FloAire Direct Fired Module Installation Manual

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FloAire Direct Fired Module Installation Manual | Manualzz

Standard and Modular Direct Fired Heaters

Installation, Operation, and Maintenance Manual

Modular Direct Fired Heater

Direct Fired Heater

FOR YOUR SAFETY

IF YOU SMELL GAS: OPEN WINDOWS, DO NOT TOUCH ELECTRICAL SWITCHES, EXTINGUISH

ANY OPEN FLAMES, IMMEDIATELY CALL YOUR GAS SUPPLIER.

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 free of damage.

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 before 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.

A0011030

June 202 1 Rev. 3 7

Table of Contents

WARRANTY ........................................................................................................................................................................................................3

Listings ........................................................................................................................................................................................................3

Patents ........................................................................................................................................................................................................3

INSTALLATION ...................................................................................................................................................................................................4

Mechanical ..................................................................................................................................................................................................4

Curb and Ductwork ......................................................................................................................................................................................6

Roof Mount Installation .......................................................................................................................................................................8

Installation with Exhaust Fan ..............................................................................................................................................................8

Duct Mount Installation .......................................................................................................................................................................9

Indoor (Inline) Installation ...................................................................................................................................................................9

Heat Module Add-On Installation ......................................................................................................................................................10

Gas ............................................................................................................................................................................................................11

ELECTRICAL .....................................................................................................................................................................................................13

Fan to Building Wiring Connection ............................................................................................................................................................14

Motorized Intake Damper .................................................................................................................................................................15

Permanent Split Capacitor (PSC) Motor Speed Control ...........................................................................................................................15

EVO™/ECM-VCU .............................................................................................................................................................................15

Electronically Commutated Motor (ECM) Speed Control ..........................................................................................................................16

External PWM Signal ........................................................................................................................................................................16

Unit Mount Controller ................................................................................................................................................................................16

Motor Speed Controller (MSC) Installation ................................................................................................................................................17

MSC Controls Overview ............................................................................................................................................................................18

MSC Menu ........................................................................................................................................................................................18

Input Threshold .................................................................................................................................................................................20

MSC Menu Tree ...............................................................................................................................................................................21

Variable Frequency Drive (VFD) ...............................................................................................................................................................22

Variable Frequency Drive (VFD) Installation ....................................................................................................................................23

Input AC Power ................................................................................................................................................................................23

VFD Output Power ...........................................................................................................................................................................23

VFD Programming ............................................................................................................................................................................24

ACTECH SMV VFD ..........................................................................................................................................................................25

Remote Control Panel ...............................................................................................................................................................................26

OPERATION ......................................................................................................................................................................................................27

Start-up Procedure ....................................................................................................................................................................................27

Pulley Adjustment ......................................................................................................................................................................................28

Pulley Alignment/Proper Belt Tension .......................................................................................................................................................29

Pulley Combination Chart ..........................................................................................................................................................................30

Pilot Adjustment ........................................................................................................................................................................................31

Main Burner Adjustment ............................................................................................................................................................................32

Heater Start-up Summary .........................................................................................................................................................................33

Final Start-up Procedure ...........................................................................................................................................................................33

Sequence of Operation .............................................................................................................................................................................34

Flame Safety Control ........................................................................................................................................................................34

Modulating Gas System ............................................................................................................................................................................36

High Temperature Limit .............................................................................................................................................................................36

Optional Remote Panel Circuit ..................................................................................................................................................................38

Static Pressure Control (Photohelic) ................................................................................................................................................39

Static Pressure Controller Installation Instructions ...........................................................................................................................40

A-306 Outdoor Sensor ......................................................................................................................................................................40

Remote Panel Option .......................................................................................................................................................................41

Components ..............................................................................................................................................................................................42

Troubleshooting ........................................................................................................................................................................................43

Remote Panel Troubleshooting Chart ..............................................................................................................................................44

Burner Troubleshooting ...................................................................................................................................................................45

MSC Troubleshooting .......................................................................................................................................................................46

Troubleshooting Flowcharts .............................................................................................................................................................47

MAINTENANCE .................................................................................................................................................................................................48

General Maintenance ................................................................................................................................................................................48

2 Weeks After Start-up ..............................................................................................................................................................................48

Every 3 Months .........................................................................................................................................................................................48

Yearly ........................................................................................................................................................................................................48

Burner Maintenance .........................................................................................................................................................................49

Re-Setting of the Unit .......................................................................................................................................................................50

Emergency Shutdown of Unit ...........................................................................................................................................................50

Prolonged Shutdown of the Unit .......................................................................................................................................................50

Unit Filters .................................................................................................................................................................................................50

Start-Up and Maintenance Documentation ...............................................................................................................................................52

2

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, or 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.

Listings

This unit is ETL-listed to standard American National Standard/CSA Standard for Gas Unit Heaters And

Gas-Fired Duct Furnaces ANSI Z83.4, CSA 3.7.

Patents

The Direct Gas Fired Make-Up Air Profile Plates is covered under the following patent: Heated Make-Up

Air System: United States Patent No. 6629523 B2.

3

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.

Clearances

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.

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.

5. All air to the heater must be ducted from the outdoors.

Recirculation of room air is not permitted. If in doubt regarding the application, consult the manufacturer.

Spreader

Bar

Figure 1 - Spreader Bar

Lifting Lugs

Lifting Lugs

4

Intake and Curb Assembly

Intakes and curbs ( Figure 2

) 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.

4. If the unit is a modular unit with a V-bank or evaporative cooler section, the V-bank or evaporative cooler will bolt to the heater with the bolts provided.

5. Slide the filters down the filter track.

Figure 2 - Intake and Curb Assembly

Direct Fired

1. Unit

2. Intake Housing

3. Intake Filter(s)

4. Curb

1

2

3

4

5

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. Flexible ductwork and square 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 on page 7 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 guides and manufacturer's requirements for the remaining duct run. 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

through Figure 6 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.

• Flexible connectors should be employed 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.

6

Blower Size (Inches)

10

15D, 16Z, 18Z

12

15

20D, 20Z, 22Z

18

24D, 25Z

20

30D, 28Z

25

36D

Table 1 - Required Supply Ductwork

Discharge

Side

Up/ Down

Side

Up/ Down

Side

Up/ Down

Side

Up/ Down

Side

Up/ Down

Side

Up/ Down

Side

Up/ Down

Side

Up/ Down

Side

Up/ Down

Side

Up/ Down

Side

Up/ Down

Duct Size

14” x 14”

20” x 20”

14” x 14”

16” x 16”

20” x 20”

26” x 26”

20” x 20”

24” x 24”

30” x 30”

24” x 24”

26” x 26”

32” x 32”

26” x 26”

32” x 32”

36” x 36”

32” x 32”

Straight Duct Length

48”

72”

48”

54”

72”

108”

72”

86”

108”

86”

108”

168”

108”

168”

189”

168”

WARNING!!

Failure to properly size ductwork may cause system effects and reduce the performance of the equipment.

7

Roof Mount Installation

Note: Refer to submittal drawings for specific unit dimensions.

Figure 3 - Roof Mount Details

1. Discharge Opening

2. Curb Outer Wall

3. Flex Conduit Located in Curb Area for Field

Wiring

1

4. Intake Housing

5. Lifting Lugs

6. Direct Fired Module

7. Service Disconnect Switch

8. Blower/Motor Access Door

9. Curb (20” High)

10. Control Drop

11. Motor Drop

12. Gas Connection

Max. Roof Opening 2” Smaller than Curb

Outside Dimension.

8

3

7

2

12

6

Installation with Exhaust Fan

Note: Refer to submittal drawings for specific unit dimensions.

Figure 4 - Exhaust Fan Details

2

1

11

AIRFLOW

10

9

AIRFLOW

5

4

8

3

7

6 5

4

9

10

1. Discharge Opening

2. Curb Outer Wall

3. Flex Conduit Located in

Curb Area for Field Wiring

4. Intake Housing

5. Lifting Lugs

6. Direct Fired Module

7. Service Disconnect Switch

Max. Roof Opening 2” Smaller than Curb Outside Dimension.

8. Blower/Motor Access Door

9. Curb with Support Legs or

Rail (20” High)

10. Gas Connection

8

Duct Mount Installation

Note: Refer to submittal drawings for specific unit dimensions.

Figure 5 - Duct Mount Details

1. Control/Valve Access Door

2. Gas Connection

3. Optional Unistrut Base

4. Lifting Lugs

AIRFLOW

1

2

4

3

Indoor (Inline) Installation

Note: Refer to submittal drawings for specific unit dimensions.

1. Flex Conduit for Field Wiring

2. Optional Unistrut Base

3. Lifting Lugs

4. Control/Filter Access Door

5. Control/Valve Access Door

6. Gas Connection

7. Blower/Motor Access Door

8. Service Disconnect Switch

Figure 6 - Indoor Installation Details

8

1

AIRFLOW

2

3

7

6

5 4

9

Heat Module Add-On Installation

Modular heat units ( Figure 7 ) that are ordered to provide heat onto an existing blower only application

require field mechanical and wiring installation.

1. Remove existing intake housing and lifting lugs from the blower section intake side.

2. Attach heat module to blower intake using the provided sheet metal screws and bolts. Tighten screws and bolts to compress the gasket between the heat module and the blower module.

3. Support and level the end of the heat module (end opposite the blower) with the provided equipment legs/rails.

4. Attach the intake housing to the intake side of the heater module.

5. Drill a hole in the discharge of the blower large enough to insert the discharge control sensor (if provided). Install the sensor through the hole.

6. Wire the sensor and coil as indicated on the supplied wiring schematic. Route all wiring through metal conduit.

7. After the add-on installation is complete, refer to

“Start-up Procedure” on page 27 .

Figure 7 - Heat Module

4

1 2

3

1. Blower

2. Direct Fired Module

3. Intake Housing

4. Filters

7

6

5

5. Equipment Legs

6. Conduit

7. Curb

10

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

Figure 8

.

5. Provide a sediment trap, as shown in Figure 8

, 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

Table 3

for gas pressure ratings.

Unit Size

Size 1

Size 2

Size 3

Size 4

Size 5

Table 2 - Gas Connection Sizes

Gas Pipe Size (NPT)

3/4”

1”

1”

1-1/4”

1-1/2”

11

1

Figure 8 - 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”

Table 3 - Gas Pressure

Gas Pressure Type

Size 1-3 Inlet

Size 4-5 Inlet

Maximum Manifold Pressure - Natural Gas

Maximum Manifold Pressure - Propane

Gas Pressure

7 -14 Inches WC

7 Inches WC - 5 psi

5 Inches WC Maximum

2.5 Inches WC Maximum

NOTICE

Refer to the heater’s rating plate for determining gas supply pressures and requirements.

12

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.

Electrical wiring ( Table 4 ) and connections must be made in accordance with local ordinances and the

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. Refer to

Figure 3

.

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

13

Fan to Building Wiring Connection

Figure 9 - 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.

2

120V Optional

208-240V 1 PH.

1

208-240/460/600V 3 PH.

1

2 2

120V 1 PH.

1

5

3

5

3

6

5

3

7

4 4 4

RD WH BK WH GR RD WH BK

1. Disconnect Switch

2. Galflex Conduit (In Unit)

3. Factory Wiring

4. Field Supplied Wiring - From building power or pre-wired control panel.

RD GR RD WH BK BK BK GR

WIRE COLOR

BK - BLACK

RD - RED

WH - WHITE

GR - GREEN

5. 120V Single Phase Standing Power

6. 208-240 Single Phase

7. Three Phase

14

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.

Permanent Split Capacitor (PSC) Motor Speed Control

Figure 10 - 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 10

) 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.

EVO™/ECM-VCU

The Visual Control Unit (VCU) used with EC motors features a 4 digit LED numerical display. The blue knob on the control allows the user to set the flow index with a screwdriver. Twenty seconds later, the display shows the motor RPM. Then, the display periodically alternates between the flow index and motor

RPM. The flow index has a range of 0 to 100% and is typically linear with motor RPM.

The ECM control requires a 24V AC input and can locally turn the motor on and off. The motor can be adjusted between 300 RPM and maximum speed with this control.

Note: A Variable Frequency Drive (VFD) is required to adjust the speed control of a non-electrically commutated 3 phase direct drive motor.

Figure 11 - EVO™/ECM-VCU Controller

EVO™/ECM-VCU

SET FLOW INDEX 0-100

FAN

ADJUST

RPM FLOW INDEX

Evolution Controls Inc.

15

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 12 - 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

16

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

Figure 13

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 13 - 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

17

MSC Controls Overview

There are four buttons to navigate through the menu screens, refer to Figure 14 .

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 14 - 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.

18

• 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

Figure 15 on page 20

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.

19

Input Threshold

Figure 15 - 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

20

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.

21

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.

22

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

Table 6 on page 25

. 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.

23

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

Table 6 on page 25 ).

To enter the PROGRAM mode to access the parameters:

1. Use the buttons on the VFD screen ( Figure 16 ) to adjust VFD settings. Press the Mode (M) button.

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 16 - VFD Screen

AUTO

M

FWD

REV

R F

RUN

STOP

24

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

Input

X

X

X

Input

-

-

-

Input Amps 1Ø

120V AC

9.2

16.6

20

Input Amps 1Ø

240V AC

4.6

8.3

10

-

-

-

-

-

X

X

Input

X

X

X

X

X

X

X

X

X

X

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

25

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

heater unit. The remote panel should be wired as shown in Figure 17 . Wiring may vary by unit, refer to

electrical schematics that were provided with your unit.

Figure 17 - 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

BR

RD

PK

YW

OR

WH

GY

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

GY

BR

10

17

18

T4

RD

PK

YW

RD

T5

BK

3

1. Motor Connection

2. Control Connection

3. Shielded Cable

4. Fire System Micro-switch

26

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 29 .

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

“Pulley

Adjustment” on page 28

. Refer to “Pulley Combination Chart” on page 30 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 43

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 29 .

27

Pulley Adjustment

The adjustable motor pulley is factory set for the RPM specified ( Table 7 ). Speed can be increased by

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 18

.

Figure 18 - Adjustable Pulley

Decrease Amperage and

Blower RPM Setscrew Thread Size Torque (in-lbs)

No. 10 (bushing)

1/4” (bushing)

5/16”

32

72

130

Blower Size

10”

12”

15”

18”

20”

25”

Belt Drive

Max. RPM

1800

1500

1400

1200

1000

900

Table 7 - Maximum RPM and HP Chart

Max. HP

5

5

2

3

10

20

Blower Size

15D

20D

24D

30D

36D

16Z

18Z

20Z

22Z

25Z

28Z

Direct Drive

Max. RPM

1800

1500

1400

1200

1000

2400

3200

2300

1900

1800

1400

Max. HP

5

5

10

4

5

5

2

3

5

8

7

28

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 19 - Pulley Alignment/Belt Tension

A. Belt Span Length

B. Deflection

C. Center Distance

A

B

Correct Incorrect

C

Incorrect Incorrect

29

Pulley Combination Chart

Motor RPM

1/3 to 1-1/2 HP

AX BELTS

1725

MOTOR PULLEY

1VL34

BLOWER PULLEY

AK114

DATUM DIAMETER

11

PITCH DIAMETER

11.2

Dd1

1.9

Open

5

308

1/3 to 2 HP

AX BELTS

BLOWER PULLEY

AK114

AK94

AK79

AK66

AK54

AK46

AK39

AK32

DATUM DIAMETER

11

9

7.5

6.2

5

4.2

3.5

3

MOTOR PULLEY

1VL40

PITCH DIAMETER

11.2

9.2

7.7

6.4

5.2

4.4

3.7

3.2

Dd1

2.4

Open

5

400

488

582

701

863

1019

1212

1402

3 to 5 HP

BX BELTS

BLOWER PULLEY

2BK160H

2BK140H

2BK120H

2BK110H

2BK100H

2BK90H

2BK80H

2BK70H

2BK60H

2BK55H

2BK50H

7-1/2 to 10 HP

BX BELTS

BLOWER PULLEY

2BK160H

2BK140H

2BK120H

2BK110H

2BK100H

2BK90H

2BK80H

3 to 5 HP

BX BELTS

BLOWER PULLEY

2B5V278

2B5V250

2B5V234

2B5V200

2B5V184

2B5V160

2B5V154

2B5V136

2B5V124

2B5V110

DATUM DIAMETER

15.4

13.4

11.4

10.4

9.4

8.4

7.4

6.4

5.4

4.9

4.4

DATUM DIAMETER

15.4

13.4

11.4

10.4

9.4

8.4

7.4

MOTOR PULLEY

2VP42

PITCH DIAMETER

15.7

13.7

11.7

10.7

9.7

8.7

7.7

6.7

5.7

5.2

4.7

Dd1

2.9

Open

6

330

378

442

484

534

595

672

772

908

995

1101

MOTOR PULLEY

2VP60

PITCH DIAMETER

15.7

13.7

11.7

10.7

9.7

8.7

7.7

Dd1

4.3

Open

6

516

592

693

758

836

932

1053

DATUM DIAMETER

27.8

25

23.4

20

18.4

16

15.4

12.6

12.4

11

MOTOR PULLEY

2VP42

PITCH DIAMETER

28.1

25.3

23.7

20.3

18.7

16.3

15.7

12.9

12.7

11.3

Dd1

2.9

Open

6

184

205

218

255

277

317

330

401

407

458

7-1/2 to 10 HP

BX BELTS

BLOWER PULLEY

2B5V278

2B5V250

2B5V234

2B5V200

2B5V184

2B5V160

2B5V154

2B5V136

2B5V124

2B5V110

DATUM DIAMETER

27.8

25

23.4

20

18.4

16

15.4

12.6

12.4

11

MOTOR PULLEY

2VP60

PITCH DIAMETER

28.1

25.3

23.7

20.3

18.7

16.3

15.7

12.9

12.7

11.3

Dd1

4.3

Open

6

289

320

342

399

434

497

516

628

638

717

15 to 20 HP

BX BELTS

MOTOR PULLEY

2VP75

BLOWER PULLEY

2B5V278

2B5V250

2B5V234

2B5V200

2B5V184

2B5V160

2B5V154

DATUM DIAMETER

27.8

25

23.4

20

18.4

16

15.4

PITCH DIAMETER

28.1

25.3

23.7

20.3

18.7

16.3

15.7

2B5V136 12.6

12.9

** 2HP Motors on 20 IN Blowers use 2VP42 Pulleys

Dd1

5.8

Open

6

381

423

451

527

572

656

681

829

Pd2

4

4 1/2

200

222

237

276

300

344

357

435

441

496

Pd2

5.9

4 1/2

307

341

364

425

461

529

549

669

679

763

Pd2

7.4

4 1/2

399

443

473

552

600

688

714

869

Pd2

5.9

4 1/2

549

630

737

806

889

991

1120

Pd2

4

4 1/2

357

409

479

524

578

644

728

837

984

1078

1193

Pd2

3

3 1/2

354

Pd2

3.6

3 1/2

447

544

650

782

962

1137

1352

1563

TURNS ON MOTOR PULLEY

3

370

TURNS ON MOTOR PULLEY

3

462

2 1/2

477

2

493

563

672

809

995

1176

1399

1617

581

694

836

1028

1215

1445

1671

600

717

863

1062

1255

1492

1725

1 1/2

508

619

739

889

1095

1294

1539

1779

4

366

420

491

537

593

661

747

858

1009

1106

1223

4

560

642

752

822

907

1011

1143

4

205

227

243

283

307

353

366

446

453

509

4

313

348

371

433

470

540

560

682

693

779

4

405

450

480

561

609

698

725

883

2 1/2

385

TURNS ON MOTOR PULLEY

3 1/2

375

430

504

551

608

677

765

880

1034

1133

1254

3

385

441

516

564

622

694

784

901

1059

1161

1285

2 1/2

394

451

528

578

637

710

803

923

1084

1189

1315

TURNS ON MOTOR PULLEY

3 1/2 3 2 1/2

571

655

767

838

925

1031

1165

582

667

781

854

943

1051

1187

593

680

796

871

960

1071

1210

TURNS ON MOTOR PULLEY

3 1/2 3 2 1/2

210

233

249

290

315

362

375

457

464

522

3 1/2

319

355

378

442

480

550

571

695

706

794

2

400

215

239

255

297

323

370

385

468

475

534

3

325

361

386

450

489

561

582

709

720

809

1 1/2

416

220

244

261

304

331

379

394

479

487

547

TURNS ON MOTOR PULLEY

2 1/2

331

368

393

459

498

571

593

722

733

824

TURNS ON MOTOR PULLEY

3 1/2

411

457

488

569

618

709

736

896

3

417

464

495

578

627

720

747

909

2 1/2

424

470

502

586

636

730

758

923

Pd1

3

5

194

216

230

269

292

335

348

423

430

483

Pd1

4.7

519

538

655

666

748

5

301

334

357

416

452

Pd1

6.2

5

393

436

466

544

590

677

703

856

Pd1

4.7

5

538

617

722

790

871

972

1098

Pd1

3

5

348

399

467

511

563

628

709

815

958

1050

1162

Pd1

2

4

339

Pd1

2.6

4

431

525

627

755

929

1098

1305

1509

Dd2

3.9

5 1/2

189

210

224

262

284

326

339

412

419

471

Dd2

5.5

508

527

642

652

733

5 1/2

295

327

349

408

443

Dd2

7

5 1/2

387

430

459

535

581

667

692

842

Dd2

5.5

5 1/2

527

604

708

774

854

952

1075

Dd2

3.9

5 1/2

339

388

455

497

548

611

691

794

933

1023

1132

Dd2

2.9

4 1/2

323

Dd2

3.4

4 1/2

416

506

605

728

896

1059

1259

1455

1

431

1/2

447

Closed

0

462

1

524

638

762

916

1128

1333

1585

1833

1/2

539

656

784

943

1161

1372

1632

1887

Closed

0

554

675

806

970

1194

1411

1678

1941

2

403

462

541

591

652

727

821

944

1110

1216

1346

2

604

693

811

887

978

1091

1232

2

225

250

267

312

338

388

403

490

498

560

2

338

375

400

467

507

582

604

735

747

840

2

430

477

509

595

646

741

769

936

1 1/2

412

472

553

605

667

744

840

965

1135

1244

1376

1 1/2

615

705

826

903

996

1110

1255

1 1/2

230

256

273

319

346

397

412

501

509

572

1 1/2

344

382

408

476

517

593

615

749

761

855

1 1/2

436

484

517

603

655

751

780

949

1

421

483

565

618

682

760

859

987

1160

1272

1407

1/2

430

493

577

631

697

777

877

1008

1185

1299

1438

Closed

0

439

504

590

645

711

793

896

1030

1211

1327

1468

1

626

718

840

919

1014

1130

1277

1

442

491

524

612

664

762

791

963

603

626

762

774

870

1

350

389

415

484

526

1

235

261

279

326

354

406

421

513

521

585

1/2

637

730

855

935

1031

1150

1299

1/2

240

267

285

333

361

414

430

524

532

598

1/2

356

395

422

493

535

614

637

776

788

885

1/2

448

498

531

620

673

773

802

976

Closed

0

648

743

870

951

1049

1170

1322

Closed

0

454

505

539

629

683

783

813

990

Closed

0

362

402

429

501

544

624

648

789

801

901

Closed

0

246

273

291

340

369

423

439

535

543

611

30

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 7 - 14 inches wc (7 inches wc - 5 psi on Size 4-5 heaters) . 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 20 - Pilot Assembly

Spark Connection

Flame Rod

Connection

Pilot Tube

Connection

Flame Rod

Clearance = 2.96”

31

Main Burner Adjustment

1. Once the pilot has been properly established, the manifold gas pressure or temperature rise should be adjusted to jobsite conditions. The gas pressure regulator (integral to the combination gas control on size 1-3 heaters and located in the modulating valve on size 4-5 heaters) is adjusted at the factory for average gas conditions. It is important that the gas be supplied to the burner in accordance with the input rating on the rating plate.

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 amplifier.

3. The manifold pressure should be checked at the pressure gauge downstream of the modulating valve. The graph 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 conditions and typically is minimum 70°F.

4. Remove the cap from the combination gas valve regulator adjustment (size 1-3) or the cap from the MR212 valve (size 4-5).

Using the regulator pressure adjusting screw, adjust the high fire manifold pressure to 5 inches wc maximum for natural gas and 2.5 inches wc maximum for propane gas. High fire should be set to generate the desired 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. Remember - The high fire DC voltage should read 12V DC minimum and should typically be 15V DC on the

Flame Safety Controller test jacks.

5. Reconnect the wire on the amplifier at terminal #4 (wires #2 and #4 for Maxitrol 44).

6. The low fire manifold pressure must now be set. Low fire can be achieved by removing the wire at terminal #5 from the amplifier

(remove #8 for Maxitrol 44). Check the low fire flame signal to ensure that the DC voltage is 12V DC minimum on the Flame

Safety Controller test jacks.

7. Using the bypass screw (located on the side of the M511 and M611 valves, and under the cap of the MR212 valve), 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 view-port located on the external wall of the heater. Replace the cap to the valve and restore all of the original wiring on the amplifier and gas components.

8. 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.

Table 8 - Mod Valve Voltage

Volts DC

0 to 5V DC

5 to 15V DC

15 to 20V DC

Firing Mode

Low Fire

Modulation

High Fire

Figure 21 - Maxitrol Low Fire

Bypass Screw Setting

MR212

M611 and 511

32

Natural

Gas

Propane

Gas

Figure 22 - 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

Heater Start-up Summary

1. Is the incoming gas pressure 7”-14”?

• Yes – If the incoming pressure is correct, continue with step 2.

• No – If the incoming pressure is incorrect, adjust incoming gas pressure.

2. Adjust the pilot flame. Lock unit into high fire. Does high fire product at least a 70°F temperature rise and the correct manifold pressure?

• Yes – If the temperature rise and manifold pressure are correct, continue with step 3.

• No – If the temperature rise and manifold pressure are incorrect, adjust high fire.

3. Lock unit into low fire. Does a thin flame fill entire burner length?

• Yes – If the flame is correct, the burner start-up is complete.

• No – If the flame is incorrect, adjust the low fire setting.

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 28

. Refer to

“Pulley Combination

Chart” on page 30

for adjustment specifications.

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

RPMs 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 ventilator has been properly set, disconnect power and recheck belt tension and pulley alignment as shown in

Figure 19 on page 29 .

33

Sequence of Operation

To better understand the direct-fired 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.

Flame strength and presence can be measured at the FSC by reading the rectified flame signal. Use a DC voltage meter, attach leads to the test jacks on the top of the control. Flame is present when DC voltage reads between 6 and 18V DC. Ideal flame intensity produces a signal of 12V DC or higher.

The FSC is also wired into an airflow switch, which relays whether there is proper airflow through the unit

(not just any airflow, but proper airflow). Proper airflow occurs when there is a .15” wc to .80” wc differential pressure drop across the burner.

When the airflow through the heater produces differential pressure in this range, the FSC indicates so by illuminating the AIRFLOW LED. 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.

Figure 23 - Flame Safety Controller

DC Voltage Flame Status

0 to 5V DC No Flame

6 to 11V DC Weak Flame

12 to 18V DC Strong Flame

34

The OPR CTRL LED indicates that there is power to the FSC. Next, the AIRFLOW LED will come on if there is proper airflow through the unit. Third, the unit will pause to purge any gases or combustible vapors before attempting flame ignition. Then, there is a Pilot Trial For Ignition (PTFI), and the PTFI LED comes on. 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 turns on the FLAME LED, turns off the PTFI LED, and powers the modulating gas system. This is the system’s normal operating mode. The FSC continues to monitor the flame and airflow. Once this occurs, the unit is in the 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.

The last LED on the FSC is the ALARM LED. The alarm will turn on when the FSC determines an unsafe condition has occurred and will not allow the unit to recycle for heat until it has properly been reset.

Anytime the FSC goes into “Alarm” mode, the issue must be diagnosed and corrected to avoid further lockouts after resetting. If the unit fails to light the first time, the unit will try one more time before locking out. This retry will not occur if the No FSC reset option is enabled. To begin troubleshooting, or to reset the

FSC, shutdown power to the unit. Restart the unit. This will clear the alarm.

Figure 24 - Proper Spark Gap

1/8” to 3/16”

Proper Spark

Gap

35

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 25 - 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 170°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 26 - High Temperature Limit Control

1. Temperature Setting

2. Adjustment Screw

3. Manual Reset Button

1

2

3

36

Air Flow Switch

There are both high and low airflow switches contained within one housing measuring the pressure drop across the burner. This is to 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 graphs in

Figure 28

illustrate 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 27 - Air Flow Switch

Figure 28 - CFM Charts

25000

23000

21000

19000

17000

15000

13000

11000

9000

7000

5000

3000

0.15

0.2

Size 4-5 Heater CFM vs. Burner Profile Pressure

Size 4

Size 5

0.25

0.3

0.35

0.4

0.45

0.5

Burner Differential Profile Pressure (in. w.c.)

0.55

0.6

0.65

Size 1-3 Heater CFM vs. Burner Profile Pressure

10000

9000

8000

7000

6000

5000

4000

3000

2000

1000

0

0.15

0.2

Size 1

Size 2

Size 3

0.25

0.3

0.35

0.4

0.45

0.5

Burner Differential Profile Pressure (in. w.c.)

0.55

0.6

0.65

37

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

38

Static Pressure Control (Photohelic)

The dampers can be controlled by a building static pressure control. This controller will sense the difference between pressure inside the building and pressure outside the building (sensed at the A-306 outdoor sensor) and will position the dampers to maintain the pressure setting on the controller. The controller has two setpoints and an indicator. The two setpoints are a minimum desired static pressure point and a maximum static pressure point.

The actual building static pressure will be shown by a visual indicator between these two settings. The controller will modulate the dampers to maintain a static pressure between these setpoints.

When the building’s static pressure is below the minimum setting, the damper motor will proportionally open the fresh air damper and close the return air damper until static increases above the minimum setting. At this point, the damper motor will stop and hold this proportion.

If the building’s static pressure continues to climb and goes above maximum setting, the damper motor will reverse proportion, closing the fresh air damper and opening the return air damper until static drops below maximum setting.

During the “OFF” or “Night” cycle of the unit, an internal switching circuit will close the return air damper.

See additional wiring and installation information on the static pressure controller and A-306 outdoor sensor.

Figure 29 - Photohelic Gauge

.25

.05

.10

.15

.25

Calibrated For

Vertical Position

39

Static Pressure Controller Installation Instructions

Avoid locating the front of the static pressure controller in sun light or other areas with high ambient light or corrosive levels. Bright light shining on the photocells can cause false actuation of the load relays. The static pressure controller should be zeroed out before attaching the low and high pressure hoses. The zero adjustment is located between the minimum and maximum dials.

Using the supplied rubber tubing, plumb the high side of the static pressure controller to the inside of the building. The low side of the static pressure controller should be plumbed to the A-306 outdoor sensor.

See the A-306 installation instructions.

Figure 30 - Static Pressure Controller

1. High Pressure Port

2. Low Pressure Port

3. Low Pressure to A-306

Outdoor Sensor

4. High Pressure to the Building

4

1

2

3

A-306 Outdoor Sensor

Use the installation instructions shipped with the A-306 Outdoor Sensor.

Figure 31 - A-306 Outdoor Sensor

Item Number

1

3

4

028

029

163

164

165

168

290

Description

10-32 x 1/2”

Machine Screw (2)

10-32 Nut (4)

10-32 x 1-3/4”

Machine Screw (2)

Antenna Clamp

Mounting Bracket

Pick Up Body

Static Pressure

Plates

“O” Ring Seal

Hole Plug

Tubing - 50’

40

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 32 - 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.

41

Components

The following image and list outline the typical direct fired heater components and their functions.

Figure 33 - Typical Cabinet Components

1

2

3 4

5

11 6

9

10

7

8

12

19

13

14

18

15

21

20 17

16

22

1.

Motor Starter – Contactor with overload protection to start and protect motor.

2.

Manual Reset High Temperature Limit – Safety device that prevents the heater from overheating.

3.

Power Transformer – Installed when motor voltage is greater than120V. Used to provide 120V service to controls.

4.

Flame Safety Control – Initiates and monitors flame.

5.

Ignition Transformer – Produces high voltage spark to ignite flame.

6.

Intake Air Thermostat – De-energize heating circuit when intake air exceeds set-point.

7.

Airflow Switch – A safety device insuring proper air flow during burner operation.

8.

Control Transformer – 120V primary; 24V secondary control transformer.

9.

Cooling Interlock Relay (Optional) – Energizes power to cooling circuit on call for cooling.

10.

Terminal Strip – Central location to terminate control wiring. Should be used for troubleshooting.

11.

Circuit Breaker – Protects electrical components from high current spikes.

12.

Modulating Amplifier - Regulates temperature by a modulating gas valve.

13.

Damper Actuator – Motor containing end switch that opens intake damper.

14.

High Pressure Airflow Probe – Measures profile pressure upstream of burner.

15.

Pilot Tubing – Pilot tube connection to combination gas valve.

16.

Manual Gas Shut-Off Valve – Allows gas flow to burner to be shut off to leak test gas train.

17.

Manifold Gas Pressure Gauge – Manifold gas pressure should be read from here.

18.

Modulating Gas Valve – Modulates gas flow to burner to provide proper air temperature.

19.

Low Pressure Airflow Probe – Measures profile pressure downstream of burner.

20.

Combination Gas Valve - A combination of redundant solenoid valves, pilot valve and gas regulator built into one unit.

21.

Inlet Gas Pressure Gauge – Inlet gas pressure should be read from here.

22.

Gas Inlet – Main gas supply connection.

42

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 wheel 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).

43

Remote Panel Troubleshooting Chart

Light Indication

No Lights

Power Light Only

Power Light and

Blower On Light illuminated

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. All panel lights illuminated

Clogged Filter Light

On (optional)

Flame Failure Light

On

Clogged filters

Flame Safety Alarm Activated - No

Flame Detected during Pilot

Establishment Period

Dirty air filters. Replace as needed.

Combination valve in “Off” position (Size 1-3

Units).

Gas valve stuck closed.

Low or no gas pressure.

Faulty spark electrode

Faulty ignition transformer.

Flame sensor failure.

Pilot orifices clogged.

44

Burner Troubleshooting

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

Figure 24 on page 35

.

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 PSI on size 4-5 heater).

Too much airflow

Burner undersized

Decrease airflow if possible.

Check design conditions.

Gas controls not wired properly Check wiring.

Heat setpoint too low Increase heat setpoint.

Broken HMI Sensor

Unit locked into low fire

Replace HMI.

Check wiring.

Defective modulating gas valve Check/replace modulating valve.

Heat setpoint too high Decrease heat setpoint.

Unit locked into high fire

Broken HMI Sensor

Check wiring.

Replace HMI.

45

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.

46

Troubleshooting Flowcharts

Nothing

Happens

Is Overload tripped on starter?

NO

Is Freeze-Stat open?

NO

YES

Reset & measure FLA of motor. Is it higher than rating?

YES

Adjust or change

Pulley

YES Adjust or

Replace

Is end switch on

Motorized

Damper closed?

NO Adjust or

Replace actuator

Blower runs but there is no heat

Is the air flow LED on Flame Saftey illuminated?

YES

Is outside air cooler than intake air thermostat setting?

YES

Is High Temp.

Limit Tripped?

NO

YES

NO

Adjust pulley to achieve proper airflow.

Proper economizer operation

Reset

NO

Is there a

Remote Panel

Installed?

YES

Is Remote set to

"Heat"

YES

Refer to Flame

Safety Guide

NO

NO

Check wiring

Set Remote

Panel to

"Manual" and

"Heat" mode.

Burner lights but heater stays in

Low Fire

Is there voltage on

Terminal #17

Yes

Are all valves powered and open?

Yes

With wires 3 & 4 removed from the

Maxitrol Amplifier, is there 9.5K to 11K

Ohms between the wires?

Yes

No

No

No

Replace

FSC

Check valve wiring or open valves

Replace

Discharge Air

Sensor

Remove Terminal #4 from the Maxitrol

Amplifier. Does the heater go into High Fire?

No

Is there a short or open circuit in Modulating

Valve? Should be 45-55

Ohms (60-80 on MR212)

No

Yes

Replace

Amplifier

Yes

Replace

Modulating

Valve

With wires 1 & 2 removed from the

Maxitrol Amplifier, is there 9.5K to 11K Ohms between the wires?

No

Replace the

Temperature

Selector

Burner lights but heater stays in High Fire

Is there a jumper between terminals 2 & 3 on the

Maxitrol Amplifier?

Yes

No

Is there a short circuit in the Remote Temperature

Selector or wiring?

No

Yes

Install

Jumper

Repair short or replace

Temperature

Selector

Is there an open circuit in the Discharge Air Sensor or wiring?

Yes

No

Is Plunger in the

Modulating Valve jammed?

Inspect and clean. It should operate freely in the sleeve.

No

Repair Circuit or replace the

Discharge Air

Sensor

Foreign object holding valve open. Remove bottom plate and inspect valve and seat. Clean or replace valve.

47

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.

See “Pulley Alignment/

Proper Belt Tension” on page 29.

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 29.

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 49 .

48

Burner Maintenance

1. Verify the unit is off.

2. Inspect the pilot assembly, refer to “Pilot Adjustment” on page 31

. 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 9 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 9 - Burner Orifice Drill Size

Orifice

Gas Port

Air Port

Drill Size

1/8”

42

49

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.

Unit Filters

Intake

Size 1 Standard Sloped

Size 2 Standard Sloped

Size 1 Modular Sloped

Size 2 Modular Sloped

Size 3 Modular Sloped

Size 4 Modular Sloped

Size 5 Modular Sloped

Size 1 V-Bank

Size 2 V-Bank

Size 3 V-Bank

Size 4 V-Bank

Size 5 V-Bank

Table 10 - Filter Quantity

16” x 20”

2

3

-

10

-

6

-

-

15

8

-

-

20” x 25”

-

2

-

8

-

3

-

8

-

3

-

12

50

Notes

51

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

52

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