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Compact Direct Fired Heaters
Installation, Operation, and Maintenance Manual
FOR YOUR SAFETY
IF YOU SMELL GAS: OPEN WINDOWS, DO NOT TOUCH ELECTRICAL SWITCHES, EXTINGUISH
ANY OPEN FLAMES, IMMEDIATELY CALL YOUR GAS SUPPLIER.
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.
RECEIVING AND INSPECTION
Upon receiving unit, check for any interior and exterior damage. If damage is found, report it immediately to the carrier. Check that all accessory items are accounted for and are not damaged.
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. ALWAYS disconnect power and gas prior to working on heater.
Save these instructions . This document is the property of the owner of this equipment and is required for future maintenance. Leave this document with the owner when installation or service is complete.
A0011029
May 2020 Rev. 15
2
Motorized Intake Damper ............................................................................................................................................... 13
EVO™/ECM-VCU .......................................................................................................................................................... 13
External PWM Signal ..................................................................................................................................................... 14
Motorized Intake Damper ................................................................................................................................................... 20
Electric Cabinet Heater ...................................................................................................................................................... 20
Start-Up and Maintenance Documentation ........................................................................................................................ 44
3
WARRANTY
This equipment is warranted to be free from defects in materials and workmanship, under normal use and service, for a period of 2-years from date of shipment. This warranty shall not apply if:
1. The equipment is not installed by a qualified installer per the MANUFACTURER’S installation instructions shipped with the product.
2. The equipment is not installed in accordance with Federal, State, Local codes and regulations.
3. The equipment is misused or neglected, or not maintained per the MANUFACTURER’S maintenance instructions.
4. The equipment is not installed and operated within the limitations set forth in this manual.
5. The invoice is not paid within the terms of the sales agreement.
The MANUFACTURER shall not be liable for incidental and consequential losses and damages potentially attributable to malfunctioning equipment. Should any part of the equipment prove to be defective in material or workmanship within the 2-year warranty period, upon examination by the MANUFACTURER, such part will be repaired or replaced by MANUFACTURER at no charge. The BUYER shall pay all labor costs incurred in connection with such repair or replacement. Equipment shall not be returned without
MANUFACTURER’S prior authorization, and all returned equipment shall be shipped by the BUYER, freight prepaid to a destination determined by the MANUFACTURER.
4
INSTALLATION
It is imperative that this unit is installed and operated with the designed airflow and electrical supply in accordance with this manual. If there are any questions about any items, please call the service department at 1-866-784-6900 for warranty and technical support issues.
Mechanical
WARNING: DO NOT RAISE UNIT BY THE INTAKE HOOD, BLOWER, MOTOR SHAFT, OR
BEARINGS. USE ALL LIFTING LUGS PROVIDED WITH A SPREADER BAR OR SLING UNDER THE
UNIT.
Clearance
The top, back, and front surfaces of this heater may not be installed less than 6” from combustible materials. The heater base may be installed on combustible surfaces. Allow 24” minimum service clearance on both sides of this heater.
Figure 1 - Spreader Bar
Site Preparation
1. Provide clearance around installation site to safely rig and
lift equipment into its final position ( Figure 1 ). Supports
must adequately support equipment. Refer to manufacturer’s estimated weights.
2. Locate unit close to the space it will serve to reduce long, twisted duct runs.
3. Consider general service and installation space when locating unit.
4. Do not allow air intake to face prevailing winds. Support unit above ground or at roof level high enough to prevent precipitation from being drawn into its inlet. The inlet must also be located at least 10 feet away from any exhaust vents. The fan inlet shall be located in accordance with the applicable building code provisions for ventilation air.
Spreader
Bar
Lifting Lugs
Lifting Lugs
5
Intake Assembly
) are shipped on a separate skid. Upon unit arrival, perform the following steps to assemble the intake to the unit.
1. Apply silicone or weather-proof gasket on the backside of the flanges of the intake hood or V-bank intake.
2. Secure the flanges of the intake hood to the unit with the supplied sheet metal screws.
3. Use caulk on the outside of the screws to prevent water leaks.
Figure 2 - Intake and Curb Assembly
1 2 3
1. Blower/Motor Access Door
2. Filtered Intake
4
3. Screened Intake
4. Curb
6
Curb and Ductwork
This fan was specified for a specific CFM and static pressure. The ductwork attached to this unit will significantly affect airflow performance. When using rectangular ductwork, elbows must be radius throat, radius back with turning vanes. Fl exible ductwork and square throat/square back elbows should not be used . Any transitions and/or turns in the ductwork near the fan outlet will cause system effect. System effect will drastically increase the static pressure and reduce airflow.
•
Table 1 shows the minimum fan outlet duct sizes and straight lengths required for optimal fan
performance.
• Do not use the unit to support ductwork in any way. This may cause damage to the unit.
• Follow SMACNA standards and manufacturer's requirements for the duct run s . Fans designed for rooftop installation should be installed on a prefabricated or factory-built roof curb.
• Follow curb manufacturer’s instructions for proper curb installation.
• The unit should be installed on a curb and/or rail that meets local code height requirements.
• Make sure the duct connection and fan outlet are properly aligned and sealed.
• Secure fan to curb through vertical portion of the ventilator base assembly flange. Use a minimum of eight (8) lug screws, anchor bolts, or other suitable fasteners (not furnished). Shims may be required depending upon curb installation and roofing material.
• Verify all fasteners are secure.
Figure 3 and Figure 4 show different mechanical installations.
• Adequate building relief shall be provided so as not to over pressurize the building when the heating system 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; or by interlocking a powered exhaust system; or by a combination of these methods.
• Heaters installed with intake ductwork must be purged to replace at least four air changes of the volume of the intake duct.
• If the failure or malfunction of this heater creates a hazard to other fuel-burning equipment in the building (e.g., when the heater is providing makeup air to a boiler room), the unit is to be interlocked to open inlet air dampers or other such devices.
• On outdoor installations, it is recommended that the discharge duct be insulated to prevent condensation during the “OFF” cycle in cold weather.
• Flexible connectors should be used on all ductwork connections. Vibration isolators are optional and can be supplied in the loose parts package.
• Units that are installed in airplane hangars should be installed in accordance with the Standard for
Aircraft Hangars, ANSI/NFPA 409. Units that are to be installed in public garages should be installed in accordance with the Standard for Parking Structures, ANSI/NFPA 88A, or the Standard for Repair
Garages, ANSI/NFPA 88B, and with CAN/CGA B149 Installation Codes.
Table 1 - Required Supply Ductwork
Duct Size
12” x 12”
Straight Duct Length
36”
7
Roof Mount Installation
Note: Refer to submittal drawings for specific unit dimensions.
Figure 3 - Roof Mount Installation Details
1. Discharge Opening
2. Curb Outer Wall
3. Flex Conduit for Field Wiring
4. Screened Intake
1
5. Filter Access Door
6. Service Disconnect Switch
7. 1/2” NPT Pipe
8. Blower/Motor Access Door
9. Control Drop
10. Motor Drop
8 6
3
7
2
AIRFLOW
5
4
10
1. Service Disconnect Switch
2. 1/2” NPT Pipe
3. Optional Unistrut Base for
Hanging
A. 1” Spacing from Unistrut to edge of unit
B. 36” Unistrut
C. Unit Height
Figure 4 - Indoor Inline
A
AIRFLOW
C
BLOWER/
MOTOR
ACCESS
DOOR
9
3
1
2
A
B
8
Gas
Installation of gas piping must conform with local building codes, or in the absence of local codes to the
National Fuel Gas Code, ANSI Z223.1 (NFPA 54) – latest edition. In Canada, installation must be in accordance with CAN/CGA-B149.1 for natural gas units and CAN/CGA-B149.2 for propane units.
WARNING: INLET GAS PRESSURE MUST NOT EXCEED PRESSURE INDICATED ON NAMEPLATE.
SEE UNIT NAMEPLATE FOR PROPER GAS SUPPLY PRESSURE AND GAS TYPE.
1. Always disconnect power before working on or near a heater. Lock and tag the disconnect switch or breaker to prevent accidental power-up.
2. Piping to the unit should conform to local and national requirements for type and volume of gas handled, and pressure drop allowed in the line. Refer to the Gas Engineer’s Handbook for gas line capacities.
3. The incoming pipe near the heater should be sized to match the connection on the outside of the unit.
Unit inlet sizes are shown in
Table 2 . The unit requires a steady supply of gas at all times, avoid
multiple taps in the gas supply line.
4. Install a ground joint union with brass seat and a manual shut-off valve external to the unit casing.
Install shut-off valve adjacent to the unit for emergency shut-off and easy servicing of controls. Refer to
.
5. Provide a sediment trap, as shown in Figure 5
, before each unit and where low spots in the pipeline cannot be avoided.
6. Clean out the gas line to remove debris before making connections. Purge gas line to remove air before attempting to start unit. Purging air from gas lines should be performed as described in ANSI
Z223.1-latest edition “National Fuel Gas Code,” or in Canada as described in CAN/CGA-B149.
7. All field gas piping must be pressure/leak tested before unit operation. Use a non-corrosive bubble forming solution or equivalent for leak testing. The heater and its individual shut-off 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 psi.
8. This unit requires the gas pressure to be within the unit’s minimum and maximum gas pressure ratings. If the pressure is greater than the maximum, the internal valve components will be damaged. If the pressure is below the minimum, the heater will not perform to specifications. Refer to
Unit Size
76
Table 2 - Gas Connection Sizes
Gas Pipe Size (NPT)
1/2”
9
1
Figure 5 - Gas Connection Diagram
1
2
3
4
A
5
1. Gas Supply Line Connection
2. Manual Gas Shut-off Valve
3. Ground Joint Union with Brass Seat
4. Plugged 1/8” NPT Test Gauge Connection
5. Sediment Trap
A. Minimum Depth = 3”
Gas Pressure Type
Natural/LP
Table 3 - Gas Pressure
Gas Pressure
5 - 14 Inches WC Maximum
NOTICE
Refer to the heater’s rating plate for determining gas supply pressures and requirements.
10
ELECTRICAL
WARNING!!
Disconnect power before installing or servicing unit. High voltage electrical input is needed for this equipment. A qualified electrician should perform this work.
Before connecting power to the heater, read and understand the entire section of this document. As-built wiring diagrams are furnished with each unit by the factory and are attached to the control module’s door or provided with paperwork packet.
National Electric Code, ANSI/NFPA 70. Verify the voltage and phase of the power supply, and the wire amperage capacity is in accordance with the unit nameplate. For additional safety information, refer to
AMCA publication 410-96, Recommended Safety Practices for Users and Installers of Industrial and
Commercial Fans.
1.
Always disconnect power before working on or near this equipment. Lock and tag the disconnect switch and/or breaker to prevent accidental power-up .
2. An electrical drop containing the line voltage power wiring is shipped with every unit. The electrical drop should be brought through one of the conduit openings located in the base of the unit, run through the curb, and connected to a junction box inside the building.
3. A dedicated branch circuit should supply the motor circuit with short circuit protection according to the
National Electric Code. This dedicated branch should be run to the junction box.
4. Verify that the power source is compatible with the requirements of your equipment. The nameplate identifies the proper phase and voltage of the equipment.
5. Units shipped with optional remote panels require a second drop through the base of the unit. It is important to route the motor wires in a separate conduit from the wiring.
6. Before connecting the unit to the building’s power source, verify that the power source wiring is deenergized.
7. Secure the power cable to prevent contact with sharp objects.
8. Do not kink power cable and never allow the cable to encounter oil, grease, hot surfaces, or chemicals.
9. Before powering up the unit, make sure that the fan rotates freely. Make sure that the interior of the unit is free of loose debris or shipping materials.
10. If any of the original wire supplied with the unit must be replaced, it must be replaced with type THHN wire or equivalent.
Table 4 - Copper Wire Ampacity
Wire Size AWG
3
2
6
4
1
14
12
10
8
Maximum Amps
65
85
100
115
130
15
20
30
50
11
Fan to Building Wiring Connection
Figure 6 - Wiring Connection Details
2
120V 1 PH.
1
Single Point Connection
208-240V 1 PH.
1
2
208-240/460/600V 3 PH.
1
2
3
4
BK WH GR
1. Disconnect Switch
2. Galflex Conduit (In Unit)
3 3
4
BK
4
RD
WIRE COLOR
GR BK BK BK GR
BK - BLACK
RD - RED
WH - WHITE
GR - GREEN
3. Factory Wiring
4. Field Supplied Wiring - From building power or pre-wired control panel.
12
Permanent Split Capacitor (PSC) Motor Speed Control
Figure 7 - PSC Motor Speed Control
Some single-phase direct-drive fans contain speed controls that regulate the amount of voltage going to the motor. Specific PSC motors must be used in conjunction with speed controls. The speed control has a knob (
Figure 7 ) with an off position along
with high to low range. At high speed, the speed control allows all of the line voltage to pass directly to the motor.
Vari-Speed
HIGH
LO
W
A minimum speed adjustment is provided to allow independent control of the minimum speed setting. Minimum speed adjustment ensures the motor runs with sufficient torque to prevent stalling. To adjust this:
OFF
SOLID STATE SPEED CONTROL
1. Motor must be in actual operating conditions to achieve proper speed adjustment. Motor will not slow down unless proper load is applied.
2. Turn main control knob to lowest speed position.
3. Locate and adjust minimum speed setting. This can be found under the speed control faceplate. Use a small screwdriver to adjust. Rotate clockwise to decrease minimum speed; counter-clockwise to increase minimum speed.
4. Motor will now operate from this preset minimum speed to full speed.
The lowest minimum voltage that may be applied to these motors is 65V AC. Running lower voltages to the motor can cause premature failure and overheating problems.
13
Electronically Commutated Motor (ECM) Speed Control
An Electrically Commutated Motor (ECM) with speed control allows for an accurate manual adjustment of the fan’s speed. The benefits of using an EC motor is exceptional efficiency, performance, and motor life.
External PWM Signal
The fan unit will be shipped with power wiring and communication wiring fed to an internal junction box.
The fan is shipped with Shielded Twisted Pair (STP) wire which is used to wire to a remote PWM signal.
Red wire is used to go to the positive PWM signal, black wire is used to go to the negative PWM signal.
Reference schematics for all wiring connections. STP is connected to the communication wiring of the motor using wire nuts in the junction box. If a preset length of STP is provided, it will be connected to the junction box from the factory. Run the STP through any available knockout in the fan base.
Unit Mount Controller
The RTC speed controller features a 4 digit LED display with a five button interface. All parameters can be accessed through the user menu. The percent of run speed can be changed by using the Up and Down buttons followed by pressing Enter (middle button) to save changes. Every ten seconds the display will toggle between current percentage of run speed and current RPMs. The flow index has a range of 0-100% and is typically linear with motor RPM.
If the remote function (re) is enabled, the speed is controlled through a 0-10V input. 0V = 0% and 10V =
100% , unless overridden by the low speed and high speed limits.
The speed controller requires a 24V AC input and can locally turn the motor on and off. The motor RPM range is fully adjustable between the minimum and maximum setpoints, see LSPD and HSPD on the programming display. For more information, see the RTC control operating manual.
For all motors except 16Z, 18Z, 20Z, 22Z, 25Z, 28Z: If “oFF” is being displayed, and the speed is set above 300 RPM, the ECM is not receiving RPM feedback. Check that the ECM is wired correctly. Check that the motor “tyP” in the settings matches the motor manufacturer. 16Z, 18Z, 20Z, 22Z, 25Z, 28Z do not send RPM feedback.
NOTE: A Variable Frequency Drive (VFD) is required to adjust the speed control of a nonelectrically commutated 3-phase direct-drive motor.
Figure 8 - RTC Speed Controller and Menu
Select the application
Column 1 Column 2
APPS FSC Fan Speed Control Application
Setpoint/Speed of the motor
DN
SP
UP 0-10
20
Programmable 0-10V reference
Default Setpoint
Set the low speed limit
Set the high speed limit
Select motor type
LSPD hSPD tyP
20
100 nid
Lowest speed motor will operate
Highest speed motor will operate
Nidec/Ziehl Motor
TC42
TC48
Telco Green TC42 Motor
Telco Green TC48 Motor
Enable/Disable remote re
View software version number ver dABl
EnAb
1.0
Disable remote
Enable remote
LT RT
14
Motor Speed Controller (MSC) Installation
The Motor Speed Controller (MSC) is a versatile device able to output various signal types to many different Electrically Commutated Motors (ECMs). The MSC signal output types can be selected under the
‘Motor Type’ section of the MSC menu. The MSC may be installed in a fan, remotely in a kitchen space, or in a mechanical room. While this device can be mounted remotely and powered using 24V, it may also be mounted with the fan where it will be exposed to higher voltages. If installed in the fan, the electrical installation must be carried out according to the appropriate regulations (e.g., cable cross-sections, circuit breaker, protective earth [PE] connection). National and local codes must be followed during the installation process.
The MSC board may be powered through a 120VAC/24VAC CLASS 2 transformer, 120V AC/24V DC
CLASS 2 power supply, or through MODBUS connections.
The MSC contains static sensitive components. Therefore, you must handle with care to avoid damage to these components. All operations concerning installation, commissioning, and maintenance must be carried out by qualified, skilled personnel who are familiar with the installation, assembly, commissioning, and operation of the electronic board and the application for which it is being used.
Ensure proper handling and avoid excessive mechanical stress. Do not bend any components when handling or installing component. Do not touch any electronic components or contacts .
Precautions must be adhered to during installation, testing, servicing, and repairing of this board.
Component damage may result if proper procedures are not followed.
Do not install the MSC where it is subjected to adverse environmental conditions such as combustibles, oils, hazardous vapors, corrosive chemicals, excessive dust, moisture, direct sunlight, or extreme temperatures. When removing or installing the MSC to the j-box, verify the gasket is present. All electrical connections for the MSC are located on the backside of the controller. Refer to
for details on installation and electrical connections. When the micro USB programming port is not in use, place the weather-seal plug into the port location.
Figure 9 - Installation/Electrical Connections
J-Box
#8-32 x 1/2”
Screw
Micro USB
Programming
Port
J2
Backside - Electrical Connections
J3
24
VAC C
0-10
OUT C
0-10
IN C
J7 J8
Gasket
#8-32 x 1/2”
Screw
15
MSC Controls Overview
There are four buttons to navigate through the menu screens, refer to Figure 10 .
Press the MENU button to access menu settings/parameters, pressing MENU will also back out of the current menu screen. To scroll through menus, use UP and DOWN buttons. Press the ENTER button to change setting/parameter selection.
To enter password, press MENU, then press ENTER when “Board Config” is displayed. Use UP and
DOWN to scroll through numbers, press ENTER to advance to the next numerical setting. To save changes, press MENU until the screen displays “SAVE CHANGES? [ENTER] TO SAVE.” Press the
ENTER button to save changes.
Figure 10 - MSC Front Detail View
Micro USB
Programming Port
(For Service Use Only)
SPEED%: 0
RPM: 0
LC
Menu Up Down Enter
MSC
MOTOR SPEED CONTROLLER
Control Type:
LC = Local
MB = Remote Modbus
10V = Remote 0-10V
EXT = External Device
MSC Menu
Board Config - Password (default is 0225)
• Motor Type - User may change motor type between Nidec, Telco 42, Telco 48, Ziehl,
0-10V, Other.
• Control Type - This setting adjusts how the fan will be controlled.
• Local - The fan will be controlled by the MSC.
• Remote Modbus - The fan will be controlled by another master board through the MSC. A connection between the 0-10V Out to 0-10V In must be made for start command.
• Remote 0-10V - The fan will be controlled by an external 0-10V signal.
• Speed Settings - Provides access to speed and voltage settings.
• Low Speed - Adjustable speed from 20% up to high speed setting, or 0-10V. Setting cannot go above High Speed parameter.
• High Speed - Adjustable speed from 100% down to low speed setting, or 10-0V. Setting cannot go below Low Speed parameter.
• Set Speed% - Adjustable speed range is dependent on Low Speed and High Speed settings. This controls the output of the motor.
• Voltage Range - Only available when Motor Type “OTHER” is selected. Default setting is 24V. 5V, and 10V are also available.
16
• Modbus # - Adjustable Modbus ID. Exhaust Fan range 11-18, Supply Fan range 21 or 22. A VFD and
MSC cannot use the same Modbus # .
• Options
• Feedback Fault - If set to ENABLED, the MSC will monitor RPM feedback. If the MSC does not receive data for 30 seconds or 70% of the expected RPM, this fault will be displayed. Ziehl motors do not provide feedback.
• 2 Speed - The 0-10V output cannot be used when the 2 Speed or Manual Speed options are On, or if the “Control Type” is set to Modbus. When the 0-10V OUT and 0-10V IN terminals are not jumped together, the fan will operate at low speed. When 0-10V OUT and 0-10V IN terminals are jumped together, the fan will operate at high speed.
• Analog Speed - The user may enable/disable the option, and calibrate a potentiometer for proper operation that is connected between the 0-10V OUT and 0-10V IN terminals. When enabled, you must calibrate the potentiometer. Follow the MSC’s on-screen instructions. The speed will be adjustable between 0V (low speed) to 10V (high speed).
• Input Threshold - When control type is set to Remote 0-10V, an input threshold will be created for motor control. Refer to
for threshold examples.
• Zero Operation - The user may select how the motor will operate when the
0-10V input is at 0V. The options will be Off or Low Speed (default).
• Threshold - Increasing the threshold value will allow for the device to hold its voltage/RPM output while the input is between the 0 - threshold value.
• Restore Settings - Provides access to restore factory settings, and test & balance settings.
• Factory Settings - This will reset all values back to factory settings.
• T & B Settings - This will reset all values back to last saved test & balance settings.
• Change Password - Users may update the password setting to their own. Password 0225 will also be stored for backup. Both passwords will allow users to enter “Board Config” settings.
Software Version - Displays the current software version installed on the board.
Faults - This provides access to “Fault History,” “Fault Totals,” and “Clear Faults.”
• Fault History - Displays fault history and board reboots in chronological order. Possible displayed faults are:
• No Faults - There are no active faults with the system.
• Feedback Fault - Only displayed for motors with feedback capabilities.
• Reboot - Any time the fan goes from OFF to ON, this “fault” will be logged. This fault will only display in “Fault History.”
• Modbus - Issue with Modbus communication between the MSC and master board.
• Variable Device Fault - When “Analog Speed” is selected and a potentiometer is connected, if the voltage drops below 1V, this fault will be displayed.
• Fault Totals - Displays amount of faults for Modbus, Feedback, Var Device, Reboot, and Total Faults.
• Clear Faults - Users may clear all faults from the board.
Service - This provides access to service settings. Password: 1234
• Save T & B - After the test & balance process has been completed, save adjustments under this menu.
• IO Status - Provides access to information about the inputs and outputs of the MSC board.
• V In - Displays the incoming voltage (0-10V) to the MSC.
• V Out - Displays the output voltage (0-10V) to the motor.
• RPM - Displays motor RPM feedback. Ziehl motors do not provide feedback.
• PWM V - Displays equivalent voltage reading of the PWM output to the motor.
• Speed% - Displays PWM percentage output value to the motor.
17
Input Threshold
Figure 11 - Input Threshold Examples
Factory Default: Zero operation set to low speed, threshold set to 0V.
HIGH SPEED
0-10V OR PWM
OUTPUT SIGNAL
DEPENDANT ON
SETTINGS
LOW
SPEED
OFF
0
OPERATING
BAND
1 2 3 4 5
INPUT VOLTS
6 7 8
Zero operation set to low speed, threshold set to 2V.
9 10
HIGH SPEED
0-10V INPUT
DEVICE OUTPUT
0-10V INPUT
DEVICE OUTPUT 0-10V OR PWM
OUTPUT SIGNAL
DEPENDANT ON
SETTINGS
LOW SPEED
OPERATING
BAND
HIGH SPEED
0 1 2 3 4 5
INPUT VOLTS
6 7 8 9 10
Zero operation set to off, threshold set to 2V.
0-10V INPUT
DEVICE OUTPUT 0-10V OR PWM
OUTPUT SIGNAL
DEPENDANT ON
SETTINGS OPERATING
BAND
OFF
0 1 2 3 4 5
INPUT VOLTS
6 7 8 9 10
18
MSC Menu Tree
BOARD CONFIG
SOFTWARE VERSION
FAULTS
SERVICE
MOTOR TYPE
CONTROL TYPE
SPEED SETTING
MODBUS #
OPTIONS
RESTORE SETTINGS
CHANGE PASSWORD
RANGE: NIDEC, TELCO 42, TELCO 48 (DEFAULT),
ZIEHL, 0-10V, OTHER
RANGE: LOCAL (DEFAULT),
REMOTE MODBUS, REMOTE 0-10V
LOW SPEED
HIGH SPEED
RANGE: 20%-100% or 0-10V
DEFAULT: 20% or 0V
RANGE: 20%-100% or 0-10V
DEFAULT: 100% or 10V
SET SPEED %
RANGE: 20%-100% or 0-10V
DEFAULT: VARIES
VOLTAGE RANGE
RANGE: 5V, 10V, 24V
DEFAULT: 24V
RANGE: 11-18 (EXHAUST FAN) / 21 or 22 (SUPPLY FAN)
DEFAULT: 11
FEEDBACK FAULT
2 SPEED
ANALOG SPEED
INPUT THRESHOLD
FACTORY SETTINGS
T & B SETTINGS
PASSWORD
0000
ENABLED/DISABLED
DEFAULT: DISABLED
RANGE: 20%-100% or 0-10V
DEFAULT: VARIES
ENABLED/DISABLED/CALIBRATION
ZERO OPERATION
RANGE: OFF - LOW SPEED
DEFAULT: LOW SPEED
RANGE: 0-10V
DEFAULT: 0V
THRESHOLD
FACTORY RESTORE?
[ENTER] TO RESTORE
T & B RESTORE?
[ENTER] TO RESTORE
PASSWORD OK?
0000
CURRENT SOFTWARE VERSION
DISPLAYED
FAULT HISTORY
FAULT TOTALS
CLEAR FAULTS
SAVE T & B
DISPLAYS FAULTS DAY/HOUR/MINUTE/SECONDS
DISPLAYS BOARD REBOOT
FEEDBACK, MODBUS, REBOOT, VARIABLE DEVICE, and TOTAL FAULT COUNTS ARE SHOWN
CLEAR FAULTS?
[ENTER] TO CLEAR
T & B SAVE?
[ENTER] TO SAVE
IO STATUS
V IN
V OUT
RPM
PWM V
SPEED %
DISPLAYS INCOMING VOLTAGE (0-10V) TO THE MSC.
DISPLAYS OUTPUT VOLTAGE (0-10 V) TO THE
MOTOR.
DISPLAYS MOTOR RPM FEEDBACK. ZIEHL MOTORS
DO NOT PROVIDE FEEDBACK
DISPLAYS EQUIVALENT VOLTAGE READING OF THE
PWM OUTPUT TO THE MOTOR.
DISPLAYS PWM PERCENTAGE OUTPUT VALUE TO
THE MOTOR.
19
Remote Control Panel
On units shipped with the optional remote control panel, an electrical drop containing the panel wiring is provided with the heater. There is a terminal strip inside the remote panel that matches the terminals in the
electrical schematics that were provided with your unit.
Figure 12 - Typical Remote Control Panel Wiring
2-POSITION DIRECT FIRED REMOTE PANEL
1
Manual
Off
Auto
Direct-Fired Remote Panel
60
Power
Blower On
50
Vent
Burner On
40
Temperature Control
80
70
Heat
Flame Failure
1
2
N
BK
8
9
10
17
18
OR
WH
GY
BR
RD
PK
YW
T1
T3
RD
BK
3
3-POSITION DIRECT FIRED REMOTE PANEL WITH COOLING CONTROL
1
Heat
Vent
Cool
Manual
Off
Auto
Direct-Fired Remote Panel
60
Power
Blower On
Burner On
50
40
Temperature Control
80
Flame Failure
70
1
2
BK
N
8
18
T1
T3
11
OR
WH
9
10
17
GY
BR
RD
PK
YW
RD
BK
BL
3
2
2
3-POSITION DIRECT FIRED REMOTE PANEL WITH EXHAUST ON IN FIRE CONTROL
1
Manual
Off
Auto
Direct-Fired Remote Panel
60
Power
Blower On
50
Vent
Burner On
40
Temperature Control
80
70
Heat
Flame Failure
1
BK
2
N
8
17
18
9
10
OR
WH
GY
BR
RD
PK
YW
T1
T3
RD
BK
PR
E
BK
1
3
3-POSITION DIRECT FIRED REMOTE PANEL WITH SPACE HEATING CONTROL
1
4
2
2
Manual
Off
Auto
Vent
Heat
Direct-Fired Remote Panel
55
Power
Blower On
Burner On
Flame Failure
90
70 75
65
60
55
Temperature Control
90
80
85
1
2
BK
N
8
9
OR
WH
10
17
18
T4
GY
BR
RD
PK
YW
RD
T5
BK
3
1. Motor Connection
2. Control Connection
3. Shielded Cable
4. Fire System Micro-switch
Motorized Intake Damper
On units shipped with the optional motorized intake damper, a power transformer is supplied with the unit if the main incoming voltage is greater than 120V. The damper motor is automatically energized when the main disconnect switch is in the ON position. No external wiring to the damper motor is required.
Electric Cabinet Heater
On units shipped with an optional electric cabinet heater, ensure that the heater is wired to a separate
120V, 15 amp input, the thermostat sensing bulb is mounted correctly in the control vestibule where the heater is located, and the thermostat set to 0 Degrees Fahrenheit.
20
Variable Frequency Drive (VFD)
WARNING!!
- Before installing the VFD drive, ensure the input power supply to the drive is OFF.
- The power supply and motor wiring of the VFD must be completed by a qualified electrician.
- The VFD is factory programmed, only change if replaced or ordered separately.
Consult the VFD manual and all documentation shipped with the unit for proper installation and wiring of
the VFD. The VFD has been programmed by the factory with ordered specific parameters. Use Table 5 as
a guide during installation.
Table 5 - VFD Installation Check List
Check
Off
Description
The installation environment conforms to the VFD manual.
The drive is mounted securely.
Space around the drive meets the drive’s specification for cooling.
The motor and driven equipment are ready to start.
The drive is properly grounded.
The input power voltage matches the drive’s nominal input voltage.
The input power connections at L1, L2, and L3 are connected and tight.
The input power protection is installed.
The motor power connection at U, V, and W are connected and tight.
The input, motor, and control wiring are run in separate conduit runs.
The control wiring is connected and tight.
NO tools or foreign objects (such as drill shavings) are in the drive.
NO alternative power source for the motor (such as a bypass connection) is connected - NO voltage is applied to the output of the drive.
21
Variable Frequency Drive (VFD) Installation
Input AC Power
• Circuit breakers feeding the VFDs are recommended to be thermal-magnetic and fast-acting. They should be sized based on the VFD amperage and according to
. Refer to the installation schematic for exact breaker sizing.
• Every VFD should receive power from its own breaker. If multiple VFDs are to be combined on the same breaker, each drive should have its own protection measure (fuses or miniature circuit breaker) downstream from the breaker.
• Input AC line wires should be routed in conduit from the breaker panel to the drives. AC input power to multiple VFDs can be run in a single conduit if needed. Do not combine input and output power cables in the same conduit.
• The VFD should be grounded on the terminal marked PE. A separate insulated ground wire must be provided to each VFD from the electrical panel. This will reduce the noise being radiated in other equipment.
ATTENTION: Do not connect incoming AC power to output terminals U, V, W. Severe damage to the drive will result. Input power must always be wired to the input L terminal connections (L1, L2, L3).
VFD Output Power
• Motor wires from each VFD to its respective motor MUST be routed in a separate steel conduit away from control wiring and incoming AC power wiring. This is to avoid noise and crosstalk between drives.
An insulated ground must be run from each VFD to its respective motor. Do not run different fan output power cables in the same conduit.
• VFD mounted in ECP: A load reactor should be used and sized accordingly when the distance between the VFD and motor is greater than specified below. The load reactor should be installed within
10 feet of the VFD output:
575/600V - Load reactor should be used when distance exceeds 25 feet.
• VFD mounted in fan: The load reactor should be sized accordingly when the VFD is mounted in the fan.
208/230V - Load reactor should be used when distance exceeds 250 feet.
460/480V - Load reactor should be used when distance exceeds 50 feet.
208/230V - Load reactor is optional but recommended for 15 HP and above motors.
460/480V - Load reactor is optional but recommended for 7.5 HP and above motors.
575/600V - Load reactors are required for all HP motors.
• If the distance between the VFD and the motor is extremely long, up to 1000 FT, a dV/dT filter should be used, and the VFD should be increased by 1 HP or to the next size VFD. The dV/dT filter should be sized accordingly and installed within 10 feet of the output of the VFD.
208/230V – dV/dT filter should be used when distance exceeds 400 feet.
460/480V – dV/dT filter should be used when distance exceeds 250 feet.
575/600V – dV/dT filter should be used when distance exceeds 150 feet.
• Do not install a contactor between the drive and the motor. Operating such a device while the drive is running can potentially cause damage to the power components of the drive.
• When a disconnect switch is installed between the drive and motor, the disconnect should only be operated when the drive is in a STOP state.
22
VFD Programming
Programming
1. The Drive should be programmed for the proper motor voltage. P107 is set to 0 (Low) if motor voltage is 120V AC, 208V AC or 400V AC. P107 is set to 1 (High) if the motor voltage is 230V AC, 480V AC, or
575V AC.
2. The Drive should be programmed for the proper motor overload value. P108 is calculated as Motor
FLA x 100 / Drive Output Rating (available in
To enter the PROGRAM mode to access the parameters:
This will activate the password prompt (PASS).
2. Use the Up and Down buttons to scroll to the password value (the factory default password is “0225”) and press the Mode (M) button. Once the correct password is entered, the display will read “P100”, which indicates that the PROGRAM mode has been accessed at the beginning of the parameter menu.
3. Use the Up and Down buttons to scroll to the desired parameter number.
4. Once the desired parameter is found, press the Mode (M) button to display the present parameter setting. The parameter value will begin blinking, indicating that the present parameter setting is being displayed. The value of the parameter can be changed by using the Up and Down buttons.
5. Pressing the Mode (M) button will store the new setting and exit the PROGRAM mode. To change another parameter, press the Mode (M) button again to re-enter the PROGRAM mode. If the Mode button is pressed within 1 minute of exiting the PROGRAM mode, the password is not required to access the parameters. After one minute, the password must be re-entered to access the parameters again.
P500 parameter provides a history of the last 8 faults on the drive. It can be accessed without entering
PROGRAM mode.
Figure 13 - VFD Screen
AUTO
M
FWD
REV
R F
RUN
STOP
23
HP
0.5
1
1.5
1
1.5
10
15
20
2
3
5
7.5
25
30
40
50
60
10
15
20
2
3
5
7.5
HP
0.5
1
1.5
25
30
40
7.5
10
15
20
50
60
3
5
1
2
Part Number
ESV371N02YXB
ESV751N02YXB
ESV112N02YXB
ESV152N02YXB
ESV222N02YXB
ESV402N02TXB
ESV552N02TXB
ESV752N02TXB
ESV113N02TXB
ESV153N02TXB
ESV751N04TXB
ESV112N04TXB
ESV152N04TXB
ESV222N04TXB
ESV402N04TXB
ESV552N04TXB
ESV752N04TXB
ESV113N04TXB
ESV153N04TXB
ESV183N04TXB
ESV223N04TXB
ESV303N04TXB
ESV373N04TXB
ESV453N04TXB
ESV751N06TXB
ESV152N06TXB
ESV222N06TXB
ESV402N06TXB
ESV552N06TXB
ESV752N06TXB
ESV113N06TXB
ESV153N06TXB
ESV183N06TXB
ESV223N06TXB
ESV303N06TXB
ESV373N06TXB
ESV453N06TXB
ACTECH SMV VFD
Part Number
ESV371N01SXB
ESV751N01SXB
ESV112N01SXB
Table 6 - Cross Reference
600V
600V
600V
600V
600V
600V
600V
600V
600V
600V
600V
600V
600V
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
480V
480V
480V
480V
480V
480V
480V
480V
480V
480V
480V
480V
480V
480V
Volts
240V
240V
240V
240V
240V
240V
240V
240V
240V
240V
Volts
120/240V
120/240V
120/240V
1Ø
Input
X
X
X
3Ø
Input
-
-
-
Input Amps 1Ø
120V AC
9.2
16.6
20
Input Amps 1Ø
240V AC
4.6
8.3
10
-
-
-
-
-
X
X
1Ø
Input
X
X
X
X
X
X
X
X
X
X
3Ø
Input Input Amps 1Ø Input Amps 3Ø
X 5.1
2.9
X
X
8.8
12
5
6.9
13.3
17.1
-
-
-
-
-
8.1
10.8
18.6
26
33
48
59
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
10.2
12.4
19.7
25
31
36
47
2
3.2
4.4
6.8
59
71
2.5
3.6
4.1
5.4
9.3
12.4
15.8
24
31
38
45
59
74
87
27
32
41
9
11
17
22
1.7
2.7
3.9
6.1
52
62
2.1
3
14
21
27
3.5
4.8
8.2
11
34
40
52
65
77
Output
Amps
2.4
4.2
6
Breaker 1Ø
120V AC
15
25
30
Breaker 1Ø
240V AC
15
15
20
Output
Amps Breaker 1Ø Breaker 3Ø
2.4
15 15
4.2
6
15
20
15
15
7
9.6
16.5
23
29
42
54
25
30
-
-
-
-
-
50
80
90
15
20
30
40
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
50
60
70
20
20
30
40
15
15
15
15
90
110
15
15
25
40
50
15
15
15
20
70
80
100
125
150
24
START-UP OPERATION
Before starting up or operating the unit, verify all fasteners are secure and tight. Check the set screw in the wheel hub, bearings, and the fan sheaves (pulleys). With power and gas OFF to the unit or before connecting the unit to power, turn the fan wheel by hand. Verify it is not striking the inlet or any obstructions. If necessary, re-center.
Special Tools Required: Standard Hand Tools, AC Voltage Meter, Tachometer, Amperage Meter,
Manometer, Differential Pressure Gauge
Start-up Procedure
1. Check all electrical connections are secure and tight.
2. Check pulley alignment and belt tension. Refer to
“Pulley Alignment/Proper Belt Tension” on page 30 .
3. Inspect the condition of the intake damper and damper linkage, if applicable.
4. Remove intake filters if not already installed, inspect the air stream for obstructions. Install intake filters.
5. Compare the supplied motor voltage with the fan’s nameplate voltage. If this does not match, correct the problem.
6. Place the external disconnect to the ON position to start the unit. Immediately place the disconnect switch off. Check the rotation of the fan with the directional arrow on the blower scroll. Reversed rotation will result in poor air performance, motor overloading and possible burnout. For units equipped with a single-phase motor, check the motor wiring diagram to change rotation. For 3-phase motors, any two power leads can be interchanged to reverse motor direction.
7. When the fan is started, observe the operation and check for any unusual noises.
8. Place the external disconnect switch back to the ON position. The system should be in full operation with all ducts attached. Measure the system airflow. The motor sheave (pulley) is variable pitch and allows for an increase or decrease of the fan RPM. If an adjustment is needed, refer to
. Refer to “Pulley Combination Chart” on page 28 for adjustment specifications.
9. Once the proper airflow is achieved, measure and record the fan speed with a reliable tachometer.
Caution - Excessive speed will result in motor overloading or bearing failure.
Do not set fan
RPMs higher than specified in the maximum RPM chart.
Refer to “Troubleshooting” on page 37
for more information.
10. Measure and record the voltage and amperage to the motor. Compare with the motor’s nameplate to determine if the motor is operating under safe load conditions. Once the RPM of the ventilator has
been properly set, disconnect power. Re-check belt tension and pulley alignment, refer to “Pulley
Alignment/Proper Belt Tension” on page 30 .
25
Pilot Adjustment
1. Restart the fan and check the gas supply pressure at the inlet gas gauge upstream of all electronic valves. The inlet pressure should be 5-14 inches wc . If the inlet pressure is too high, install an additional pressure regulator external to the unit.
2. Open the field-installed manual gas shut-off valve and the manual main gas valve on the combination gas control valve.
3. Close the ball valve located inside the cabinet.
4. Call for heat with the intake air thermostat (turn set-point to temperature above outside air) and allow the pilot to light. If the pilot does not light, purge the pilot line. If air purging is required, disconnect the pilot line at the outlet of the pilot valve.
5. Check the pilot flame voltage at the Flame Safety Control interface test jacks. A weak pilot flame can be caused by low gas pressure, or a dirty pilot orifice.
6. To adjust the pilot flame, remove the cap from the pilot adjustment screw on the combination gas valve. Increase the pilot gas flow by turning the screw counter-clockwise. Decrease the pilot gas flow by turning the screw clockwise. The pilot DC voltage should read 12V DC minimum and should typically be 15V DC .
7. Once the pilot has been established, open the main manual gas shut-off valve downstream of the electronic valves. Check to make sure that the main gas valve opens, and gas flows to the burner.
Figure 14 - Pilot Assembly
Spark Connection
Flame Rod
Connection
Pilot Tube
Connection
Flame Rod
Clearance = 2.96”
26
Main Burner Adjustment
1. Once the pilot has been properly established, the manifold gas pressure or temperature rise should be adjusted to nameplate or design specifications. The gas pressure regulator is adjusted at the factory for average gas conditions. It is important that the gas supplied to the burner is in accordance with the input rating on the rating plate.
See “Gas Pressure” on page 10.
2. Create a high fire call for heat. This should be done with the blower on and all gas controls on. High fire can be achieved by removing the wire at terminal #4 (remove wires #2 and #4 for Maxitrol 44 systems) from the Maxitrol 14 amplifier.
3. The manifold pressure should be checked at the pressure gauge downstream of the modulating valve.
Figure 16 indicates the proper manifold pressure for the desired amount of BTUs per foot of burner.
For natural gas systems, the high fire manifold pressure should not exceed 5 inches wc . For propane gas, the high fire manifold pressure should not exceed 2.5 inches wc .
Another method of checking high fire is to measure the temperature rise of the unit. The temperature rise should be set to design specifications and typically is minimum 70°F.
4. Every unit has a specific design manifold gas pressure based on CFM and temperature rise. Refer to the unit’s nameplate for the design manifold gas pressure.
5. Remove the cap from the combination gas valve for regulator adjustment.
6. Use the regulator pressure adjusting screw to adjust the high fire manifold pressure to design temperature rise ( 5 inches wc maximum for natural gas and 2.5 inches wc maximum for propane gas). High fire should be set to generate the design temperature rise. If the high fire screw is at the end of its adjustment and more pressure is needed, then adjust the main building gas pressure regulator spring (located external to the unit) to achieve the proper manifold pressure. Turning the regulator screw clockwise will increase pressure and counter-clockwise will decrease pressure.
7. Reconnect the wire on the Maxitrol 14 amplifier at terminal #4 (wires #2 and #4 for Maxitrol 44).
8. The low fire manifold pressure must now be set. Low fire can be achieved by removing the wire at terminal #5 from the Maxitrol 14 amplifier (remove #8 for Maxitrol 44).
9. Locate the bypass screw (under the cap of the valve - location #1), refer to Figure 15
.
10. Adjust the low fire manifold pressure until there is a very thin flame along the entire length of the burner. No dark spots should be seen in the burner. The burner may be observed through the viewport located on the external wall of the heater. Replace the cap to the valve. Make sure all wiring and gas components are connected and operational.
11. A final gas leak check shall be performed to verify the gas-tightness of the heater’s components and piping under normal operating conditions. This can be done by measuring the gas pressure at the
1/4” gas plug just downstream of the modulating valve.
Figure 15 - High Fire/Low Fire Bypass Screw Setting
Modulating Valve
Adjustment Screw Location
Firing Mode
Low Fire = 0-5V DC
Modulation = 5-15V DC
High Fire = 15-24V DC
27
Natural
Gas
Propane
Gas
Figure 16 - Pressure vs. Firing Rate
Average Manifold Pressure vs. Firing Rate/Ft. of Burner
6.00
5.00
4.00
3.00
2.00
1.00
0.00
-1.00
0 100000 200000 300000 400000 500000
Firing Rate (BTU/Hr/Ft. of Burner)
600000
Final Start-up Procedure
1. With the air and burner systems in full operation and all ducts attached, measure the system airflow.
The motor sheave (pulley) is variable pitch and allows for an increase or decrease of the fan RPM. If
an adjustment is needed, refer to “Pulley Adjustment” on page 29
.
2. Once the proper airflow is achieved, measure and record the fan speed with a reliable tachometer.
Caution - Excessive speed will result in motor overloading or bearing failure. Do not set fan
RPM higher than specified in the maximum RPM chart. See the troubleshooting guide for more information.
3. Measure and record the voltage and amperage to the motor and compare with the motor nameplate to determine if the motor is operating under safe load condition.
4. Once the rpm of the wheel has been properly set, disconnect power and recheck belt tension and
pulley alignment, refer to Figure 18 .
28
Pulley Adjustment
closing or decreased by opening the adjustable motor sheave. Two groove variable pitch pulleys must be adjusted to an equal number of turns open or closed. Any increase in speed represents a substantial increase in horsepower required by the unit. Motor amperage should always be checked to avoid serious damage to the motor when the speed is varied. Always torque set screws according to the torque
specifications shown in Figure 17
.
Figure 17 - Adjustable Pulley
Decrease Amperage and
Blower RPM Setscrew Thread Size Torque (in-lbs)
No. 10 (bushing)
1/4” (bushing)
5/16”
32
72
130
Table 7 - Maximum RPM and HP Chart
Blower Size
7”
Maximum RPM
2400
Maximum HP
2
29
Pulley Alignment/Proper Belt Tension
1. Belts tend to stretch and settle into pulleys after an initial start-up sequence. Do not tension belts by changing the setting of the motor pulley , this will change the fan speed and may damage the motor.
• To re-tension belts, turn OFF power to the fan motor.
• Loosen the fasteners that hold the blower scroll plate to the blower.
• Rotate the motor to the left or right to adjust the belt tension. Belt tension should be adjusted to allow 1/64” of deflection per inch of belt span. Use extreme care when adjusting V-belts as not to misalign pulleys. Any misalignment will cause a sharp reduction in belt life and produce squeaky noises. Over-tightening will cause excessive belt and bearing wear as well as noise. Too little tension will cause slippage at startup and uneven wear.
• Whenever belts are removed or installed, never force belts over pulleys without loosening motor first to relieve belt tension. When replacing belts, use the same type as supplied by the manufacturer. On units shipped with double groove pulleys, matched belts should always be used.
2. All fasteners should be checked for tightness each time maintenance checks are performed before restarting unit.
Belt tension examples:
• Belt span 12” = 3/16” deflection
• Belt span 32” = 1/2” deflection
Figure 18 - Pulley Alignment/Belt Tension
A. Belt Span Length
B. Deflection
C. Center Distance
A
B
Correct Incorrect
C
Incorrect Incorrect
30
Motor RPM
1/3 to 1-1/2 HP
AX BELTS
BLOWER PULLEY
AK32H
1/3 to 1-1/2 HP
AX BELTS
BLOWER PULLEY
AK32H
1/3 to 2 HP
AX BELTS
BLOWER PULLEY
AK66
AK54
AK46
AK39
AK32
Pulley Combination Chart
DATUM
DIAMETER
3
DATUM
DIAMETER
3
DATUM
DIAMETER
6.2
5
4.2
3.5
3
Table 8 - 7” Blower Pulley Chart
1725
MOTOR PULLEY Dd1 Dd2 Pd1 Pd2
1VP50
PITCH
3.4 4.4 3.6 4.6
Open TURNS ON MOTOR PULLEY
DIAMETER 5 4 1/2 4 3 1/2 3 2 1/2 2 1 1/2 1 1/2
3.2
Closed
0
1941 1995 2048 2102 2156 2210 2264 2318 2372 2426 2480
MOTOR PULLEY Dd1 Dd2 Pd1 Pd2
1VL44 2.8 3.8
3 4
PITCH
Open TURNS ON MOTOR PULLEY
DIAMETER 5 4 1/2 4 3 1/2 3 2 1/2 2 11/2 1 1/2
Closed
0
3.2
1617 1671 1725 1779 1833 1887 1941 1995 2048 2102 2156
MOTOR PULLEY Dd1 Dd2 Pd1 Pd2
1VL40 2.4 3.4 2.6 3.6
Open TURNS ON MOTOR PULLEY
PITCH
DIAMETER 5 4 1/2 4 3 1/2 3 2 1/2 2 1 1/2 1 1/2
Closed
0
6.4
5.2
4.4
3.7
3.2
701 728 755 782 809 836 863 889 916 943 970
863 896 929 962 995 1028 1062 1095 1128 1161 1194
1019 1059 1098 1137 1176 1215 1255 1294 1333 1372 1411
1212 1259 1305 1352 1399 1445 1492 1539 1585 1632 1678
1402 1455 1509 1563 1617 1671 1725 1779 1833 1887 1941
31
Sequence of Operation
To better understand the heater, it is easier to break the unit out into smaller individual systems. There are two main systems, a make-up air fan, and a heater. The make-up air fan consists of a blower and motor.
The heater may be further broken down into two control systems, the Flame Safety Control (FSC) and the
Modulating Gas System (MGS). The burner mixes air with the gas (Natural or LP), which heats the air.
Flame Safety Control
The first system to understand is the Flame Safety Controller. The FSC is there only to monitor the flame,
NOT to control the temperature. The FSC uses a flame rectification sensor mounted on the pilot assembly to detect the presence of flame in the burner.
The FSC also works with the airflow sensor, which relays if there is proper airflow through the unit (not just any airflow, but proper airflow). Proper airflow occurs when there is a .15” w.c. to .80” w.c. differential pressure drop across the burner . The FSC controls the opening of the redundant solenoid gas valves and the operation of the spark igniter to initiate a pilot flame upon start-up.
Upon a call for heat, there is a 15 second Pilot Trial For Ignition (PTFI). During PTFI, the FSC opens the pilot gas valve and allows gas to flow to the pilot assembly. At the same moment, the spark igniter is started, causing the spark to ignite the pilot gas. When the flame rod sensor detects the flame it powers the modulating gas system. This is the normal operating mode. The FSC continues to monitor the flame and airflow. Once this occurs, the unit is in a main flame cycle and thus powers the main gas valve and the modulating gas system. This is the normal operating mode. The FSC continues to monitor the flame and airflow. If the flame fails to light after 15 seconds of sparking, the FSC goes in to lock-out mode. Anytime this occurs, the problem must be diagnosed and corrected to avoid future lockouts after resetting. To begin troubleshooting, or to reset the FSC, shut down power to the heater and restart the heater. This will clear the alarm from the flame safety.
Figure 19 - Flame Safety Controller
Terminals
1/8” to 3/16”
Proper Spark
Gap
32
Air Flow Switch
There are both high and low airflow switches contained within one housing
(
Figure 20 ) measuring the pressure drop across the burner. This is to
ensure that there is proper airflow (.15 inches wc to .80 inches wc ) across the burner and proper combustion at all times. Both switches are wired in series and have single pole double throw (one common contact, one normally open contact, and one normally closed contact) switches that are
‘switched’ by air pressure.
There are two airflow tubes in the heater, located near the burner and profile plate assembly (profile plates surround the burner and control air into the burner section). In the case of clogged filters, blocked intake, excessive duct static pressure, or a broken belt, the correct burner differential pressure may not be achieved, not allowing the low airflow switch to close. The high airflow switch protects against profile plate failures that cause excessive airflow through the burner. In the event that the pressure drop across the burner is not in the range of the airflow switch, gas flow to the burner is stopped by the
Flame Safety Control.
The graph in Figure 21 illustrates the approximate CFM going through the
unit vs. the differential pressure measured by the airflow switch. Simply measure the differential profile pressure drop at the airflow tubes in the unit and match that value up to the matching unit curve below. This will show the
CFMs traveling through the burner and will indicate proper airflow or airflow problems (too much or not enough).
If the pressure drop is outside of the
.15” to .80” range, the blower RPM should be adjusted to fix airflow .
Figure 20 - Air Flow Switch
Figure 21 - CFM Charts
76 Profile Chart
1800
1600
1400
1200
1000
800
600
400
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
0.55
0.6
0.65
Burner Differential Profile Pressure (in. w.c.)
0.7
0.75
0.8
33
Modulating Gas System
The second system, the modulating gas system, consists of a temperature selector dial, a discharge air sensor, an amplifier, and a modulating gas valve. The two types of modulating gas systems used are the
Maxitrol 14 or RTC Solutions controls and the Maxitrol 44 series. The Maxitrol 14/RTC utilizes a discharge air sensor and modulates the Maxitrol gas valve to provide discharge air to match the selected temperature on the temperature selector. The Maxitrol 44 utilizes a room temperature sensor to control room temperature as well as a discharge air sensor in order to control the discharge air temperature. The modulating gas valve controls the amount of gas flow to the burner based on the temperature rise needed.
When the modulating gas valve is all the way open and achieving the maximum BTUs and temperature rise of the unit, it is called “high fire”.
Figure 22 - Maxitrol 14 Amplifier
DECREASE
SENSITIVITY
INCREASE
FACTORY CALIBRATED
DO NOT
TAMPER
High Temperature Limit
One of the backup safety devices is the high temperature limit switch. This switch is a mechanical thermostat that measures the temperature inside the unit downstream of the burner. If the factory-set temperature of 180°F is exceeded, it will signal the FSC to turn off the burner. This requires a manual reset of the high temperature limit. This ensures that the discharge does not exceed 185°F.
Figure 23 - High Temperature Limit Control
1. Temperature Setting
2. Adjustment Screw
3. Manual Reset Button
1
2
3
34
Optional Remote Panel Circuit
Power
Supply From
Heater
"Power" Light Off
No Power to
Panel
On
Panel is
Powered
"Auto"
Power is Sent to
Heater to Open
Damper (if provided) and
Start Blower
Blower Switch
"Off"
Position
(3-Position Panels Only)
"Manual"
Nothing Happens
No Power is Sent to Heater
Power is Sent to
Heater to Open
Damper (if provided) and
Start Blower
"Blower On"
Light
Off
Damper is not
Open or Freeze-
Stat has Detected
Low Temperature
Operation
On
Nothing Happens
Intake Air is
Warmer Than
Thermostat
Set-Point
Intake Air
Thermstat is
Powered
"Blower On"
Light
On
Off
Damper is not
Open or Freeze-
Stat has Detected
Low Temperature
Operation
Blower Operates
Cooling Circuit is
Energized
"Cool"
Position
(if provided)
Temperature
Control Switch
"Vent"
Position
Blower Operates
Heat Does not
Operate
Intake Air is Cooler Than
Thermostat Set-Point
Heat Circuit is Energized
"Burner On" Light Illuminates with proper flame.
"Flame Failure" Light illuminates if proper flame is not established
"Heat"
Position
Heat Circuit is Energized
"Burner On" Light Illuminates with proper flame.
"Flame Failure" Light illuminates if proper flame is not established
35
Remote Panel Option
The remote panel is a device used to control the operation of the heater from a remote location. This unit is available in both a “2 Position” and “3 Position” configuration, and with or without a cooling output. It also will accommodate both discharge and space heating configurations. It is important to understand the following remote panel controls and uses:
Figure 24 - Remote Heater Controls
2
1
4
MANUAL
OFF
AUTO
VENT
HEAT
REMOTE HEATER CONTROLS
POWER
BLOWER
ON
BURNER
ON
FLAME
FAILURE
CLOGGED
FILTER
65
60
55
70
75
90
80
3
1.
Manual/Off/Auto Switch - Used to control blower operation and tempering mode of unit. The AUTO position allows the unit to “decide”, through the use of the intake air thermostat, whether or not heating is needed. The MANUAL position allows the user to control whether or not heat is needed. The OFF position will turn the blower off when a “3 Position” remote panel is ordered. The OFF position will disable all temperature controls when a “2 Position” remote panel is ordered and fan power is then controlled by the pre-wire package only.
2.
Lights Displays the current status of unit features. The light definitions are as follows:
POWER - Illuminated when there is power to the remote panel.
BLOWER ON - Illuminated when the blower motor is powered.
BURNER ON - Illuminates after pilot flame has established and main valve is powered.
FLAME FAILURE - Illuminated when the Flame Safety Control is in alarm mode.
CLOGGED FILTER – (Optional) Illuminated when the intake filters are dirty.
3.
Temperature Control Controls the discharge temperature of a standard unit. The temperature dial is replaced with a Maxitrol Selectrastat in space heating applications and is used to control the space temperature.
4.
Heat/Vent Switch - This switch is powered when the Manual/Off/Auto switch is in the MANUAL position.
It is used to control the tempering mode of the unit. The VENT position will prevent the burner from operating and the heater will deliver untempered air. The HEAT position will force the burner on and the unit will heat the incoming air. This switch becomes a Heat/Vent/Cool switch when the cooling interlock is ordered. This option provides a 120V cooling output from the remote panel.
36
Troubleshooting
The following table lists causes and corrective actions for possible problems with the fan units. Review this list prior to consulting manufacturer. The following table lists causes and corrective actions for possible problems with the fan units. Review this list before consulting manufacturer.
Airflow Troubleshooting Chart
Problem
Fan Inoperative
Motor Overload
Insufficient Airflow
Potential Cause
Blown fuse/Open circuit breaker
Disconnect switch in “OFF” position
Incorrect wiring to motor
Broken fan belt
Motor starter overloaded
Incorrect fan rotation
Fan speed is too high
Incorrect wiring to motor
Overload in starter set too low
Motor HP too low
Duct static pressure lower than design
Incorrect fan rotation
Poor outlet conditions
Intake damper not fully open
Duct static pressure higher than design
Blower speed too low
Supply grills or registers closed
Dirty/clogged filters
Corrective Action
Check amperage.
Check fuse, replace if needed.
Check circuit breaker.
Place switch to the “ON” position.
Inspect motor wiring. Verify connections with wiring diagram located on fan motor.
Replace belt.
Check amperage.
Reset starter.
Verify that the fan is rotating in the direction shown on rotation label.
Reduce fan RPM.
Inspect motor wiring. Verify connections with wiring diagram located on fan motor.
Set overload to motor’s FLA value.
Determine if HP is sufficient for job.
Reduce fan RPM.
Verify that the fan is rotating in the direction shown on rotation label.
Check duct and connections. There should be a straight duct connection to the outlet.
Inspect damper linkage. If the linkage is damaged, replace damper motor.
Check ductwork. Adjust/resize to eliminate or reduce duct losses.
Increase fan RPM. Do not overload motor.
Open/Adjust.
Clean filters. Replace filters if they cannot be cleaned or are damaged.
Adjust belt tension.
Reduce fan RPM.
Install filters.
Reduce fan RPM.
Excessive Airflow
Belt slippage
Blower speed too high
Filters not installed
Duct static pressure lower than design
Excessive Vibration and
Noise
Damaged/Unbalanced Replace wheel.
Misaligned pulleys
Fan is operating in unstable region of fan curve
Align pulleys.
Refer to performance curve for fan.
Bearings need lubrication/Damaged bearing Lubricate bearings, replace if damaged.
Fan speed is too high Reduce fan RPM.
Dirty/oily belt(s)
Belt(s) too loose
Worn belt(s)
Clean belt(s).
Adjust, replace if necessary.
Replace belt(s).
37
Burner Troubleshooting
Table 9 - Burner Troubleshooting Chart
Problem
Pilot Does Not Light/Stay Lit
Main Burner Does Not Light
(Pilot is lit)
Not Enough Heat
Too much heat
Potential Cause Corrective Action
Main gas is off
Air in gas line
Dirt in pilot orifice
Gas pressure out of range
Pilot valve is off
Leak at pilot orifice
Excessive drafts
Safety device has cut power
Open main gas valve.
Purge gas line.
Clean orifice with compressed air.
Adjust to proper gas pressure.
Turn pilot valve on.
Tighten pilot orifice.
Redirect draft away from unit.
Check limits and airflow sensor.
Dirty flame sensor
No call for heat
Clean flame sensor.
Adjust heat setpoint.
No spark at igniter
Check wiring, sensor, and ignition controller. Check spark gap, refer to
on
.
Replace combination valve.
Defective valve
Loose valve wiring
Defective flame rod
Shut off valve closed
Check wiring to valve.
Replace flame rod.
Open shut off valve.
Defective flame safety controller Replace flame safety controller.
Pilot fails as main gas valve opens, and main gas flows.
Main gas pressure too low
Plug the first burner port next to the pilot gas tube with burner cement.
Increase main gas pressure - do not exceed 14 inches wc inlet pressure(5-14” wc).
Too much airflow
Burner undersized
Thermostat malfunction
Decrease airflow if possible.
Check design conditions.
Gas controls not wired properly Check wiring.
Heat setpoint too low Increase heat setpoint.
Check Wiring. Replace
Thermostat.
Unit locked into low fire Check wiring.
Defective modulating gas valve Check/replace modulating valve.
Heat setpoint too high
Unit locked into high fire
Decrease heat setpoint.
Check wiring.
Thermostat malfunction
Check Wiring. Replace
Thermostat.
38
Remote Panel Troubleshooting Chart
Table 10 - Troubleshooting Chart
Light Indication
No Lights
Power Light Only
Power Light and
Blower On Light
Power Light, Blower
On Light, and Burner
On Light
Condition Possible Cause
Power not available to remote panel Incorrect voltage to unit.
Main disconnect switch in “OFF” position.
Circuit breaker tripped.
Faulty main transformer.
Proper unit - Off operation
No power to motor starter
No correction required.
Manual/Off/Auto switch in “Off” position (3 position remote panels only).
Improper damper function.
Proper ventilation operation
Low temperature thermostat timed out
(optional).
No correction required.
No power to flame safety controller Manual/Off/Auto switch in “Off” position (2 position remote panels only).
Heat/vent switch in “Vent” position.
Gas pressure switch tripped (option).
Improper Airflow
Proper heating operation
High temperature limit thermostat tripped
Manual/Off/Auto switch in “Auto” position and intake air thermostat not satisfied.
Excessive airflow.
Faulty airflow switch.
Issue with air probes and/or tubing
Broken belt.
Dirty air filters. Replace as needed.
No correction required.
39
MSC Troubleshooting
Fault
Feedback Fault
Modbus
Variable Device Fault
Motor not responding
Problem
Feedback Fault on
MSC Display
Motor not functioning as expected
Potential Cause
Disconnected/faulty wiring
No feedback for 30 seconds
Less than 70% of RPM
Modbus fault on MSC
Display
Motor not responding to changes made on variable device
(potentiometer)
Faulty Cat 5 connection/cable
ECPM03 does not recognize device
Defective potentiometer
Faulty wiring to motor
2-Speed switch not working
Wiring to motor defective
Check for other faults on MSC display
Corrective Action
Secure connections to fan. If faulty wiring is found, repair or replace as required.
Check parameters
Check duct/fan for obstructions.
Find and replace faulty cable
Verify Modbus # on device is set correctly.
Replace potentiometer
Find and replace faulty wiring.
Check switch and wiring.
Find and replace faulty wiring.
If no other faults are present, motor maybe defective.
TURN OFF POWER TO THE MOTOR WHILE PROGRAMMING THIS DEVICE.
• If the device has a potentiometer or a 2-Speed switch, a jumper wire can be placed in between the 10V
In and 10V Out terminals to rule out a defective device. This will cause the motor to go to HIGH
SPEED.
• The IO STATUS menu can be used to verify the inputs and outputs of the device are functioning as expected.
• The FAULT HISTORY menu can be used to keep track of faults while working on the device.
40
MAINTENANCE
To guarantee trouble-free operation of this heater, the manufacturer suggests following these guidelines.
Most problems associated with fan failures are directly related to poor service and maintenance.
Please record any maintenance or service performed on this fan in the documentation section located at the end of this manual.
WARNING: DO NOT ATTEMPT MAINTENANCE ON THE HEATER UNTIL THE ELECTRICAL SUPPLY
HAS BEEN COMPLETELY DISCONNECTED AND THE MAIN GAS SUPPLY VALVE HAS BEEN SHUT
OFF.
General Maintenance
1. Fan inlet and approaches to ventilator should be kept clean and free from any obstruction.
2. All fasteners and electrical connections should be checked for tightness each time maintenance checks are performed before restarting unit.
3. These units require very little attention when moving clean air. Occasionally oil and dust may accumulate, causing imbalance. If the fan is installed in a corrosive or dirty atmosphere, periodically inspect and clean the wheel, inlet, and other moving parts to ensure smooth and safe operation.
4. Motors are normally permanently lubricated. Caution: Use care when touching the exterior of an operating motor. Components may be hot enough to burn or cause injury.
5. If bearings require lubrication, very little is needed. A general rule is one-half pump from a grease gun for 1/2” to 1-7/16” shaft diameters and one full pump for 1-11/16” and large diameter shafts for every
1500 to 3000 hours of operation. A lithium-based grease should be used. Bearings should be rotated as they are lubricated to evenly distribute the grease, either by hand or via extended grease lines. Do not attempt to grease bearings from inside the enclosure while the motor is energized. Caution:
Bearings are sealed, over-greasing can cause damage to the bearings. Do not grease until grease comes out of seals. Only add the appropriate amount of grease.
2 Weeks After Start-up
1. Belt tension should be checked after the first 2 weeks of fan operation.
Proper Belt Tension” on page 30.
2. All fasteners should be checked for tightness each time maintenance checks are performed before restarting unit.
Every 3 Months
1. Belt tension should be checked quarterly. See “Pulley Alignment/Proper Belt Tension” on page 30.
Over-tightening will cause excessive bearing wear and noise. Too little tension will cause slippage at start-up and uneven wear.
2. Filters need to be cleaned and/or replaced quarterly, and more often in severe conditions. Washable filters can be washed in warm soapy water. When re-installing filters, be sure to install with the airflow in the correct direction as indicated on the filter.
Yearly
1. Inspect bearings for wear and deterioration. Replace if necessary.
2. Inspect belt wear and replace torn or worn belts.
3. Inspect bolts and set screws for tightness. Tighten as necessary.
4. Inspect motor for cleanliness. Clean exterior surfaces only. Remove dust and grease from the motor housing to ensure proper motor cooling. Remove dirt from the wheel and housing to prevent imbalance and damage.
5. Check for gas leak and repair if present.
6. Clean flame sensor by rubbing with steel wool to remove any rust build-up.
7. Inspect burner assembly. Refer to “Burner Maintenance” on page 42 .
41
Table 11 - Filter Quantity Chart
Intake
76
16” x 20”
1
Burner Maintenance
1. Verify the unit is off.
2. Inspect the pilot assembly, refer to “Pilot Assembly” on page 26 . Replace if required.
3. Inspect the burner plates.
4. Clean the burner plates. Make sure the baffles are secure and attached to the burner.
5. Clean burner with wire brush and make sure the burner ports are free of debris. Refer to Table 12
for drill size(s) to clear ports. Wipe the burner with a clean rag.
6. After cleaning the system, turn the system. Visually inspect the flame.
Table 12 - Burner Orifice Drill Size
Orifice
Gas Port
Air Port
Drill Size
1/8”
42
Re-Setting of the Unit
If the flame safety control is locked out (alarm light on), reset the unit by:
1. Turn OFF power to the unit.
2. Turn power to the unit back ON.
Emergency Shutdown of Unit
To shutdown the unit in the event of an emergency, do the following:
1. Turn power OFF to the unit from main building disconnect.
2. Turn the external disconnect switch to the OFF position.
3. CLOSE the inlet gas valve located on the heater.
Prolonged Shutdown of the Unit
For prolonged shutdown, the following steps should be done:
1. Turn the external disconnect switch to the OFF position.
2. CLOSE the inlet gas valve located on the heater.
To re-start the unit, the following steps should be done:
1. Turn the external disconnect switch to the ON position.
2. OPEN the inlet gas valve located on the heater.
42
Notes
43
Start-Up and Maintenance Documentation
START-UP AND MEASUREMENTS SHOULD BE PERFORMED AFTER THE SYSTEM HAS BEEN AIR
BALANCED AND WITH THE HEAT ON (Warranty will be void without completion of this form)
Job Information
Job Name
Address
City
State
Zip
Phone Number
Fax Number
Contact
Purchase Date
Service Company
Address
City
State
Zip
Phone Number
Fax Number
Contact
Start-up Date
Heater Information
Refer to the start-up procedure in this manual to complete this section.
Name Plate and Unit Information
Model Number
Serial Number
Hardware Rev.
Software Rev.
Motor Volts
Motor Hertz
Motor Phase
Motor FLA
Motor HP
Blower Pulley
Motor Pulley
Belt Number
Min. Btu/Hr
Max. Btu/Hr
Gas Type
Field Measure Information
Motor Voltage
Motor Amperage**
RPM
Burner Differential Pressure
Pilot Flame Signal
Low Fire Flame Signal
High Fire Flame Signal
High Fire Inlet Gas Pressure
Inches WC
VDC
VDC
VDC
Inches WC
Low Fire Manifold Gas Pressure Inches WC
High Fire Manifold Gas Pressure Inches WC
Thermostat Set Point
Gas Type
Temperature Control Discharge
Space
Airflow Direction Correct
Incorrect
**
If measured amps exceed the FLA rating on the nameplate, fan RPM must be reduced to decrease the measured amps below the nameplate FLA rating.
Maintenance Record
Date Service Performed
Factory Service Department | Phone: 1-866-784-6900 | Fax: 1-919-516-8710
44
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