. See Troubleshooting Guide for your
condensing unit or evaporative
cooler.
2. Incorrect Minimum Cooling
Discharge Temperature Setpoint.
3. Unit Enable Potentiometer (MP-15)
not set correctly.
4. Cooling Occupied and/or
Unoccupied setpoints not set
correctly.
5. Insufficient cooling.
6. Condensing section or evaporative
cooler is not operating correctly.
2. Correct wiring.
3. See Troubleshooting Guide for your
condensing unit or evaporative
cooler.
(Refer to Digital Control System User Manual for additional troubleshooting suggestions)
– 20 –
TROUBLESHOOTING GUIDE
To Calibrate the Building Pressure Transducer
(PT-13)
1. Remove the tubes at the Low and High pressure
fittings.
2. The voltage at –COM and OUT should be 2.5 VDC.
If not adjust Z (do not adjust S).
3. Make sure the Low and High fittings are clean
and clear (do not insert any sharp objects into
the pressure fittings). Make sure the tubing is
also clean, clear of any debris and then reinstall
the tubes on the transducer. It is very important
that the High tube be placed inside the building,
and positioned so that air movement does not
affect it. The Low side should be to atmosphere,
and positioned so it is not exposed to the
weather.
4. With the use of a BACview 6 (KP-01) place the
unit in the Building Pressure mode. (See the Digital
Control System User Manual).
5. The voltage at –COM and OUT will vary between
0 to 5 VDC. O VDC means the building is in a
negative pressure and should open the Outside
Air/Profile and close the Return Air damper. 5 VDC
means the building is in a positive pressure and
should open the Return Air Damper and close the
Outside 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,
clear of any debris and then reinstall the tubes
on the transducer. It is very important that
the Low and High tubes from the Flow Station
are installed on the transducer correctly (see
drawing #C000643 below).
4. With the use of a BACview 6 (KP-0l) place the unit
in the Calibration Mode (see the Digital Control
System User Manual). This will open the Return Air
damper and close the Outside Air damper. The unit
will calibrate for 5 minutes. IMPORTANT: Be sure
there is no blockage in the return air duct.
5. The voltage at –COM and OUT should be at least
2 VDC. If the voltage is less than 2 VDC contact the
factory.
PT-13
PT-15
SETRA P/N
MESTEX P/N
RANGE
SETRA P/N
MESTEX P/N
RANGE
26510R1WBABT1C
68.0330.69
± .1 IN WC
26510R1WDABT1C
68.0330.66
0 - 0.1 IN WC
2651R25WDABT1C
68.0330.67
0 - .25 IN WC
26510R5WDABT1C
68.0330.68
0 - .5
– 21 –
IN WC
TROUBLESHOOTING GUIDE
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 between the burner and profile plates
the same opening on both the top and bottom of the
burner when making these adjustments.
Checking The Burner Velocity Pressure
PS-10 & PS-11 air switches are factory calibrated.
Do not adjust.
Check the velocity pressure by disconnecting both
pressure sensing tubes from one of the high airflow
switch. Connect one end of your manometer to each
sensing tube and start the fan. The permissible
pressure range should be marked on the switches.
If it’s close to the high or low trip points of the airflow
switches, you could have a problem: High pressure
switch open means too much velocity; low pressure
switch open means not enough velocity.
Depending on the motor amps you may want to
change the speed of the fan if the unit has adjustable
sheaves.
Don’t forget to remove the jumper and reconnect the
sensing tubes to the switch.
Call factory with any questions.
Jumper the switch from which you’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.
Profile
Plates
– 22 –
MULTIPLEXED VOLTAGE CHART
RESISTOR
VALUE
RESISTOR ID
1000
2000
4020
8060
RS1
RS2
RS3
RS4
MULTIPLEXED VOLTAGE
VALUES
SWITCH
CLOSED
OHMS IN
CIRCUIT
VOLTS DC
RS1,2,3,4
RS2,3,4
RS1,3,4
RS3,4
RS1,2,4
RS2,4
RS1,4
RS4
RS1,2,3
RS2,3
RS1,3
RS3
RS1,2
RS2
RS1
NONE
UNPLUGGED
0
1000
2000
3000
4020
5020
6020
7020
8060
9060
10060
11060
12080
13080
14080
15080
NA
0
0.30
0.55
0.76
0.95
1.10
1.24
1.36
1.47
1.57
1.65
1.73
1.80
1.87
1.92
1.98
3.30
IN-3
JUMPER
RE-56
RE-09
SW-72
RS-04
RS-03
RS-02
RS-01
MIXED AIR TEMP
SAFETY CKT STATUS
FLAME FAILURE
100% OA or 100% OUTPUT
IN-4
RE-27
RE-65
RE-12
SW-09
RS-04
RS-03
RS-02
RS-01
BURNER STATUS
FAN STATUS
CLOGGED FILTER
AUXILIARY UNIT ENABLE
– 23 –
SECTION VIII - MAINTENANCE SCHEDULE AND LUBRICATION REQUIREMENTS
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 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 first 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 flame 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 fire
and low fire. At low fire setting, be sure there
is a continuous flame along the entire burner
length without any blowout spots.
e. Clean the flame sensor.
f. Inspect filters. 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
fittings. CAUTION: Remove tubes from switches,
transducers, and flow 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.
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 lubricate bearings if necessary.
e. Check the flame and spark rod wiring and connections.
f. Check the flame and spark rods. Replace if necessary.
g. Inspect the burner carefully. Clean and adjust if necessary.
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 flame 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 manufacturer.
n. Inspect fan motor wiring for loose connections.
o. Lightly oil all door latches.
p. Check that cabinet is weathertight, replace door gaskets and recaulk as necessary.
q. Check all nuts and bolts for tightness.
NOTE: Keep screened air intakes clear of obstructions at all times.
– 24 –
B. Lubrication Instructions
CAUTION: An excess of grease will overheat the
bearings.
Item
Manufacturer
Bearing Type
All 3 phase
US., Baldor
Single row ball
fan motors
or equal
bearings
(1 HP to
100 HP)
ODP, TEFC
Recommendation: See following note.
NOTE: On totally enclosed fan cooled (TEFC)
motors, the 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 prelubricated with a number 2 lithium base grease. Relubrication 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 frequent intervals while the shaft is
being manually rotated.
All 1 phase
Century, G.E.,
Bronze sleeve
motors
or equal
bearings
(Fractional
HP) ODP,
TEFC or
TEAO
Recommendation: See following note.
Fractional HP Century, G.E.
Bronze sleeve
single phase, or equal
bearings
ODP or
TEFC
Recommendation: See following note.
Fan shaft
bearings
Fafnir
or equal
Self-aligning
single row or
double row
ball bearings,
resilient mounted
Recommendation: See following note.
Dampers
Factory
Sleeve
or equal
Recommendation: See following note.
1. Blower Motors – Some motors require lubrication
while others do not. Those that require lubrication can
be identified by the presence of grease plugs in the
motor casing at each end. Motors that do not have
grease plugs cannot be greased and are lubricated for
the life of the motor bearing.
Lubrication of motors should be done while the motor is warm and at a standstill. Remove and clean all
grease plugs and insert a grease fitting in the upper
hole in the motor casing at each end. (Viewed as if
motor were sitting horizontally on its base). There may
be one or two plugs in each end casing of the motor.
Add a small amount of a clean, good grade ball bearing grease, such as Exxon Polyrex EM or equal, with a
low pressure grease gun. Run the motor five minutes
before removing the grease fittings and replacing the
plugs.
A slight showing of grease at the seals with accompanying normal bearing temperature indicates proper
lubrication. Normal temperature can range from “cool”
to “hot to the touch” depending on size, speed and
surrounding conditions. Excessive bearing temperature
indicates faulty lubrication. An insufficient amount of
grease is suggested by a bearing showing no grease
at the seals, and a higher than normal temperature
and noise level. Excessive leakage of grease at the
seals, and a high operating temperature suggest too
much grease.
Frequency of Lubrication – Frequency of lubrication depends upon operating conditions. The bearing
operating temperature is the best index for determining a relubrication schedule. The following chart gives
the frequency of relubrication based upon continuous
operation for various operating temperatures and can
be used as a satisfactory guide for determining when
all ball and roller bearings should be relubricated.
Speed
100 RPM
500 RPM
1000 RPM
1500 RPM
Any Speed
Temperature
Up to 125°F
Up to 150°F
Up to 210°F
Over 150°F
Up to 150°F
Cleanliness
Clean
Clean
Clean
Clean
Dirty
Any Speed Over 150°F
Dirty
Any Speed Any Temp.
Very Dirty
Any Speed Any Temp.
Extreme
Conditions
– 25 –
Interval
6 months
2 months
2 weeks
weekly
1 week
to 1 month
daily to
1 week
daily to
1 week
daily to
1 week
Browning Bearing Set Screw Torque Values
Model#
Shaft Size
Torque (in-lbs)
Set Screw
VPS-212
VPS-214
VPS-116
VF2S-116
VPS-219
VF4S-219
VPS-220
VPS-223
VPS-323
VF4S-227
VPS-327
VPS-231
VF4S-231
VPS-331
VPS-235
VF4S-235
VPS-236
VPS-239
VF4S-243
VPS-343
VPS-347
3/4
7/8
1
1
1 3/16
1 3/16
1 1/4
1 7/16
1 7/16
1 11/16
1 11/16
1 15/16
1 15/16
1 15/16
2 3/16
2 3/16
2 1/4
2 7/16
2 11/16
2 11/16
2 15/16
66 - 85
66 - 85
66 - 85
66 - 85
66 - 85
66 - 85
126 - 164
126 - 164
126 - 164
126 - 164
228 - 296
228 - 296
228 - 296
228 - 296
228 - 296
228 - 296
228 - 296
228 - 296
348 - 452
348 - 452
348 - 452
BOA Concentric
VPB-231
VPB-331
1 15/16
1 15/16
220 - 240
220 - 240
Spherical Roller
SPB 1000 NE
SPB 1000 NE
SPB 1000 NE
SPB 1000 NE
SPB 1000 NE
SPB 1000 NE
SPB 1000 NE
SPB 1000 NE
1 3/16
1 7/16
1 11/16
1 15/16
2 3/16
2 7/16
2 11/16
2 15/16
290 - 380
290 - 380
290 - 380
290 - 380
290 - 380
620 - 930
620 - 930
620 - 930
Sealmaster Sleevloc
SPB 2115 C2
1 15/16
65
When replacing bearings refer to the manufacturers
installation instructions included with the bearing.
Typical Procedure For Changing The Shaft And
Bearings
1. Remove protective shaft coating.
2. Remove the drive side sheave.
3. Disconnect the grease lines from the existing
bearings.
4. Identify the total shim thickness at each bearing
and mark the bearing mount for future reference.
5. Remove mounting bolts for bearings and remove
any shims.
6. Loosen bearing and blower wheel shaft setscrews.
7. Remove the shaft from the unit by sliding the
bearings and blower wheels along the shaft as
the shaft is extracted. Unless a blower wheel is
damaged, it should be unnecessary to remove the
blower wheel from the blower housing.
8. Slide the new shaft through the first blower wheel
hub.
9. Once the shaft is completely through the first
blower wheel, slide a bearing onto 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 the blower hub keyways are in
the middle of the shaft keyways.
15. Adjust the shaft so it protrudes past the non-drive
end bearing, the blower sheave keyway mates with
the shaft keyway, and the drive side sheave can be
aligned with the motor sheave. Ideally, the blower
sheave should be as close to the drive side bearing
as possible, the motor sheave should be as close
to the motor housing as possible, and the belts
should be straight.
16. Be sure the shaft does not rub on or interfere with
the closing of the access door.
17. Align all bearing setscrews, so that the same set
screw on each bearing is pointed in the same
direction as the other bearings’ setscrews.
18. Place a drop of “BLUE” Loctite on the bearing
setscrews and tighten all of the setscrews. Follow
the mounting instruction’s procedure on the inside
of the bearing box, for the proper tightening and
torque values.
19. Align the blower hubs’ keyway with those in the
shaft. Be sure the clearance between the blower
wheel and blower housing is the same on each
side.
20. Rotate the shaft by hand to insure free operation.
Correct any rubbing of the blowers on the
housings.
21. Place a drop of “BLUE” Loctite on the blower setscrews and tighten all of the setscrews.
22. Align the blower and motor sheaves using a laser
or straight edge and tighten the blower sheave to
the shaft.
23. Replace the belts and tighten the motor base
adjustment for the proper belt tension. Over
tightening the belt tension will severely reduce
belt and bearing life. Belt deflection should be
approximately 1/64 inch of the belt span.
– 26 –
24. Monitor for excessive heat or vibration during
operation.
25. All bearings are pre-lubricated and should
not require greasing. Refer to the bearing
manufacturer’s instructions or the unit
manufacturer’s instructions for proper bearing
maintenance.
Note: Drive side Sleevlock bearing installation
(SPB-2115-C2).
1. Mount all the bearings and leave all the bolts
and setscrews loose
2. Tighten setscrews on Sleevlock bearing to
the tightening pattern as described in the
installation sheet that comes with the bearing
to a final 65 inch lbs while rotating the shaft.
Check to make sure the insert of the bearing is
centered in the bearing housing and then bolt
bearing down.
3. Tighten down the bolts and setscrews on
the remaining bearings per installation sheet
starting from the end bearing back toward’s the
Sleevlock while rotating the shaft.
3. Dampers – Dampers should be inspected monthly
(daily in icy weather) for securely fastened linkages,
and smooth operation. If dampers are binding or
excessively noisy, then lubrication may be required.
Place one drop of #20 wt. machine oil, silicone spray,
graphite or equal on each blade bearing, and linkage
ball joint. Do not over lubricate, and wipe any excess
from the area. Be sure to note that dampers over 49
inches long have intermediate bearings which require
lubrication.
C. Air Filters
All filter banks should be equipped with a manometer
or differential pressure switch to indicate when the
filters are dirty. Filters should be replaced when
the differential pressure across them reaches the
manufacturer’s recommended final value. Dirty filter
elements should be replaced with a clean element of
the same type and size. In addition, the factory not
only suggests, but insists, that air filters be checked
every 30 days and replaced with new filters (throwaway type) or cleaned (washable type) as required.
Cleanable filters should be given new application of
filter coating after washing to maintain optimum filter
performance.
It is necessary, therefore, to tighten all belts during the
first few months of operation, and to check for proper
tension weekly during the first 60 days, after which
30-day check intervals are sufficient.
NOTE: Turn off all power to the equipment before
checking belt tensions.
CAUTION: Do not attempt to tighten any belt or belts
by changing the pitch of an adjustable pulley, as this
will change the speed of a driven pulley, causing the
unit to be rendered OUT OF AIR BALANCE. Do not
overtighten belts.
Suggested Belt Tension Method
1. Check tension frequently during the first 24-48
hours of run-in operation. Ideal tension is the
lowest tension at which the belt will not slip under
peak load conditions. Over tensioning shortens belt
and bearing life.
2. To properly tension a conventional V-belt drive use
the following procedure:
a. Measure the span length.
b. At the center of the span, apply a force perpendicular to the span to deflect the belt 1/64 inch
for every inch of span length. For example, for a
40 inch span, apply a force that will deflect the
belt 40/64 or 5/8 of an inch.
c. Compare the force you have applied with the
values given in the table below. If the force is
between the values for normal tension and 1-1/2
times normal tension, the belt tension should be
satisfactory. If the belt tension is not within this
range, it can be adjusted by loosening the motor
mounting bolts, and adjusting the position of the
motor along its base.
B Section
small
Pounds
pulley
Pounds
Force for
diameter Belt
Force for 11/2 times
range in
Manufacturer
Normal
Normal
Inches
& Type Belt
Tension
Tension
3.4-4.2
Gates Hi-Power
4.4
6.6
4.4-4.6
Gates Hi-Power
4.9
7.4
5.8-8.6
Gates Hi-Power
5.8
8.7
Note: For recommendation of other types of belts,
consult respective manufacturers.
The frequency of cleaning and replacing air filters
applies twelve months of the year, where 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.
E. Optional Coils And Related Items
1. Coils – Coil surfaces must be kept clean of dirt
and lint in order to operate at rated efficiency.
Coils should be inspected on a regular basis and
cleaned as required.
– 27 –
If any mixing plates are loose or missing
fasteners, tighten/replace as necessary. Always
use zinc plated or stainless fasteners. The
mixing plates on the burner may display “hairline”
cracks. These cracks are normal, and caused by
thermal stresses occurring during combustion.
The presence of these “hairline” cracks in no
significant way affects the combustion efficiency
or performance of the heater. Should a large
opening develop, it may cause difficulties in cross
ignition of flame across the face of the burner. If
this does occur, the specific mixing plate or plates
involved must be replaced.
c. Put system back into operation and view burner
while cycling through full firing range. This will
give a visual check for blocked burner ports.
CAUTION: Solutions used to clean coils must
not be corrosive to metals or materials used in
the manufacturer of this equipment. If cleaning
solutions are applied through means of high
pressure spray, care must be taken to avoid
damaging the coil fins.
2. Condensate Drain Pan – Periodically flush the
condensate pan and drain system with a water
hose.
F. Gaskets
Gaskets are used on doors, inspection covers, some
filter racks, and some outdoor air dampers. Inspect
gaskets periodically and repair or replace as required.
G. Caulking
Inspect cabinet and add caulking as required.
H. Casing
Periodic cleaning of the casing is recommended to
remove dirt, grease and corrosive substances that
may injure finish. Rusted or corroded areas should be
cleaned and painted.
I. Support
Inspect the entire support structure to be sure
everything is firmly in place.
J. Heater
1. At least a yearly inspection is recommended
for heating installations and more frequently for
process applications in year-round operation. Your
own experience is the best guide in determining
frequency of inspection, but as a minimum the
following procedure should be followed:
a. Shut the system down totally, disconnecting or
locking out power supply so there can be no
accidental start-up during inspection.
b. Inspect the burner carefully, including upstream
and downstream sides of mixing plates as well
as burner body face. Note that complete burner
assembly may have to be removed for proper
inspection and cleaning. Any accumulation of
scale or foreign material 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.
2. Inspect the flame rod and ignition electrode for dirt
and moisture. Wipe off if necessary. Examine for
any evidence of premature arcing. If in doubt, check
continuity of flame rod to be sure it is not grounding
out. Replace if required.
The porcelain on the ignition electrode must be
intact - not cracked. The spark gap should be 1/8
of an inch on Mestek burners.
3. Replace all access panels which have been removed
and operate the unit for a test period. Check for
normal response and function of all controls.
4. Check all gas piping for possible leaks using a soap
bubble solution.
5. Inspect the support means to be sure that
everything is firmly anchored in place.
WARNING: Do not enlarge burner ports or
performance may be drastically affected.
– 28 –
SECTION IX - MESTEK LINE BURNERS
Inspection and Maintenance of Gas Ports
Conduct initial inspection within the first month after
commissioning. Visually check the gas ports of new
burner assemblies for any piping scale or debris. Use
Pin Vise with drill bit to remove.
Use of an electric drill motor is not suggested unless
both Pin Vise and Drill can be chucked up in a varispeed drill unit. Use caution, because it is easy to snap
the bits off in a port when using a drill motor. Removal of
broken bits from the gas ports is difficult.
Annual inspections are normally adequate once
the initial piping debris is removed. The operating
conditions of the burner will determine how frequently
maintenance is actually required.
Alternate drill size which may be used is a 5/64" (for
#45).
P001117 - Mestek Line Burners
– 29 –
SECTION X - MANIFOLD AND VALVE ADJUSTMENTS
The I/O Zone 583 Controller
(UC-01) must be calling for the
burner to be enabled. The
DO-2 light will be on and Burner
Enable Relay (RE-28) needs to
be energized. This will put power
to the Burner Relay (RE-02). If
the outside air temperature is
above the Heating Economizer
65°F Setpoint the burner will
be disabled. You will need to
disconnect the plug where the
Outside Air Temperature Sensor
(TS-01) and Discharge Air
Temperature Sensor (TS-03)
are wired to the I/O Zone 583
Controller (UC-01), see High
Fire and Low Fire Adjustment
in following section. Reconnect
the plug if you are getting close
to the Freezestat lockout time,
approximately 3 minutes. To reset
the Freezestat alarm simply turn
the power off and back on at the
disconnect switch.
NOTE: A BACview or PC is
required to change settings.
See the Digital Control System
User Manual for a more detailed
sequence of operation.
Prior to setting high and low
fire you should have your test
equipment installed and be familiar
with the gas valve (VG-07) and
its adjustment, see High Fire and
Low Fire Adjustment in following
section. For High Fire Setpoint
refer to rating plate on unit for
Normal Manifold Pressure in
inches of water column. The typical
high fire flame should be blue and
approximately 12 to 18 inches long
with short orange to yellow tips.
After high fire has been set, low
fire may need to be re-adjusted.
Cycle the burner several times to
be sure it lights off reliably. Low fire
is a visual setting.
CAUTION: There should be a continuous flame along the entire
burner length without any blowout spots.
HIGH AND LOW FIRE MANIFOLD ADJUSTMENT
FOR MAXITROL VALVES WITH DDC
M611
MR212
(MR212)
(M611)
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 on freezestat after
approximately 3 minutes.
2. Remove seal cap (A) and turn
regulator pressure adjusting
screw to obtain normal
manifold pressure (clockwise
rotation increases pressure).
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
shutdown on freezestat after
approximately 3 minutes.
2. Adjust the gas pressure
regulator (GP-05) to obtain the
normal manifold pressure.
Low Fire or Bypass Adjustments
1. Disconnect wire from (RE-26)
terminal #8. This causes valve
to call for continuous low fire.
2. Remove cap (B) and loosen
lock screw (C). Turn (D) to
desired low fire adjustment.
(Clockwise rotation reduces
minimum flow rate.)
3. Tighten screw (C), replace cap
(B), and reconnect wire to
(RE-26) terminal #8.
4. Reconnect the plug back into
the jack on the unit control
module (UC-01).
– 30 –
Low Fire or Bypass Adjustments
1. Disconnect wire from (RE-26)
terminal #8. This causes valve
to call for continuous low fire.
2. Remove cap (A) and turn
adjusting screw (B) to desired
low fire adjustment. (Clockwise
rotation reduces minimum flow
rate.)
3. Replace cap (A) and reconnect
wire to (RE-26) terminal #8.
4. Reconnect the plug back into
the jack on the unit control
module (UC-01).
CIRCUIT ANALYSIS – MAXITROL GAS VALVES
Connect a DC volt meter (capable of reading 0-24V DC) on the Modulator (M611) or Modulator-Regulator
(MR212) Valve terminals.
The operation of the Valve with regard to voltage is as follows: from 0 volts to approximately 5 volts, the modulating valve should be on bypass flow with the heater operating on low or minimum fire. From approximately 5 volts
to 15 volts DC, the valve should be performing its modulating function, and the heater should be firing at a modulated flow rate between low and high fire, depending upon the 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 electronics and/or electronic relay
(RE-26). See the Trouble Shooting Section and the Digital Control System User Manual.
See the Thermistor Output Curve in the following section.
SECTION XI - THERMISTOR OUTPUT CURVE
Typical 10,000 Ohm Thermistor Output Curve
Resistance (Ohms)
30000
25000
20000
15000
10000
5000
0
32
41
50
59
68
77
86
Temperature in Degrees F
– 31 –
95
104
SECTION XII - REPLACEMENT PARTS
Replacement parts may be ordered from the factory.
All warranty parts will be shipped freight allowed from
factory for normal ground service. Warranty parts must be
returned prepaid within 30 days. Credit will be issued if
part is complete, defective and returned on time.
When parts are ordered, MODEL NUMBER, SERIAL
NUMBER, FACTORY ORDER (F.O.) and PART NUMBERS are required. Belts, filters, and fuses are not
covered under warranty.
Dealer/Contractor Name:
Address:
City:
State:
Zip:
Ph:
SECTION XIII - RECIRCULATION
WARNING: On Heaters, which recirculate room
air, outside ventilation air must be provided in
accordance with the information shown on the
heater nameplate.
Recirculation of room air may be hazardous in the
presence of:
• flammable solids, liquids and gases
• explosive materials such as grain dust, coal dust,
gunpowder, etc.
• substances such as refrigerants or aerosols which
may become toxic when exposed to heat or flame
Recirculation is not recommended in uninsulated buildings where outside temperatures fall below 32°F (0°C).
Excessive recirculation or insufficient ventilation air,
which results in inadequate dilution of combustion
products generated by the heater, may create hazardous concentration of carbon monoxide, nitrogen
dioxide, and other combustion products in the heated
space.
If gas fork trucks or other fossil fuel powered equipment are utilized in the conditioned area, additional
ventilation requirements for the facility must be addressed separately.
The heater inlet shall be located in accordance with
applicable building code provisions for ventilation air.
Field constructed intake accessories should be properly 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 labeled heaters must be equipped with a control
system and an air measuring station provided by the
heater manufacturer and installed on the return air
damper or duct.
4830 Transport Drive, Dallas, TX 75247
Phone: 214-638-6010 Fax: 214-905-0806
www.ljwing.com

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