advertisement
Modular Indirect Fired Heaters and Inserts
Installation, Operation, and Maintenance Manual
Modular Indirect Fired Heater Indirect Fired Module
FOR YOUR SAFETY
If you smell gas:
1. Open windows.
2. Don’t touch electrical switches.
3. Extinguish any open flames.
4. Immediately call your gas supplier.
Indirect Fired Furnace
FOR YOUR SAFETY
The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous.
RECEIVING AND INSPECTION
Upon receiving unit, check for any interior and exterior damage. If damage is found, report it immediately to the carrier. Also check that all accessory items are accounted for and are damage free. Turn the blower wheel by hand to verify free rotation and check the damper (if supplied) for free operation.
WARNING!!
Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read the installation, operating and maintenance instructions thoroughly before installing or servicing this equipment. ALWAYS disconnect power and gas prior to working on heater.
Save these instructions . This document is the property of the owner of this equipment and is required for future maintenance. Leave this document with the owner when installation or service is complete.
A0016988
March 2021 Rev. 39
2
TABLE OF CONTENTS
3
WARRANTY
This equipment is warranted to be free from defects in materials and workmanship, under normal use and service, for a period of 2-years from date of shipment. This warranty shall not apply if:
1. The equipment is not installed by a qualified installer per the MANUFACTURER’S installation instructions shipped with the product.
2. The equipment is not installed in accordance with Federal, State, and Local codes and regulations.
3. The equipment is misuse d or neglected, or not maintained per the MANUFACTURER’S maintenance instructions.
4. The equipment is not operated within its published capacity.
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.
Furnace Warranty
Subject to all terms stated herein, the MANUFACTURER warrants to BUYER the stainless-steel heat exchanger to be free from defects in material and workmanship under normal use and service for 25-years from the date of manufacture, and warranty is limited to replacement of the heat exchanger only.
CERTIFICATIONS AND PATENTS
Listing
This unit is ETL-listed to standard American National Standard/CSA Standard for Gas Unit Heaters And
Gas-Fired Duct Furnaces ANSI Z83.8-2016, CSA 2.6-2016.
Patents
The Indirect Bent Tube Heater is covered under the following patent: Heated Make-Up Air: United States
Patent No. 8777119 B2.
INSTALLATION
It is imperative that this unit is installed and operated with the designed airflow, gas, 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.
4
Mechanical
WARNING: DO NOT RAISE VENTILATOR BY THE INTAKE HOOD, BLOWER OR MOTOR SHAFT, OR
BEARINGS – USE ALL LIFTING LUGS PROVIDED WITH A SPREADER BAR OR SLINGS 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. Supports must adequately support equipment. Refer to manufacturer’s estimated weights.
2. Consider general service and installation space when locating unit.
3. Locate unit close to the space it will serve to reduce long, twisted duct runs.
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 heater inlet shall be located in accordance with the applicable building code provisions for ventilation air.
IMPORTANT
Figure 1 – Spreader Bar
To prevent premature heat exchanger failure, do not locate any gas fired unit in areas where chlorinated, halogenated, or acid vapors are present in the atmosphere.
Assembly
Intakes and curbs are shipped unassembled to heater module. Upon unit arrival, use the following procedure to assemble the intake to the heater.
1. Apply silicone or weather-proof gasket on the back side of the flanges of the intake hood or v-bank intake.
2. Screw the flanges of the intake hood or v-bank to the unit with the supplied sheet metal screws. Place caulk on the outside of the screws to prevent water leaks. 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.
Figure 2- Intake and Curb Assembly
INDIRECT FIRED MODULE
CURB
BLOWER
RAIL
INTAKE HOOD
FILTERS
5
Curb and Ductwork
This fan was specified for a specific CFM and static pressure. The ductwork attached to this unit will significantly affect the airflow performance. When using rectangular ductwork, elbows must be radius throat, radius back with turning vanes. Flexible ductwork and square throat/square back elbows should not be used. Any transitions and/or turns in the ductwork near the fan outlet will cause system effect.
System effect will drastically increase the static pressure and reduce airflow.
•
shows the minimum fan outlet duct sizes and straight lengths recommended for optimal fan
Table 1 - Recommended Supply Ductwork performance.
•
Follow SMACNA standards and manufacturer’s requirements for the duct runs. Fans designed for rooftop installation should be installed on a
Blower
Size
(Inches)
10
Discharge
Side
Duct Size
(Inches)
14 x 14
Straight Duct
Length
(Inches)
48
Down prefabricated or factory built roof curb. Follow curb manufacturer’s instructions for proper curb installation.
15D,
16Z, 18Z
Side
Down
20 x 20
14 x 14
72
48
•
Do not use unit to support ductwork in any way.
Side
This may cause damage to the unit. 12 16 x 16 54
Down
•
The unit should be installed on a curb and/or rail that meets local code height requirements.
15
Side
20 x 20 72
•
Make sure duct connection and fan outlet are
Down properly aligned and sealed.
20D,
20Z, 22Z
Side
Down
26 x 26
20 x 20
108
72 •
Secure fan to curb through vertical portion of the ventilator base assembly flange using 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.
18
24D, 25Z
Side
Down
Side
24 x 24
30 x 30
86
108
Down 24 x 24 86
•
Check all fasteners for tightness. Figure 3 through
Figure 6 show different mechanical installation
configurations.
20
30D, 28Z
Side
Down
Side
26 x 26
32 x 32
108
168
Down 26 x 26 108
25
Side
Down
32 x 32 168
36D
Side
Down
36 x 36
32 x 32
189
168
WARNING!!
Failure to properly size ductwork may cause system effects and reduce the performance of the equipment.
6
Roof Mount Installation
Figure 3
CURB OUTER
WALL
INDIRECT MODULE
DISCHARGE
OPENING
AIRFLOW
FLEX CONDUIT FOR
FIELD WIRING
SLOPED FILTER
INTAKE
POWER VENT RAIN CAP
INDIRECT FIRED MODULE
LIFTING LUG
4 PLACES
SERVICE DISCONNECT
SWITCH
BLOWER/
MOTOR
ACCESS
DOOR
GAS
CONNECTION
Installation with Exhaust Fan
Figure 4
POWER VENT RAIN CAP
LIFTING LUG
4 PLACES
20 IN HIGH
EQUIPMENT RAIL
AND CURB
INDIRECT FIRED MODULE
SERVICE DISCONNECT
SWITCH
BLOWER/
MOTOR
ACCESS
DOOR
GAS
CONNECTION
20 IN HIGH
EQUIPMENT RAIL
AND CURB
7
Indirect Fired Module Installation
Figure 5
Ø5" TYPE B GAS
VENT FLUE CONNECTIONS
INDIRECT MODULE
AIRFLOW
INDIRECT FIRED MODULE
LIFTING LUG
4 PLACES
SERVICE
DISCONNECT
SWITCH
FLEX CONDUIT FOR
FIELD WIRING
Ø5" TYPE B GAS
VENT FLUE CONNECTIONS
GAS
CONNECTION
2 1/4 in
FLEX CONDUIT
FOR FIELD WIRING
OPTIONAL UNI-STRUT BASE
FOR HANGING
2 PLACES
Indoor (INLINE) Installation
Figure 6
INDIRECT MODULE
DISCHARGE
OPENING
AIRFLOW
FLEX CONDUIT FOR
FIELD WIRING
V-BANK
FILTER
MODULE
UNI-STRUT BASE
FOR HANGING
4 PLACES
Ø5" TYPE B GAS
VENT FLUE CONNECTIONS
INDIRECT FIRED MODULE
LIFTING LUG
4 PLACES
SERVICE DISCONNECT
SWITCH
BLOWER/
MOTOR
ACCESS
DOOR
FILTER/
CONTROL
ACCESS
DOOR
GAS
CONNECTION
8
Condensation Drain
In some applications, condensation can form in the flue collection box, primarily when furnaces are located downstream of cooling coils. If condensation occurs in the flue collection boxes, there are barbed fittings in the bottom of the flue collection boxes to drain condensation out of the boxes. Each burner in the unit is provided with a burner drain pan or a condensation drain assembly located underneath this fitting for the condensation to collect. If the drain assembly is installed on the heater, it w ill have ¼” quick seals located below the front access door for field piping or drainage onto the roof. Consult your local code as to the proper drainage regulations of the condensation.
The internal drain piping is heated to prevent freezing. If drains are field piped, ensure that the field piping is installed to avoid the condensation from freezing. Do not plug the holes under any circumstance, as it will cause the burners to overflow.
In the event the IBT does not have condensation drains and condensation exceeds the pan capacity, IBT condensation drain kits can be ordered for installation in the field.
The part names for the kits are:
“IBT Condensation Kit-1” Single Furnace IBT
“IBT Condensation Kit-2” Double Furnace IBT
“IBT Condensation Kit-3” Triple Furnace IBT
“IBT Condensation Kit-4” Quadruple Furnace IBT
Condensate Drain Trap Installation
Figure 7 – ¼” NPT Condensation Drain
Figure 8 – IBT Condensation Drain
Assembly Connections
When a drain trap is required, refer to Figure 9
for trap details. If you do not install the trap as described, drainage system failures will occur.
1. The trap depth must be 1/2 x the trap height. For example, if the trap height is 6”, the trap depth must be 3”.
2. All joints must be water tight.
3. After the exit from the trap, the drain must be pitched down from the unit connection at least 1” for every 10 feet of horizontal run to promote proper drainage. Check local installation code, if allowed, the drain can be routed to a wastewater system.
4. When the trap can experience freezing temperatures, drain the system or use a heating device. This will prevent water from freezing and damaging the trap.
5. The trap must be primed before the unit is put into operation and properly maintained on a regular schedule.
6. To prime the trap, remove the cleanout cap. Fill the trap with water. Put the cleanout cap back onto the drainage system. Make sure the trap is
operating properly. Refer to Figure 10 .
Figure 9
Figure 10 – Trap Water Flow
Water
Flow
– Trap Dimensions
Trap Height
Cleanout with Cap
1/2 x Trap Height =
Trap Depth
Water
Flow
9
Indoor Flue Venting
This appliance requires a Category III venting system. Refer to appliance manufacturer’s installation instructions for proper vent installation. Indoor gas fired heating equipment must be vented. Do not operate un-vented . Gas fired heating equipment which has been improperly vented, or which experiences a blocked vent condition may emit flue gases into heated spaces.
IMPORTANT
Furnace Only Modules must be installed in a positive pressure airstream. Do not install in a duct on the suction side of a fan. Use only venting materials and components that are UL listed and approved for Category III venting systems. Do not mix pipe, fittings, or joining methods from different manufacturers.
General Venting Guidelines
1. Installation of venting must conform to local building codes, or in the absence of local codes, follow the National Fuel Gas Code.
2. On Units with multiple furnaces, each furnace must be ducted to the outside using its own isolated duct run. Ducts used on each single furnace MUST NOT be connected together in any fashion. Failure to adhere to this may result in a build-up of Carbon-Monoxide in the space when the furnace is operating with less than all of its furnaces powered.
3. Do not use a vent pipe smaller than the size of the outlet on the heater.
4. Install with a minimum upward slope from unit of ¼ inch per foot and suspend from overhead structure at points no greater than 3 feet apart. For best venting, put as much vertical vent as close to the unit as possible.
5. Fasten individual lengths of vent together with at least three corrosion resistant sheet metal screws.
6. Vent pipes should be fitted with a tee with a drip leg and clean out tap at the low point in the vent run. This should be inspected and cleaned out periodically during the heating season.
7. Do NOT use dampers or other devices in the vent or combustion air pipes.
8. Use a vent terminal to reduce downdrafts and moisture in the vent line.
9. A vent system that terminates vertically but has a horizontal run that exceeds 75% of the vertical rise is considered horizontal.
10. Pressures in Category III venting systems are positive, and therefore care must be taken to prevent flue products from entering the heated space.
11. Vent pipes must all be sealed and gastight.
Vertically Vented Furnaces
1. Use single wall or double wall (Type B) vent pipe of a diameter listed in the following table for the appropriate model.
2. Maximize the height of the vertical run of vent pipe. A minimum of five (5) feet (1.5m) of vertical pipe is required. The top of the vent pipe must extend at least two (2) feet (0.61m) above the highest point on the roof. Use Listed Type B vent for external runs. An approved weatherproof vent cap must be installed on the vent termination.
3. Horizontal runs should be pitched upward ¼ in. per foot (21mm/m) and should be supported at three (3) foot (1m) maximum intervals.
4. Design vent pipe runs to minimize the use of elbows. Each 90 ⁰ elbow is equivalent to five (5) feet
(1.5m) of straight vent pipe.
5. Vent pipe should not be run through unheated spaces. If such runs cannot be avoided, insulate the vent pipe to prevent condensation. Insulation should be a minimum of ½ in. (12.7mm) thick foil faced fiberglass minimum of 1½ # density.
6. Dampers must not be used in vent piping runs, as spillage of flue gases into the occupied space could result.
7. Vent connectors serving Category 1 heaters must not be connected into any portion of a mechanical draft system operating under positive pressure.
National Fuel Gas Code Venting Pipe requirement
75,000-149,999 Use 5-inch pipe
150,000-400,000 Use 6-inch pipe
10
Figure 11 - Vertical Venting
Horizontally Vented Furnaces – Category III
Horizontal vent systems terminate horizontally (sideways)
WARNING: Do not use Type B vent within a building on horizontally vented units.
1. All vent pipe joints must be sealed to prevent leakage. Follow the instructions provided with the approved venting materials.
2. The total equivalent length of vent pipe must not exceed 50 ft. (15.25m). Equivalent length is the total length of straight sections, plus 5 ft. (1.52m) for each 90⁰ elbow and 2.5 ft. (0.76m) for each 45° elbow.
3. The vent system must also be installed to prevent collection of condensates. Horizontal runs should be pitched upward ¼ in. per foot (21mm/m) and should be supported at three (3) foot (1m) maximum intervals.
4. Insulate vent pipe exposed to cold air or routed through unheated areas. Insulate vent pipe runs longer than 10 ft. (3m). Insulation should be a minimum of ½ in. (12mm) thick foil faced fiberglass of 1
½ # density. Maintain 6 in. (152mm) clearance between vent pipe and combustible materials.
5. An approved Breidert Type L, Field Starkap or equivalent vent cap must be provided. Vent cap inlet diameter must be the same as the vent pipe diameter.
6. The vent terminal must be at least 12 in. (305mm) from the exterior wall that it passes through to prevent degradation of building material by flue gases.
7. The vent terminal must be located at least 12 in. (305mm) above grade, or in snow areas, at least 3 ft. (1m) above snow line to prevent blockage.
8. The vent terminal must be installed with a minimum horizontal clearance of 4 ft. (1.2m) from electric meters, gas meters, regulators, or relief equipment.
Through-the-wall vents shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard. Provide vent termination clearances to building or structure features as follows:
11
Structure Minimum
Door, Window or gravity inlet
Forced air inlet within 10 ft. (3m)
Adjoining building or parapet
Adjacent public walkways
Clearance
4 ft. (1.2 m) below
4 ft. (1.2 m) horizontally
1 ft. (305 mm) above
3 ft. (.91 m) above
6 ft. (1.8 m)
7 ft. (2.1 m) above grade
Figure 12 - Horizontal Venting
EACH APPLIANCE MUST HAVE ITS OWN INDIVIDUAL VENT PIPE AND TERMINAL.
Do not connect vent system from horizontally vented units to other vent systems or a chimney
12
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 14 IN. W.C. SEE UNIT RATING PLATE 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 . Avoid multiple taps in the gas
supply so the unit always has a steady supply of gas .
4. Install a ground joint union with brass seat and a manual shut-off valve external to the unit casing, as shown in
Figure 13 , adjacent to the unit for emergency shut-off and
easy servicing of controls.
5. Provide a sediment trap, as shown below, before each unit and where low spots in the pipe line cannot be avoided.
6. Blow out the gas line to remove debris before making connections. Purge line to remove air before attempting to start unit. Purging of air from gas lines should be performed as described in ANSI Z223.1-latest edition
“National Fuel Gas Code”, or in Canada in CAN/CGA-B149.
7. All field gas piping must be pressure/leak tested prior to 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 ½ psi. The heater must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than ½ psi.
8. This unit requires a constant 7 in. w.c. minimum natural gas supply, (LP should be 11 in. w.c. minimum) when the unit is operating at maximum gas flow. If the gas supply exceeds 14 in. w.c.
it will damage the internal valve components, and if it is below 7 in. w.c., the heater may not perform to specifications.
Table 2 – Gas Sizing Reference
Table 3 - Gas Pressure
Gas Pressure Type
Inlet Pressure - Natural Gas
Inlet Pressure - Propane
Max. Manifold Pressure -
Natural Gas
Max. Manifold Pressure -
Propane
Min. Manifold Pressure -
Natural Gas
Min. Manifold Pressure -
Propane
Gas Pressure
7 in. w.c. – 14 in. w.c.
11 in. w.c.
– 14 in. w.c.
3.5 in. w.c. maximum
10 in. w.c. maximum
0.15 in. w.c. minimum
0.75 in. w.c. minimum
Figure 13 – Gas Connection Diagram
NOTICE
Refer to the heater rating plate for determining the minimum gas supply pressure for obtaining the maximum gas capacity for which this heater is specified.
13
LP Conversion Kit
LP/Natural gas conversion kits are used to convert from one gas type to another in the field. This kit is used on all units and the part numbers below should be used on furnace sizes listed. Kits contain:
•
Main Safety Gas Valve Regulator Spring
•
Furnace orifices clearly indicated with orifice size
This unit is configured for the gas type listed on the nameplate. To convert gases, you must replace the following parts listed in the table below. The size specific parts include the orifice conversion parts and the combination gas valve spring(s). These parts are available by contacting the phone number in this manual. All field gas piping must be pressure/leak tested prior to unit operation. Use a non-corrosive bubble forming solution or equivalent for leak testing. The equipment 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. The equipment must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psi. This must be performed on an annual basis.
Table 4 - Gas Conversion Kit Part Numbers
Gas
Type
Modulating
Valve Part
Number
E50
150
Furnace Size (MBH)
200 250 300 400
Natural
LP E50
NAT-
HMG150
LP-
HMG150
NAT-
HMG200
LP-
HMG200
NAT-
HMG250
LP-
HMG250
NAT-
HMG300
LP-
HMG300
NAT-
HMG400
LP-
HMG400
Pre-Conversion Unit Check-Out
The following procedure is intended as a guide to aid in determining that the appliance is properly installed and is in a safe condition for continuing use. It should be recognized that generalized test procedures cannot anticipate all situations. Accordingly, in some cases, deviation from this procedure may be necessary to determine safe operation of the equipment:
▪ This procedure should be performed prior to any attempt at modification of the appliance or the installation.
▪ If it is determined there is a condition that could result in unsafe operation, the appliance should be shut off and the owner advised of the unsafe condition.
The following steps should be followed in making the safety inspection:
1. Conduct a gas leakage test of the appliance piping and control system downstream of the shut-off valve in the supply line to the appliance.
2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restrictions, leakage or corrosion, or other deficiencies which could cause an unsafe condition.
3. Shut off all gas to the appliance and shut off any other fuel-burning appliance within the same room. Use the shut-off valve in the supply line to each appliance.
4. Inspect burners and crossovers for blockage and corrosion.
5. Inspect heat exchangers for cracks, openings, or excessive corrosion.
6. Insofar as is practical, close all windows and all doors between the space in which the appliance is located and other spaces of the building. Turn on any exhaust fans, so they will operate at maximum speed. After completing steps 6 through 10, it is believed sufficient combustion air is not available, refer to the section covering air for combustion, venting and ventilation of Natural
Gas and Propane Installation Code , CSA B149.1, or National Fuel Gas Code , ANSI
Z223.1/NFPA 54, for guidance.
7. Place the appliance in operation following the lighting instructions. Adjust thermostat so the appliance will operate continuously. Other fuel-burning appliances shall be placed in operation.
14
8. Determine that the pilot is burning properly and that the main burner ignition is satisfactory by interrupting and re-establishing the electrical supply to the appliance in any convenient manner; a. Visually determine that main burner gas is burning properly, i.e. no floating, lifting, or flashback. Adjust the primary air shutter(s) as required. b. If the appliance is equipped with high- and low-flame control, or flame modulation, check for proper main burner operation at low flame.
9. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use a draft gauge, the flame of a match, or candle.
10. Return doors, windows, exhaust fans, and all other fuel-burning appliances to their previous conditions of use.
11. Check both limit control and fan control for proper operation. Limit control operation can be checked by temporarily disconnecting the electrical supply to the blower motor and determining that the limit control acts to shut off the main burner gas.
15
Electrical
WARNING!!
Disconnect power before installing or servicing fan. High voltage electrical input is needed for this equipment. This work should be performed by a qualified electrician.
Before connecting power to the heater, read and understand this entire section of this document. As-built wiring diagrams are furnished with each fan by the factory and are attached to the door of the unit.
Electrical wiring and connections should be made in accordance with local ordinances and the National
Electric Code, ANSI/NFPA70. Be sure the voltage and phase of the power supply and the wire amperage capacity are in accordance with the motor 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 Table 5 - Copper Wire Ampacity a heater. Lock and tag the disconnect switch or breaker to prevent accidental power up.
Wire Size AWG Maximum Amps
14 15
2. An electrical drop containing the motor power wiring is shipped with every fan. The electrical drop should be
12 20
10 30 brought through one of the conduit openings located in the base of the unit, run through the curb, and connect to a junction box inside the building.
8
6
50
65
3. A dedicated branch circuit should supply the motor
4 85 circuit with short circuit protection according to the
National Electric Code. This dedicated branch should be run to the junction box and connected as shown in
Figure 14 – Electrical Drops
4. Make certain that the power source is compatible with the requirements of your equipment. The heater nameplate identifies the proper phase and voltage of the motor.
5. Units shipped with an optional remote HMI panel have separate wiring requirements. It is important to route the main electrical wires (high voltage) in a separate conduit from the remote HMI Cat 5 wiring
(low voltage). Maximum distance on any low voltage wire is 1000 feet.
6. Before connecting the heater to the building ’s power source, verify that the power line wiring is de-energized.
7. Secure the power cables to prevent contact with sharp objects.
8. Do not kink power cable and never allow the cable to come in contact with oil, grease, hot surfaces or chemicals.
9. Before powering up the heater, check fan wheel for free rotation and make sure that the interior of the heater is free of loose debris or shipping materials.
10. If any of the original wire supplied with the heater must be replaced, it must be replaced with type TW wire or equivalent.
INDIRECT FIRED MODULE
20 IN HIGH
EQUIPMENT RAIL
AND CURB
Motor Drop
SERVICE DISCONNECT
SWITCH
BLOWER/
MOTOR
ACCESS
DOOR
Control Drop
16
Input AC Power
1. 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 . Refer to the
installation schematic for exact breaker sizing.
2. Each VFD should be fed by 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.
3. Input AC line wires should be run 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.
4. 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.
5. Motors should be grounded to the VFD ground terminal only. Do not connect the motor ground to the heater ground terminal.
Fan to Building Wiring Connection
120V 1 PH.
Gal-flex conduit
(in unit)
Figure 15
208-240V 1 PH.
Gal-flex conduit
(in unit)
208-240/460/600V 3 PH.
Gal-flex conduit
(in unit)
120V 1 PH.
Standing
Power
Disconnect
Switch
Factory wiring 120V 1 PH.
Standing
Power
Disconnect
Switch
Factory wiring
208-240
1 PH.
120V 1 PH.
Standing
Power
Disconnect
Switch
Factory wiring
3 PH.
BK WH GR
Customer supplied wiring from building power or pre wired control panel
BK WH BK BK GR
Customer supplied wiring from building power or pre wired control panel
BK WH BK BK BK GR
Customer supplied wiring from building power or pre wired control panel
17
COMPONENTS
Part Identification
The following image and list identify typical indirect fired heater components and their functions.
Figure 16 – Typical Main Cabinet
# Name
1. Exhaust Flue Pipe
2. Flame Roll-Out Switch
3. Flame Sensor
4. Contactor
5. 750VA Transformer
6. Control Transformer
7. Control Transformer
8. Terminal Strip
9. Circuit Breaker
10. Dirty Filter Airflow Switch
(Optional)
11. Main Airflow Switch
Description
Ventilates combustion between the power-vent exhaust discharge and top of the unit.
Normally closed temperature activated switch. Mounted on bracket at inlet of the upper-most firing tube. Senses flame roll-out in the event of a blocked tube, low airflow, or low gas pressure. If flame-rollout is present, the switch de-energizes heater circuit on individual furnace. Must be manually reset by pressing small red button on back.
Continuously senses for the presence of flame in heating mode after ignition has commenced. Wired to Flame Safety
Control.
Contactor with overload protection to start and protect motor.
The transformer is designed to change one voltage to another by magnetic induction.
120V primary; 24V secondary control transformer.
120V primary; 24V secondary control transformer.
Central location to terminate control wiring. Should be used for troubleshooting.
Protects electrical components from high current spikes.
Senses whether the filters at the intake to the main blower are free of dirt and contaminant.
Senses that there is main airflow across the Heat-exchanger of the furnace. Adjustable set-point. Heater circuit will not energize unless proven.
18
# Name
12. Power-vent Airflow Switch
13. Flame Safety Control
14. IBT Board
*2 required if heat stages > 2
15. Cabinet Heater (Optional)
16. Modulating Valve Control
Transformer
17. HMI
Description
Normally open, non-adjustable airflow switch. Senses whether the power-vent blower is running and allows furnace to spark when airflow is proven.
Initiates and monitors flame. Equipped with non-adjustable time settings for pre-purge, inter-purge, and post-post of the exhaust flue and control cabinet.
Controls the 0-10V DC signal to the modulating gas valve(s), speed controller(s) and 24V AC signals to staged furnace controls. Speed controllers are built into the board. Main board DIP switches should all be set to off. When a slave board is used, the slave board DIP switch 1 should be set to on. Slave board DIP switches 2, 3 and 4 should remain off.
Use a Cat-5 cable from J5 of main board to J1 or J2 of slave board.
Recommended for winter design temperatures of 0°F or below.
120V primary; 24V secondary control transformer. Provides standing 24V power to Modulating Gas Valve.
IBT Board interface. The 4 buttons are used to navigate through the menus. (There can be up to 4 additional HMIs added. These can be used for interface or as a part of space tempering)
19
Figure 17 – Typical Burner Cabinet
# Name
1. Power-vent Motor
Description
Induces airflow through heat exchanger and flue of furnaces
A) Modulating furnace variable speed blower motor.
B) Non-modulating furnace constant speed blower motor.
Power Vent Motor Orifice Size
Furnace BTU (x1000/hr) Dia. (in.)
400 2.625
300
200
150
2.25
2.375
1.875
2. Main Disconnect Switch
3. Fan Motor Speed Control Options:
PSC Motor Speed Control
(Not Shown)
ECM Speed Control
(Not Shown)
Controls all electrical power to entire unit.
Manual knob split capacitor fan motor speed control.
Electronic motor speed control
Variable Frequency Drive (Shown) Used in place of motor starter to protect main blower motor and to control the speed of the main blower to vary main airflow across unit.
4. High pressure gas switch
5. Manifold Gas Pressure Gauge
6. Flame Roll-Out Switch
Monitors pressure and cuts off the electrical control circuit when pressure rises above the desired set point. (Optional)
Indicates manifold gas pressure on individual furnace.
Normally closed temperature activated switch. Mounted on bracket at inlet of the upper-most firing tube. Senses flame roll-out in the event of a blocked tube, low airflow, or low gas pressure. If flame-rollout is present, the switch de-energizes heater circuit on individual furnace. Must be manually reset by pressing small red button on back.
20
# Name
7. On/Off Gas Valve
8. Modulating Gas Valve
9. Low pressure gas switch
10. Main Inlet Gas Pressure Gauge
Not Shown:
- High Limit Switch
- Spark Ignitor
- Discharge Sensor
- Intake Air Sensor (not shown)
Description
On/off gas valve with built in regulator and manual shut off switch. One used on each furnace gas train.
Controls the amount of gas to the furnace to meet desired discharge/Space temperature. (Modulating units only)
Monitors pressure and cuts off the electrical control circuit when pressure drops below the desired set point. (Optional)
Indicates inlet gas pressure to unit.
Normally closed high temperature switch. De-energizes heater circuit on individual furnace if temperature exceeds mechanical set-point. Automatic recycling. 200°F set-point.
Powered by Flame safety control to initiate light-off.
10k Thermistor. Controls the discharge to which the heating module heats to and constantly tries to maintain. Freezestat and discharge Firestat functionality is built into this sensor if the options are enabled.
10k Thermistor. Reports intake temperature to the IBT board.
Heating/cooling will activate based off the set points on the
IBT Board. Does not control the temperature to which the unit heats the discharge. Located in the supply fan,
Motor Speed Control Options
ECM (Electronically Controlled Motor) Speed Control
EC motors and control allows accurate manual adjustment of fan speed. The benefit of EC motors is exceptional efficiency, performance, and motor life.
When using an EC motor, the blower control should be set to ECM. This menu item is located under factory settings > unit options > blower configuration. Once this is set, there is a PWM rate setting under user settings. This will be used to control the speed of the EC motor. The PWM signal will be sent directly to the ECM via J13-(2) PWM + and J13-(9) PWM ( –) pins.
NOTE: A Variable Frequency Drive (VFD) is required to adjust the speed control of a nonelectrically commutated 3 phase direct drive motor.
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 and 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.
21
Variable Frequency Drive Speed Control (Installation Instructions)
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
1. Motor wires from each VFD to its respective motor MUST be run in a separate steel conduit away from control wiring and incoming AC power wiring 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.
2. VFD mounted in ECP: If the distance between VFD and the motor is greater than the distances specified below, a load reactor should be used between VFD and motor. The load reactor should be sized accordingly and installed within 10 feet of the output of the VFD.
208/230V – Load reactor should be used when distance exceeds 250 feet.
460/480V – Load reactor should be used when distance exceeds 50 feet.
575/600V – Load reactor should be used when distance exceeds 25 feet.
3. VFD mounted in fan: The load reactor should be sized accordingly when VFD is mounted in the fan.
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.
575V/600V – Load reactors are required for all HP motors.
4. If the distance between VFD and the motor is extremely long, up to 1000 FT, a dV/dT filter should be used. 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.
5. No contactor should be installed 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.
6. When a disconnect switch is installed between the drive and motor, the disconnect switch should only be operated when the drive is in a STOP state.
VFD 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 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 below).
To enter the PROGRAM mode to access the parameters:
1. 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 also 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 in order to access the parameters again.
P500 parameter provides a history of the last 8 faults on the drive. It can be accessed without getting into
PROGRAM mode.
22
1
1.5
2
3
5
7.5
10
15
20
0.5
1
1.5
2
3
5
7.5
1
2
3
5
7.5
10
15
20
25
30
10
15
20
25
ACTECH SMV VFD
HP
0.33
0.5
Part Number
ESV251N01SXB571
ESV371N01SXB571
Volts
120/240V
Table 6 – Cross-Reference Table
1Ø
Input
3Ø
Input
Input Amps 1Ø
120V AC
Input Amps 1Ø 240V
AC
X -
-
6.8 3.4
120/240V X 9.2 4.6
-
1 ESV751N01SXB571 120/240V X 16.6 8.3
-
1.5
HP
ESV112N01SXB571
Part Number
120/240V
Volts
X
1Ø
Input
3Ø
Input
20
Input Amps 1Ø
10
Input Amps 3Ø
ESV371N02YXB571
ESV751N02YXB571
ESV112N02YXB571
ESV152N02YXB571
ESV222N02YXB571
ESV402N02TXB571
ESV552N02TXB571
ESV752N02TXB571
ESV113N02TXB571
ESV153N02TXB571
ESV751N04TXB571
ESV112N04TXB571
ESV152N04TXB571
ESV222N04TXB571
ESV402N04TXB571
ESV552N04TXB571
ESV752N04TXB571
ESV113N04TXB571
ESV153N04TXB571
ESV183N04TXB571
ESV223N04TXB571
ESV751N06TXB571
ESV152N06TXB571
ESV222N06TXB571
ESV402N06TXB571
ESV552N06TXB571
ESV752N06TXB571
ESV113N06TXB571
ESV153N06TXB571
ESV183N06TXB571
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
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
X
X
X
X
X
X
X
X
240V
240V
240V
480V
480V
480V
480V
480V
480V
240V
240V
240V
240V
240V
240V
240V
600V
600V
600V
600V
600V
480V
480V
480V
480V
480V
600V
600V
600V
600V
2.5
3.6
4.1
5.4
9.3
12.4
33
48
59
2.9
5
6.9
8.1
10.8
18.6
26
2
3.2
4.4
6.8
10.2
15.8
24
31
38
45
12.4
19.7
25
31
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
17.1
-
-
-
-
5.1
8.8
12
13.3
30 ESV223N06TXB571 600V X 36
1.7
2.7
3.9
6.1
9
14
21
27
34
40
11
17
22
27
2.1
3
3.5
4.8
8.2
11
29
42
54
2.4
4.2
6
7
9.6
16.5
23
Output
Amps
1.7
2.4
4.2
6
Output
Amps
32
Breaker 1Ø
120V AC
15
15
25
30
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Breaker 1Ø
15
15
20
25
30
-
-
-
-
Breaker 1Ø
240V AC
15
15
15
20
15
15
15
15
15
20
50
80
90
Breaker 3Ø
15
15
15
15
20
30
40
15
15
15
15
20
25
40
50
70
80
20
30
40
50
60
23
Optional Components
Electric Cabinet Heater
Units can be shipped with an optional 120V electric cabinet heater powered from the IBT board. There is a temperature sensor built onto the IBT Board that will regulate when the cabinet heater activates.
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 energized whenever the blower gets a call to run. No external wiring to the damper motor is required .
AC Interlock
On units equipped with an optional AC interlock, 24V AC power from Y1 in the condensing unit or rooftop unit should be field wired to screw terminal J11-(5) on the IBT board. 24V AC common from C in the condensing unit or rooftop unit should be field wired to terminal block J11-(8) on the IBT board. When these terminals are powered, heat will be locked out on the IBT.
Remote (HMI) Control Panel
On units shipped with a space HMI, a Cat 5 cable will need to be run from J3 on the main IBT Board to J2 on the HMI. If additional space
HMIs have been added, they can be daisy chained from the first HMI.
In the event there is a slave IBT board, HMIs can also be powered from
J1 or J2 of the slave board. An end of line resistor should be added to the last HMI in the chain.
OPERATION
Figure 18 – Space HMI
HMI Configuration
General Overview
The HMI allows the user to change parameters, and options. You can use the HMI to view operating Information regarding sensors, temperatures, pressures, and fault history.
There are four buttons to navigate through the HMI screens.
Note: Buttons change functions during certain options, and tests.
Verify the screen, and buttons throughout the menu display.
The user can access the HMI configuration screen by pressing the top two buttons simultaneously. To exit this screen, simply press the BACK button. When setting certain options or functions, pressing the BACK button multiple times will bring up the reboot screen. The user may select
‘YES’ to save the changes or select ‘NO’ to return to factory settings, or select ‘CANCEL’. When selecting ‘CANCEL’, any changes made will not be saved, and the screen will return to the top menu.
The HMI menu system allows full access to every configurable parameter in the HMI. The parameters are factory configured to the specific application. Parameters may need to be modified to fine tune automatic operation after the original setup.
Figure 19 – Idle Screen
Figure 20 – Warning Screen
24
HMI Options Screen
To set the HMI number or to adjust the screen contrast, press the bottom two buttons simultaneously on the HMI faceplate. Use the UP and Down buttons to select the parameter that will be adjusted. Press
Enter to select the highlighted parameter.
Setting the HMI number configures the Modbus address for that HMI.
To change the contrast, select “Advanced Options”. The user may adjust the setting from 0 to 10. Setting the contrast to 0 is the lowest setting available and 10 is the highest contrast setting available. The factory default contrast setting is 5.
HMI Notification Letters
The HMI will display notification letters when the unit is in a specific status.
Figure 21 – Notification Letters
• When the blower is in a delay, a “B” will be displayed.
•
When the condensers are in a Min ON or Min OFF time, a
“T” will be displayed.
HMI Menu Description
USER SETTINGS
(Any changes within this menu do not require a reboot to take effect)
•
Temp Set Points – Some of these may not be available based on settings. If scheduling is enabled there will be both occupied and unoccupied values for each set point.
•
Scheduling – This menu will only show when scheduling option has been turned on. Each day contains the option for two occupied time periods. If the time is scrolled past 11:59pm it will display UNOCC.
•
Copy Schedule – This will allow the user to copy an existing schedule from one day of the week to individual days in the week, to Week Days, or ALL.
•
Fan Speed - Enabled when blower control is set to VFD Manual. The range of this menu is limited by the min and max frequency set points under factory settings. When occupied scheduling is set to on, occupied and unoccupied settings are available.
•
HMI Dimming Timer - Configurable menu time until dim, 10 seconds - 60 seconds.
•
PWM Rate - Enabled when blower control is set to ECM. This will be used to control the speed of the ECM motor. The PWM signal will be sent directly to the ECM motor. When occupied scheduling is set to on, occupied and unoccupied settings are available.
•
Mixing Box Voltage - Enabled when ‘Mixing Box Config’ is set to ‘Manual’. Voltage output to air box damper.
•
Outdoor Air % - Enabled when ‘Mixing Box Config’ is set to ‘Schedule’, or ‘Outdoor Air %’.
Limited by min and max outdoor air percentages in factory settings. When occupied scheduling is set to on, occupied and unoccupied settings are available.
•
Active Faults – Contains the current faults on the board
•
Fault History - Will show time stamped history of the last 20 faults, most recent fault showing first.
•
Reset Fault Lockout – Resets lock out faults.
25
FACTORY SETTINGS
( Password = 1111 )
(These will be set job specific from the plant. Any changes within this menu require a reboot to take effect. Upon exiting factory settings, if anything has been altered, the board will reboot itself.
Password = 1111. There is a 5 minute timer before having to re-enter password.)
•
Temperature Control - If scheduling is enabled there will be both occupied and unoccupied values for each set point.
▪ Tempering Mode Heat – Discharge, Space, Analog Control, DDC, None.
▪ Tempering Mode Cool – Intake, Space, Analog Control, DDC, None.
▪ Activate Based On – Intake, Space, Both, Either, Stat. Default is Either.
•
Heating Config
▪ # Of Heat Stages – 0, 1, 2, 3, 4 heat stages.
▪ Intake Heat Hysteresis (Hyst) – Intake sensor must go this amount of degrees above the set point before heating will turn off.
▪ Space Heat Hysteresis (Hyst) – Space sensor must go this amount of degrees above the set point before heating will turn off.
▪ Heater Firing Order – Standard, alternate. Standard firing order is furnace 1, 2, 3, 4.
Alternate firing order is furnace 2, 1, 3, 4. This option has no effect for single furnace units.
▪ Input Source – 0-10V DC, 2-10V DC, 0-20 mA, 4-20 mA. This lets the board know what signal to expect from an Analog Control system.
▪ Cabinet Diff – This is the differential for the cabinet heater. The outdoor air temp must fall this many degrees below the activation set point to turn off.
▪ Freezestat Timer – The discharge temp must stay below the freezestat set point for this amount of time before the unit will lock out on freeze stat.
▪ ROT Delay – This is the time after a furnace loses a call for heat before the furnace shuts down.
▪ RCT Delays – If the heat stage value is greater than 1,
RCT Delay Defaults (in Seconds) the user may adjust Relay Close Time (RCT) delay for stages 2, 3, 4. Range settings is 30-600 seconds.
•
Cooling Config
▪ Cooling Type – None, DX, Evap, Both. If “None” is
RCT Stage 2 Stage 3 Stage 4
1
2
3
4
0
120 s
0
0
0
90 s
120 s
0
0
90 s
90 s
120 s selected all cooling options under user settings are hidden.
▪ Min Cool OA Temp – When the space temperature is calling for cooling, and the outdoor air temperature is below the set point, the unit will shut the condensers off, and start the blower to use outdoor air to cool the space. Default is 55°F. Range setting is 40-90°F.
▪ Condenser Staging – 0, 1, 2, or 3 condensers. Within the 2 and 3 condenser selection, there is another submenu which allows for 2 or 3 stages. For 2 condenser units, 3 stages should only be selected when the condensers are of unequal tonnages.
▪ Intake Cool Hysteresis (Hyst) – Intake sensor must fall this many degrees below the set point for the stage to turn off.
▪ Space Cool Hysteresis (Hyst) – Space sensor must fall this many degrees below the set point for the stage to turn off.
▪ Cond Min Time On – Minimum time each condensing stage must remain on after becoming activated. This is to prevent stage cycling. A “T” will be present in the lower left corner of the home screen when any of the condensers are in a MIN ON/OFF TIME.
▪ Cond Min Time Off – Minimum time each condensing stage must remain off after being deactivated. This is to prevent stage cycling. A “T” will be present in the lower left corner of the home screen when any of the condensers are in a MIN ON/OFF TIME.
▪ Evap Config (continued) o Spray Time On – Time the evaporative cooler will spray in the cycle. o Spray Time Off – Time the evaporative cooler will be idle in the cycle. o Evap Drain – On/Off. Default is Off. o Evap Drain SP - This setting will monitor outside air so that the water does not freeze within the evaporator module. Default setting is 40°F. Range setting is 35-50°F.
26
FACTORY SETTINGS
( Password = 1111 )
▪ Evap Config (continued) o Drain Differential – Temperature differential setting before the drain shuts off. Default setting is 2°F. Range setting is 1-5°F. o Evap Differential – Temperature differential before the evap cooling shuts off. Default setting is 3°F. Range setting is 1-10°F.
•
Occupied Scheduling – This menu is where the scheduling can be turned On or Off. Default is
Off.
•
Occupancy Override – This menu is where the occupancy override can be turned On or Off.
Default is On.
•
Unit Options
▪ Board Config o IBT Address – Modbus address of the IBT board.
o Startup Timer – Time upon power up where the board will sit idle. o Celsius/Fahrenheit – Celsius, Fahrenheit. Changing between the two will reset all set points. o # of HMIs – Number of HMIs connected to the IBT board. Must always be at least one. o HMI Averaging – If there are multiple space HMIs connected, this menu allows you to select which will be included in the space averaging. If a thermistor is connected into the ST screw terminals, it will automatically be averaged into any HMIs included. o HMI Dimming – This is an On/Off menu. Default is set to Off. If set to On, a ‘HMI
Dimming Timer’ option will be available under ‘User Settings’. o Screensaver - This is an On/Off menu. Default is set to On. If set to Off, the home screen will not time out to the screensaver.
▪ Blower Config o Blower Control – 120V Contactor, VFD Manual, VFD Jog, VFD 0-10V, ECM, ECM 0-
10V.
➢ 120V Contactor – 120V output on the IBT board to drive the coil of a contactor. This option should be selected when the IBT is used in conjunction with a DCV package.
➢ VFD Manual – HMI selectable VFD frequency.
➢
VFD Jog – For use with VFD using photohelic control. Uses the aux pins to control the VFD. Powering aux 1 will speed the fan up, powering aux 2 will slow the fan down. When aux
1 or aux 2 are not powered, the VFD will hold current speed.
➢ VFD 0-10V – For use when an external 0-10V signal is being provided to control the speed of the VFD. The VFD output from this input will be based on the VFD min and max freq set under protected params in factory settings. 0 Volts will equal VFD min,
10V will equal VFD max, and all voltages in between will be scaled linearly. This option will utilize 0-10V J14-(6) and 0-10V common J14-(7) screw terminals and will o require field wiring.
➢ Electronically Controlled Motor (ECM) - HMI selectable PWM rate.
➢
ECM 0-10V For use when an external 0-10V signal is being provided to modulate the ECM supply output between min and max speed.
Blower Mode – If the Occupied Scheduling is set to ON, the menu screen for the blower mode will allow you to choose ON/AUTO/OFF for Occupied or Unoccupied. If the
Occupied Scheduling is set to OFF, the menu screen for the blower mode will allow you to choose MANUAL/AUTO/OFF. In blower auto mode, the blower will only run when it gets a call for heating/cooling. In blower manual mode, the blower will run as long as the fan button is enabled regardless of whether the unit is heating/cooling. In blower off mode, powering the unit interlock pin will cause the blower to run. This setting should be used when an IBT is covered by a prewire package.
27
FACTORY SETTINGS
( Password = 1111 ) o Blower Start Delay – On, Off. Enabling this menu will run the furnace before starting the blower. A “B” will be present in the lower-left corner when the unit is in a blower
START/STOP DELAY.
o Blower Stop Delay – On, Off. Enabling this menu
Table 7 – Fan Speed Presets will stop the furnace and allow the blower to run until timer expires.
A “B” will be present in the lower-left corner when the unit is in a blower
PRESET AUX 1 AUX 2 AUX 3
Speed 1
Speed 2
X
X
Speed 3 X X START/STOP DELAY.
o Blower Delay Time – This sets the time that the furnace will run before the blower starts. o Blower Preset Speed – This allows the user to
Speed 4
Speed 5
Speed 6
Speed 7
X
X
X
X
X
X
X
X set blower preset option On or Off. o VFD Direction – Sends a command to the VFD to run in forward or reverse. o
Fan Speed Presets - Uses aux pins to control supply fan VFD, see Table 7 .
o Occ Fan Presets – Occupied scheduled presets 1-7. o Unocc Fan Presets – Unoccupied scheduled presets 1-7.
▪ Purge Config o Purge Button – On, Off. This function will be active when the mixing box is enabled.
When the purge button is pressed, the mixing box dampers will open to max outdoor air and turn on the exhaust contactor.
o Purge Time –This is setting is adjustable from 1 – 120 minutes, default is 15 minutes.
This is the amount of time that the unit will run the purge process, if the user does not stop the purge manually. o VFD Purge Speed – Adjustable between VFD Min and Max frequency. This is the speed the blower will run during the purge cycle. Default is 60 Hz. o ECM Purge Speed – This is the speed the blower will run during the purge cycle. This is adjustable between PWM Min and Max frequency.
▪ Monitoring Sensors – These are On/Off menus. Default is Off.
Smoke Detector, Filter Monitor, Intake Firestat, Discharge Firestat, Freezestat, Low Gas Switch,
High Gas Switch.
▪ Mixing Box Config o Mixing Box – None, Manual, 2 Position, Schedule, Table 8 – Damper Presets
Outdoor Air %, 100% OA, Analog Control. o Mixing Box Deadband – If the temperature difference
PRESET AUX 1 AUX 2 AUX 3
Position 1 X between the outdoor and return sensor is less than or
Position 2 X equal to this set point, the IBT board will not attempt Position 3 X X to adjust the output voltage until it matches the outdoor air percentage set point. This setting only
Position 4
Position 5 X
X
X
Position 6 X X takes effect when either outdoor air % or schedule is
Position 7 X X selected. o Return As Space – On, Off. Setting this to on will not require a space sensor or HMI. It
X will use the return air thermistor (RT) in place of the space sensor. o Min Outdoor Air % - Minimum allowed outdoor air percentage. User can set occupied and unoccupied percentage range. o Max Outdoor Air % - Maximum allowed outdoor air percentage. User can set occupied and unoccupied percentage range. o Off Position – Allows user to select how the dampers will be positioned when the supply fan is off. Standard (default), Max Outdoor Air %, or Min Outdoor Air %. o Damper Presets – This allows the user to set damper preset option On or Off. o Preset Volts
– Uses aux pins to control damper actuator, see Table 8 .
28
(Password = 1111)
FACTORY SETTINGS
▪ Intake Damper – On, Off.
▪ Room Override – On, Off option. This setting will only have an effect when the heat tempering mode is set to Discharge and “Activate Based On” is set to “Either” (intake or space temperature). When the space is calling for heat it will use the Room Override SP instead of
Discharge SP to heat the space.
▪ Exhaust Cntctr (Contactor) – Off, before airflow, after airflow. If scheduling is enabled there will be both occupied and unoccupied values for each set point.
▪ Exhaust On Smoke – Off, On. Input that when enabled, if it receives a 120V signal from a fire system, will shut down the supply fan and enable the exhaust contactor.
▪ Cabinet Heater – On, Off.
▪ Drain Heater – On, Off.
•
Occupied Override (Occpd Ovrd) Duration – Length of override timer. If override is active it can be manually stopped by pressing the end override button on the HMI. The default setting is 1 hour but can be adjusted up to 16 hours.
•
Limit Set Point (SP) Adjust - This allows the user to change the current temperature set point from the home screen. The range adjustment is 0-100 degrees. The default is 5 degrees. When the setpoint is set to 0°F/C the adjustment buttons (+/-) will not be visible.
•
Protected Params – VFD Min and Max Frequency can be adjusted here. PID values within this menu should not be changed
SERVICE SETTINGS
(Password = 1234)
•
Temperatures – Menu to view all of the temperature sensors.
•
Discharge Disp Offset – Display offset for discharge temp. This can be used if actual discharge temperature is measured differently on site.
•
Space Disp Offset – Display offset for space temp. This can be used if actual space temperature is measured differently on site.
•
Inputs
▪ Open/Closed Status – Menu to view the open/closed status of all inputs.
▪ Voltages – Voltage Inputs. Analog Control, Air quality, Mixing Box Damper, Indoor RH and
Outdoor RH.
▪ VFD Status – Live parameter feedback from the VFD.
•
Outputs – Board output equipment status.
•
Test Menu – To stop any test, hit the abort button on the HMI.
▪ Test Fans – All, Supply, Exhaust.
▪ Test Heating – Contains high and low fire tests for stages. If “Heating Config” is set to 0, then
“No Heat Stage Set” will display.
▪ Test Cooling Evap/DX – All, 1, 2, 3, Evap. If “Cooling Config” is set to none, then "No Cooling
Type Set" will display.
▪ Test Analog Control – This test will simulate a voltage input from an analog control system.
The test will begin at 0 volts. The up and down buttons allow for modulation of input.
▪ Test Options.
o Cabinet Heater – Beginning this test will turn the cabinet heater on. o Drain Heater – Beginning this test will turn the drain heater on. o Mixing Box – Beginning this test will create an output to the mixing box. The test will begin at 0 volts. The up and down buttons allow for modulation of the output.
•
Clear Fault History – Will clear the entire fault history. If there is an active fault when cleared, that fault will show up until it is fixed.
•
Factory Reset – Will reset board to factory commissioned settings.
•
Update Factory Defaults – This allows the original factory default settings to be overridden.
When confirming the updated settings, these settings will now be used when “Factory Reset” is needed.
29
HMI Menu Tree
The top menu of the IBT Board contains 3 main categories. These categories are user settings, factory settings, and service.
TEMP SET
POINTS
HEATING
COOLING
OPTIONS
INTAKE HEAT
SPACE HEAT
DISCHARGE
HEAT
MIN DISCHARGE
HEAT
MAX DISCHARGE
HEAT
INTAKE COOL
STAGE 1
SPACE COOL
INTAKE COOL
DIFFERENTIAL
SPACE STAGE
DIFFERENTIAL
EVAP COOL
ROOM
OVERRIDE
INTAKE
FIRESTAT
DISCHARGE
FIRESTAT
FREEZESTAT
CABINET HEAT
DRAIN HEAT
EVAP DRAIN
DRAIN
DIFFERENTIAL
EVAP
DIFFERENTIAL
RANGE
35-110 °F / 2-43°C
RANGE
35-110 °F / 2-43°C
RANGE
40-150 °F / 4-66°C
RANGE
40-150 °F / 4-66°C
RANGE
40-150 °F / 4-66°C
RANGE
55-120 °F / 13-50°C
RANGE
50-120 °F / 10-32°C
RANGE
0-20 °F / 1-13°C
RANGE
0-20 °F / 1-13°C
RANGE
55-100 °F / 13-38°C
RANGE
40-150 °F / 4-66°C
RANGE
100-300 °F
38-149 °C
RANGE
100-300 °F
38-149 °C
RANGE
(-40)-75 °F
(-40)-24 °C
RANGE
0-40 °F / (-18)-4°C
RANGE
35-45 °F / 2-7°C
RANGE
35-50 °F / 2-10°C
RANGE
1-5 °F / 1-3°C
RANGE
1-10 °F / 1-6°C
DEFAULT
240 °F / 116°C
DEFAULT
35 °F / 2°C
DEFAULT
0 °F / -18°C
DEFAULT
35 °F / 2°C
DEFAULT
40 °F / 4°C
DEFAULT
2 °F / 1°C
DEFAULT
3 °F / 2°C
DEFAULT
60 °F / 16°C
DEFAULT
70 °F / 21°C
DEFAULT
80 °F / 21°C
DEFAULT
80 °F / 10°C
DEFAULT
120 °F / 66°C
DEFAULT
75 °F / 29°C
DEFAULT
74 °F / 23°C
DEFAULT
10 °F / 6°C
DEFAULT
2 °F / 2°C
DEFAULT
85 °F / 29°C
DEFAULT
90 °F / 31°C
DEFAULT
135 °F / 57°C
30
SCHEDULING
COPY SCHEDULE
FAN SPEED
HMI DIMMING TIMER
PWM RATE
MIXING BOX VOLTAGE
OUTDOOR AIR %
ACTIVE FAULTS
FAULT HISTORY
RESET LOCKOUTS
START TIME A
END TIME A
START TIME B
END TIME B
COPY FROM: (DAY)
COPY TO: (DAY, WEEK DAYS, ALL)
RANGE - MIN TO MAX VFD
FREQUENCY
RANGE
10-60 SECONDS
RANGE
0-100%
RANGE
0-10V
RANGE
MIN TO MAX
OUTDOOR AIR %
DISPLAYS ACTIVE FAULTS
SHOWS MOST RECENT
FAULTS IN SYSTEM
RESETS FAULTS THAT
LOCKOUT THE SYSTEM
MON/FRI 8AM
SAT/SUN UNOCC
MON/FRI 6PM
SAT/SUN UNOCC
DEFAULT
UNOCC
DEFAULT
UNOCC
DEFAULT
60 HZ
DEFAULT
60 SECONDS
DEFAULT
100%
DEFAULT
0.00 V
DEFAULT
100%
31
ENTER
PASSWORD
1111
TEMPERATURE
CONTROL
HEATING
CONFIG
DISCHARGE
HEAT
TEMPERING
MODE
COOL
TEMPERING
MODE
SPACE
ANALOG
CONTROL
DDC
NONE
INTAKE
SPACE
ANALOG
CONTROL
DDC
NONE
INTAKE
SPACE
ACTIVATE
BASED ON
# OF HEAT
STAGES
SPACE HEAT
HYST
INTAKE HEAT
HYST
HEATER FIRING
ORDER
INPUT SOURCE
CABINET DIFF
FREEZESTAT
TIMER
ROT DELAY
RCT DELAYS
2/3/4
BOTH
EITHER
STAT
0-4
RANGE
0-3 °F / 0-10°C
RANGE
0-5 °F / 0-3°C
STANDARD
DEFAULT
DEFAULT
1
DEFAULT
3
0
°F / 1°C
°F / 2°C
ALTERNATE
0-10V
2-10V
0-20mA
4-20mA
RANGE
1-4 °F / 1-20°C
RANGE
0-20 MINUTES
RANGE
30-240
SECONDS
RANGE
30-600
SECONDS
DEFAULT
1 °F / 5°C
DEFAULT
20 MINUTES
DEFAULT
45 SECONDS
DEFAULT
VARIES PER STAGE
32
COOLING
CONFIG
OCCUPIED
SCHEDULING
OCCUPANCY
OVERRIDE
COOLING TYPE
MIN COOL
OA TEMP
CONDENSER
STAGING
INTAKE COOL
HYST
SPACE COOL
HYST
COND MIN ON
TIME
COND MIN OFF
TIME
EVAP CONFIG
ON/OFF
ON/OFF
NONE
DX
EVAP
BOTH
RANGE
40-90 °F / 4-32°C
NONE
1 CONDENSER
1 STAGE
2 COND
2 STAGES
2 COND
3 STAGES
3 COND
2 STAGES
3 COND
3 STAGES
RANGE
0-5 °F / 0-10°C
RANGE
0-3 °F / 0-10°C
RANGE
1-5 MINUTES
RANGE
1-5 MINUTES
SPRAY TIME ON
SPRAY TIME OFF
EVAP DRAIN
EVAP DRAIN SP
DRAIN
DIFFERENTIAL
EVAP
DIFFERETIAL
DEFAULT
OFF
DEFAULT
ON
DEFAULT
55 °F / 13°C
DEFAULT
3 °F / 2°C
DEFAULT
1 °F / 1°C
DEFAULT
2 MINUTES
DEFAULT
2 MINUTES
RANGE
0-60 SECONDS
RANGE
0-500 SECONDS
ON/OFF
RANGE
35-50 °F / 2-10°C
RANGE
1-5 °F / 1-3°C
RANGE
1-10 °F / 1-6°C
DEFAULT
SET BY PLANT
DEFAULT
SET BY PLANT
DEFAULT
OFF
DEFAULT
40 °F / 4°C
DEFAULT
2 °F / 2°C
DEFAULT
3 °F / 2°C
33
UNIT OPTIONS
BOARD CONFIG
BLOWER CONFIG
IBT ADDRESS
STARTUP TIMER
CELSIUS /
FAHRENHEIT
# OF HMIS
HMI DIMMING
SCREENSAVER
HMI AVERAGING
BLOWER CONTROL
RANGE
1-247
RANGE
5 SECONDS -
4 MINUTES
CELSIUS /
FAHRENHEIT
RANGE 1-5
ON/OFF
ON/OFF
HMI: 2-5
AVERAGE SENSOR:
ON/OFF
120V CONTACTOR
VFD MANUAL
VFD JOG
VFD 0-10V
ECM
ECM 0-10V
BLOWER MODE
BLOWER START
DELAY
BLOWER STOP
DELAY
BLOWER DELAY
TIME
BLOWER PRESET
SPEED
VFD DIRECTION
FAN SPEED
PRESETS
ON/AUTO/
MANUAL/OFF
ON/OFF
ON/OFF
RANGE
0-120 SECONDS
ON/OFF
FORWARD/REVERSE
PRESET
1-7
DEFAULT
AUTO
DEFAULT
OFF
DEFAULT
OFF
DEFAULT
90 SECONDS
DEFAULT
OFF
DEFAULT
FORWARD
DEFAULT
PRESET 1: 30 HZ
DEFAULT
71
DEFAULT
00:05
DEFAULT
FAHRENHEIT
DEFAULT
1
DEFAULT
OFF
DEFAULT
ON
DEFAULT
2
OFF
34
UNIT OPTIONS
PURGE CONFIG
MONITORING
SENSORS
MIXING BOX
CONFIG
INTAKE DAMPER
ROOM OVERRIDE
PURGE BUTTON
PURGE TIME
VFD PURGE
SPEED
ECM PURGE
SPEED
SMOKE
DETECTOR
FILTER MONITOR
INTAKE FIRESTAT
DISCHARGE
FIRESTAT
FREEZESTAT
LOW GAS SWITCH
HIGH GAS
SWITCH
MIXING BOX
MIXING BOX
DEADBAND
MIN OUTDOOR
AIR %
MAX OUTDOOR
AIR %
RETURN AS
SPACE
DAMPER
PRESETS
PRESET VOLTS
OFF POSITION
ON/OFF
ON/OFF
ON/OFF
RANGE
1-120 MINUTES
RANGE
30-60 HZ
RANGE
PWM MIN-MAX
DEFAULT
OFF
DEFAULT
15 MINUTES
DEFAULT
60 HZ
VARIES BASED ON
DESIGN
ON/OFF
DEFAULT
OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
DEFAULT
OFF
DEFAULT
OFF
DEFAULT
OFF
DEFAULT
OFF
DEFAULT
OFF
DEFAULT
OFF
OFF
MANUAL
2 POSITION
SCHEDULE
OUTDOOR AIR %
ANALOG CONTROL
DEFAULT
MANUAL
0-10 °F / 0-6°C
0-100%
0-100%
ON/OFF
DEFAULT
5 °F / 3°C
DEFAULT
0
DEFAULT
100
DEFAULT
OFF
ON/OFF
RANGE
PRESET 1-7
STANDARD
MAX OUTDOOR AIR %
MIN OUTDDOR AIR %
DEFAULT
OFF
DEFAULT
PRESET 1: 0V
DEFAULT
STANDARD
DEFAULT
ON
DEFAULT
OFF
35
UNIT OPTIONS
OCCPD OVRD
DURATION
LIMIT SP ADJUST
PROTECTED
PARAMS
ENTER
PASSWORD
1234
EXHAUST
CNTCTR
EXHAUST ON
SMOKE
CABINET HEATER
DRAIN HEATER
RANGE
1-16 HOURS
RANGE
0-100 °F / 0-55°C
DO NOT ADJUST
THESE
PARAMETERS
NONE
BEFORE AIRFLOW
AFTER AIRFLOW
ON/OFF
ON/OFF
ON/OFF
DEFAULT
1 HOUR
DEFAULT
5 °F / 3°C
TEMPERATURES
SENSOR OFFSET
INPUTS
DEFAULT
NONE
DEFAULT
OFF
DEFAULT
OFF
DEFAULT
OFF
INTAKE
DISCHARGE
RETURN
OUTSIDE
SPACE (ST THERMISTOR)
CABINET
SPACE AVG
HMI2 (SPACE HMI1)
HMI3 (SPACE HMI2)
HMI4 (SPACE HMI3)
HMI5 (SPACE HMI4)
DISCHARGE DISP
OFFSET
SPACE DISP
OFFSET
OPEN/CLOSED
STATUS
VOLTAGES
VFD STATUS
RANGE
+/- 20 °
RANGE
+/- 5 °
CURRENT
STATUS OF
INPUTS
BOARD
INPUT/OUTPUT
VOLTAGE
READINGS
REAL TIME VFD
FEEDBACK
DEFAULT
0 °
DEFAULT
0 °
36
OUTPUTS
TEST MENU
CLEAR FAULT HISTORY
SET CLOCK
FACTORY RESET
UPDATE FACTORY
DFLTS
OPEN/CLOSED STATUS
CURRENT STATUS OF
INPUTS/OUTPUTS
VARIABLE VALUES
OUTPUT SOURCE
TEST FANS
TEST HEATING
TEST COOLING
EVAP/DX
TEST ANALOG
CONTROL
TEST OPTIONS
ENTER TO CONFIRM
BACK TO EXIT
MONTH DAY YEAR
TIME
ENTER TO CONFIRM
CANCEL TO EXIT
ENTER TO CONFIRM
CANCEL TO EXIT
MOD VALVES
POWER VENT 1
POWER VENT 2
MIXING BOX
PWM RATE
SOFTWARE/HMI
ALL/SUPPLY/EXHAUST
RUN HIGH FIRE TEST
RUN LOW FIRE TEST
ALL/1/2/3/EVAP
0-10V INPUT
SIMULATION
CABINET HEATER
DRAIN HEATER
MIXING BOX
ON/OFF STATUS
ADJUST PARAMETER
TO TEST
ADJUST PARAMETER
TO TEST
ADJUST PARAMETER
TO TEST
ADJUST PARAMETER
TO TEST
ALL/1/2/3/4
ALL/1/2
ON/OFF
ON/OFF
0-10V OUTPUT
SIMULATION
37
Start Up
Prior to starting up or operating the heater, check all fasteners for tightness. In particular, check the set screw in the wheel hub, bearings, and the fan sheaves (pulleys). With power and gas to the heater OFF or prior to connecting ventilator to power, turn the fan wheel by hand to be sure it is not striking the inlet or any obstacles. Re-center, if necessary.
Tools Required
•
AC Voltage Meter
•
Tachometer
•
Standard hand Tools
•
Amperage Meter
•
Manometer
•
Thermometer
Start Up Procedure
1. Check all electrical connections for tightness and continuity.
2. Check pulley alignment and belt tension as shown in Pulley Alignment/Proper Belt Tension (page
3. Inspect the condition of the intake damper and damper linkage, if provided.
4. Inspect the air-stream for obstructions and install intake filters if missing.
5. Compare the supplied motor voltage with the fan’s nameplate motor voltage. If this does not match, correct the problem.
6. Start the fan up by turning the external disconnect to the ON position, and shut it OFF immediately.
Check rotation of the wheel 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 up, observe the operation and check for any unusual noises.
38
Gas Pressure Adjustment
Table 9 - Reference Information (Natural Gas)
1st Furnace
(Modulating)
2nd Furnace
(On/Off or
Modulating)
1 Furnace
On/Off Valve Fully
Open Maxitrol
Modulating Valve @
3.5" w.c.
N/A
# of Furnaces in Unit
2 Furnaces
On/Off Valve Fully
Open Maxitrol
Modulating Valve @
3.5" w.c.
On/Off Valve Fully
Open Maxitrol
Modulating Valve @
3.5" w.c.
3 Furnaces
On/Off Valve Fully
Open Maxitrol
Modulating Valve @
3.5" w.c.
On/Off Valve Fully
Open Maxitrol
Modulating Valve @
3.5" w.c.
3rd Furnace
(On/Off)
4th Furnace
(On/Off)
N/A
N/A
N/A
N/A
3.5" w.c.
N/A
FURNACE
# 1
(MODULATING)
FURNACE
# 2
(MODULATING)
Figure 22 – Typical Furnace Layout
FURNACE
# 3
(ON/OFF)
FURNACE
# 4
(ON/OFF)
4 Furnaces
On/Off Valve Fully
Open Maxitrol
Modulating Valve @
3.5" w.c.
On/Off Valve Fully
Open Maxitrol
Modulating Valve @
3.5" w.c.
3.5" w.c.
3.5" w.c.
INDIRECT FIRED MODULE INDIRECT FIRED MODULE
BLOWER MODULE
39
Furnace Start-Up (Summary)
Setting Incoming Pressure
Pressure must be measured at the first “T” in the supply gas line before the first gas valve.
Adjusting On/Off Stages
Remove the pressure regulator adjustment cover screw on the On/Off valve and using a screwdriver. Refer to
Table 9 for proper adjustment settings based on # of
furnaces in the unit. Turn the inner adjustment screw clockwise to increase the gas flow and counter-clockwise to decrease the gas flow. Replace the pressure regulator adjustment screw cover.
Adjusting the High Fire (modulating stage)
Set pressure according to Table 9 .
Press and hold button
#1 down on the modulating gas valve until the LED light is solid red. This will drive the valve into its fully open position. Adjust high fire. Press or hold button #1 to increase gas flow. Press or hold button #2 to decrease gas flow. Hold down both buttons to save the high fire setting.
Adjusting the low fire (modulating stage)
Low fire manifold pressure
:
•
The desired pressure reading for natural gas is
0.15” . If this cannot be obtained, set the low fire pressure as low as possible.
•
The pressure reading for propane gas should be
0.75” .
Press and hold button #2 down on the modulating gas valve until the LED blinks red. This will drive the valve into its minimum flow position. Adjust low fire. Press or hold button #1 to increase gas flow. Press or hold button
#2 to decrease gas flow. Hold down both buttons to save the low fire settings. Replace cover.
40
Furnace Startup
1. Open the field installed manual gas shut-off valve, and ensure the On/Off gas control valve knob is set to ‘On’.
2. Check the inlets to all of the firing tubes on the furnace and ensure that they are all clear of foreign debris. Verify that the tubes line up properly with each nozzle of the gas manifold.
3. Start the unit and check the gas supply pressure at the inlet gas gauge, this gauge is upstream of all electronic gas valves.
The inlet pressure should be 7 in. - 14 in. w.c. on natural gas or 11 in. – 14 in. w.c. on propane gas . If the inlet pressure is too high, install an additional pressure regulator external to the unit.
4. Verify DIP switches are set correctly on the modulating valve.
Factory settings are all DIP switches ‘OFF’.
5. A final gas leak check shall be performed to verify the gastightness of the heater’s components and piping under normal operating conditions.
6. At any point during high/low fire burner adjustment, check the characteristics of the flames in every firing tube of the furnace.
Non-existence of flame or a lazy flame can be caused by low gas pressure, a dirty nozzle orifice, or clogged section of exhaust flue.
7. When testing is complete, replace all caps and covers removed during the adjustment procedure.
Table 10 – DIP Switch Position
High Fire Burner Adjustment
1. Set the unit into high fire mode. This is achieved by configuring
high fire by going into the HMI Configuration menu (page 24).
Service>test menu>test heating>run high fire test>stages: all .
2. After it has been verified that the furnace(s) are lighting off properly, the manifold gas pressure should be adjusted to jobsite conditions. The gas pressure regulator (integral to the
On/Off gas control valve) is adjusted at the factory for average gas conditions. It is important that the gas supplied to the furnace is in accordance with the input rating on the rating plate.
Figure 23 – ON/Off Gas Valve
See “Gas Pressure Adjustment Reference Information” (page
39) for an overview of proper pressure settings of all furnaces
and for a visual representation of the layout of the furnaces.
Once the gas pressure is verified, exit the high fire test.
Once the gas pressure is verified, continue to step 3.
Figure 24 – Modulating
Valve
3. If the unit is set up for analog control, continue with high fire using the method above or send the unit a constant 10V DC or 20mA signal.
o Remove the cover on the modulating valve. Read the manifold gas pressure gauge (0-10 in. w.c.) located directly on the gas manifold. The pressure should read
3.5 in. w.c. for natural gas / 10 in. w.c.
for propane.
If the pressure is incorrect, adjust the pressure.
41
o To adjust the pressure, press button #1 until the LED lights solid red. Release the button. The valve is now in high fire setting mode. o Buttons #1 and #2 are used to set desired high fire setting. Press once to step or hold to auto step.
➢ Button #1 = increases flow
➢ Button #2 = decreases flow
To save the high fire setting, simultaneously hold buttons
#1 and #2 until the LED turns off.
4. If the proper ( in. w.c
.) gas pressure cannot be achieved by adjusting the modulating gas valve, and it has been verified that the inlet gas pressure is within the acceptable range of 7 in. - 14 in. w.c. on natural gas and 11 in. – 14 in. w.c. on propane gas , adjust the regulator on the On/Off gas control valve.
Figure 25 – Modulating Valve Electric
Controls
Low-Fire Burner Adjustment
1. Lock the unit into low fire mode. This is achieved by
configuring low fire by going into the HMI Configuration menu (page 24).
Service>test menu>test heating>run low fire test . See
for an overview of proper pressure settings.
2. Press and hold button #2 on the modulating valve until the
LED light blinks red. Release the button. The valve is now in low fire setting mode.
3. Press button #1 to increase flow or press button #2 to decrease flow.
•
The desired pressure reading for natural gas is
0.15 in. w.c.
If this cannot be obtained, set the low fire pressure as low as possible.
•
The pressure reading for propane gas should be
0.75 in. w.c.
4. Save the low fire setting by simultaneously holding down buttons #1 and #2 until the blinking LED turns off. Press the abort button on the HMI to exit low fire mode.
Figure 26 – On/Off Gas Valve Regulator
42
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.
See below Pulley Adjustment section if airflow needs to be adjusted. Refer to Table 11
and
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 Pulley Alignment/Proper Belt Tension (page 44).
Table 11 – Maximum RPM and HP Chart
Belt Drive
Blower Size Maximum RPM Maximum HP
10” 1800 2
12”
15”
1500
1400
3
5
18”
20”
1200
1000
5
10
25” 900 20
Direct Drive
Blower Size Maximum RPM Maximum HP
15D 1800 2
20D
24D
30D
36D
16Z
1500
1400
1200
1000
2400
3
5
5
10
4
18Z
20Z
22Z
25Z
28Z
3200
2300
1900
1800
1400
5
5
5
8
7
Pulley Adjustment
The adjustable motor pulley is factory set for the RPM specified.
Speed can be increased by closing or decreased by opening the adjustable motor sheave. Two groove variable pitch pulleys must be adjusted an equal number of turns 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 setscrews according to Table 12
torque specifications.
Figure 27 - Pulley Adjustment Illustration
Decrease Amperage and Blower RPM
Table 12 - Setscrew Torque
Thread Size Torque (IN/LB)
No. 10
1/4”
5/16”
3/8”
7/16”
1/2”
32
72
130
275
384
600
43
Pulley Alignment/Proper Belt Tension
Figure 28 – Alignment Reference
Figure 29 – Belt Tension
44
Pulley Combination Chart
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
Motor RPM
1/3 to 1-1/2 HP
AX BELTS
BLOWER PULLEY
AK114
1/3 to 2 HP
AX BELTS
BLOWER PULLEY
AK114
AK94
AK79
AK66
AK54
AK46
AK39
AK32
BLOWER PULLEY
2B5V278
2B5V250
2B5V234
2B5V200
2B5V184
2B5V160
2B5V154
2B5V136
2B5V124
2B5V110
7-1/2 to 10 HP
BX BELTS
BLOWER PULLEY
2B5V278
2B5V250
2B5V234
2B5V200
2B5V184
2B5V160
2B5V154
2B5V136
2B5V124
2B5V110
DATUM DIAMETER
11
DATUM DIAMETER
11
9
7.5
6.2
5
4.2
3.5
3
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
DATUM DIAMETER
27.8
25
23.4
20
18.4
16
15.4
12.6
12.4
11
DATUM DIAMETER
27.8
25
23.4
20
18.4
16
15.4
12.6
12.4
11
1725
MOTOR PULLEY
1VL34
PITCH DIAMETER
11.2
Dd1
1.9
Open
5
308
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
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
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
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
DATUM DIAMETER
27.8
25
23.4
20
PITCH DIAMETER
28.1
25.3
23.7
20.3
2B5V184
2B5V160
2B5V154
2B5V136
18.4
16
15.4
12.6
18.7
16.3
15.7
12.9
** 2HP Motors on 20 IN Blowers use 2VP42 Pulleys
Dd1
5.8
Open
6
381
423
451
527
572
656
681
829
Table 13
5
538
617
722
790
871
972
1098
Pd1
3
Pd1
3
5
348
399
467
511
563
628
709
815
958
1050
1162
Pd1
4.7
Pd1
2
4
339
Pd1
2.6
4
431
525
627
755
929
1098
1305
1509
5
301
334
357
416
452
519
538
655
666
748
Pd1
6.2
5
393
436
466
544
590
677
703
856
5
194
216
230
269
292
335
348
423
430
483
Pd1
4.7
4 1/2
549
630
737
806
889
991
1120
Pd2
4
Pd2
4
4 1/2
357
409
479
524
578
644
728
837
984
1078
1193
Pd2
5.9
Pd2
3
3 1/2
354
Pd2
3.6
3 1/2
447
544
650
782
962
1137
1352
1563
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
4 1/2
200
222
237
276
300
344
357
435
441
496
Pd2
5.9
TURNS ON MOTOR PULLEY
3
370
2 1/2
385
2
400
4
405
450
480
561
609
698
725
883
4
313
348
371
433
470
540
560
682
693
779
4
205
227
243
283
307
353
366
446
453
509
4
366
420
491
537
593
661
747
858
1009
1106
1223
4
560
642
752
822
907
1011
1143
TURNS ON MOTOR PULLEY
3 2 1/2 2
462 477 493
563
672
809
995
1176
1399
1617
581
694
836
1028
1215
1445
1671
600
717
863
1062
1255
1492
1725
1 1/2
416
TURNS ON MOTOR PULLEY
3 1/2 3 2 1/2
375
430
504
551
608
677
765
880
1034
1133
1254
385
441
516
564
622
694
784
901
1059
1161
1285
923
1084
1189
1315
394
451
528
578
637
710
803
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
215
239
255
297
323
370
385
468
475
534
394
479
487
547
220
244
261
304
331
379
TURNS ON MOTOR PULLEY
3 1/2 3 2 1/2
319
355
378
442
480
550
571
695
706
794
325
361
386
450
489
561
582
709
720
809
722
733
824
331
368
393
459
498
571
593
TURNS ON MOTOR PULLEY
3 1/2 3 2 1/2
411
457
488
569
618
709
736
896
417
464
495
578
627
720
747
909
424
470
502
586
636
730
758
923
1 1/2
508
619
739
889
1095
1294
1539
1779
5 1/2
527
604
708
774
854
952
1075
Dd2
3.9
Dd2
3.9
5 1/2
339
388
455
497
548
611
691
794
933
1023
1132
Dd2
5.5
Dd2
2.9
4 1/2
323
Dd2
3.4
4 1/2
416
506
605
728
896
1059
1259
1455
5 1/2
295
327
349
408
443
508
527
642
652
733
Dd2
7
5 1/2
387
430
459
535
581
667
692
842
5 1/2
189
210
224
262
284
326
339
412
419
471
Dd2
5.5
1
431
2
430
477
509
595
646
741
769
936
2
338
375
400
467
507
582
604
735
747
840
2
225
250
267
312
338
388
403
490
498
560
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
1 1/2
412
472
553
605
667
744
840
965
1135
1244
1376
1
421
483
565
618
682
760
859
987
1160
1272
1407
2
604
693
811
887
978
1091
1232
1 1/2
615
705
826
903
996
1110
1255
1
626
718
840
919
1014
1130
1277
1 1/2
436
484
517
603
655
751
780
949
1 1/2
344
382
408
476
517
593
615
749
761
855
1 1/2
230
256
273
319
346
397
412
501
509
572
1
442
491
524
612
664
762
791
963
1
350
389
415
484
526
603
626
762
774
870
1
235
261
279
326
354
406
421
513
521
585
1/2
448
498
531
620
673
773
802
976
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
1/2
637
730
855
935
1031
1150
1299
Closed
0
648
743
870
951
1049
1170
1322
1/2
240
267
285
333
361
414
430
524
532
598
Closed
0
246
273
291
340
369
423
439
535
543
611
1/2
356
395
422
493
535
614
637
776
788
885
Closed
0
362
402
429
501
544
624
648
789
801
901
Closed
0
454
505
539
629
683
783
813
990
45
High Altitude Orifice Sizing
The burner orifices should be sized per the table below depending on fuel type, furnace size and altitude.
Standard orifice sizes are for sea level. The unit should either be ordered with the altitude specific orifices or the parts should be ordered through the manufacturer.
Table 14 – High Altitude
Natural Gas High ALT Conversion
High ALT for 400,000BTU
Altitude Input Rate Drill Size
High ALT for 300,000 to 75,000BTU
Input Rate Input Rate Input Rate Drill Size
0 - 1999ft
2000-2999ft
3000-3999ft
4000-4999ft
5000-5999ft
6000-6999ft
7000-7999ft
8000-8999ft
9000-10000ft
400000
384000
368640
353894
339739
326149
313103
300579
288556
#41
#42
2.35mm
2.3mm
#43
2.25mm
#44
#45
#46
300,000
288000
276480
265421
254804
244612
234827
225434
216417
200,000
192000
184320
176947
169869
163075
156552
150290
144278
150,000
144000
138240
132710
127402
122306
117414
112717
108209
#3/32
2.35mm
2.3mm
#43
2.25mm
#44
2.15mm
#46
#47
Size
#41
#42
2.35mm
2.3mm
#43
2.25mm
#44
#45
#46
#47
#3/32
2.15mm
1.45mm
#54
#55
#56
#57
High ALT for 400,000BTU
LP Gas High ALT Conversion
High ALT for 300,000 to 75,000BTU
Altitude
0 - 1999ft
2000-2999ft
3000-3999ft
4000-4999ft
5000-5999ft
6000-6999ft
7000-7999ft
8000-8999ft
9000-10000ft
Input Rate
400000
384000
368640
353894
339739
326149
313103
300579
288556
Drill Size
1.45mm
#54
#54
#54
#54
#55
#55
#55
#56
Input Rate
300,000
288000
276480
265421
254804
244612
234827
225434
Input Rate
200,000
192000
184320
176947
169869
163075
156552
150290
Input Rate
150,000
144000
138240
132710
127402
122306
117414
112717
Drill Size
#54
#54
#55
#55
#55
#55
#56
#56
#57
Orifice Part Numbers
Part#
BG100-41
AX#
A0023045
BG100-42
BG101-19
BG101-05
A0023050
A0023053
A0023051
BG100-43
BG101-20
BG100-44
BG100-45
BG100-46
BG100-47
BG100-3/32
BG101-21
A0023047
A0023054
A0023046
A0028800
A0028801
A0028802
A0023044
A0023055
BG101-16
BG100-54
BG100-55
BG100-56
BG100-57
A0023052
A0023048
A0023049
A0023057
A0028803
216417 144278 108209
Orifice Qty. Per Furnace
Size
150,000 BTU
200,000 BTU
300,000 BTU
400,000 BTU
Qty
6
8
12
15
46
Sequence of Operation (Summary)
▪ Main Blower is turned “On” and the Main Airflow Switch is proven.
▪ Air temperature at the intake of the unit falls below the setting of the Intake Air Set-point initiating a “Call for Heat” to the IBT Board.
▪ FSC-1 sends 24V AC power back to the IBT Board.
▪ IBT BOARD sends a 120V AC signal to Power-vent Blower Motor to initiate 1 min pre-purge at high speed.
▪ 24V AC signal runs through the safety circuit (Power-vent Airflow Switch/High Temperature Limit/Flame
Roll-out Switch) and into FSC-1.
▪ FSC-1 initiates Trial for Ignition by sending signal to Spark Igniter to light furnace and 24V AC power to On/Off Gas Valve and signal to IBT BOARD that it is sparking. This opens On/Off Gas Valve and triggers the start of the 17 seconds of 10V DC from the IBT BOARD to the modulating valve(s) and
120V AC output to the Power-vent Blower Speed Controller(s).
▪ Flame is sensed by FSC1’s Remote Flame Sensor at the upper-most firing tube of furnace.
▪ IBT BOARD’s 17 second high-fire sequence runs out and 0-10V DC modulating signal from IBT BOARD is output to Modulating Gas Valve and modulates the Power-vent Blower Speed Controller along with the modulating gas valves to maintain efficiency.
▪ IBT BOARD continues to modulate the heat output of MAU by adjusting the 0-10V DC signal to
Modulating Gas Valve and turning other modulating furnaces or On/Off Staged Furnaces on and off as required to satisfy the Temperature Selector Dial setting.
Note: If two modulating furnaces are present this sequence occurs with FSC-2 and a second speed controller if the call for heat dictates a need for a second furnace.
Sequence of Operation (Detailed)
The Indirect-fired heater is most easily understood when broken down 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 heavy-duty blower and motor. The heater may be further broken down into two control systems, the Modulating Gas
System (MGS) and the Flame Safety Control (FSC). The burner mixes air with the gas (Natural or Propane) which burns into a heat exchanger which heats the air. There are between one and four furnaces in each heater depending on the total required heating output capacity for the application. Included in every unit is at least one modulating furnace, located furthest downstream, closest to the discharge of the heating module. The modulating furnace(s) and additional On/Off furnaces (if used) are controlled using verniertype modulation methods resulting in fully linear heating output over the entire gas-firing range.
47
Modulating Gas System
The first system, the Modulating Gas System, consists of an Intake Air Sensor, a Vernier Auto Balancing
Module (IBT Board), a Discharge Air Sensor, a Space Air Sensor (only on space temp control option), and a modulating gas valve(s). The Intake Air Sensor, the space sensor, or a combination of the two can be used to give a call for heat signal to the IBT board. Using a PID loop, the IBT board looks at the difference between the temp sensor readings in order to appropriately modulate the heat. For Kitchen MUA heating applications, Intake Air setpoint should be set at 45°F, whereas the discharge setpoint should be set at
55°F. For all other applications, the setpoint should be set appropriately based on the end-users preferences and on-site conditions.
There are 4 different options for controlling the gas firing output of these units. These include Discharge
Temperature Control, Space Temperature Control, and Building Automation Control, and DDC. Refer to
HMI Menu Description (page 25)
to see where the menu items are located to configure for each type of control:
1. Discharge Control: When used in discharge control, the IBT board receives a call to heat from the intake sensor, the IBT board will modulate the discharge temperature until it hits the desired set point. The user can choose whether discharge heating/cooling is activated based on intake temperature, space temperature, either, or both.
2. Space Control: When the space control option has been selected, there will be an HMI that contains an internal temperature sensor. The user can choose whether the space heating/cooling is activated based on intake temperature, space temperature, either, or both.
3. Analog Control/Direct Digital Control (DDC) :
A 0-10V DC or 0-20mA signal is sent to the IBT board from the building control system to regulate the heating output of the unit. Refer to Appendix B for BACNET/LONWORK DDC points. If Analog
Control is utilized, dipswitch 4 on the IBT board should be set to up (main and slave if 2 IBT boards are present).
In all cases, the IBT board controls the amount of gas to the burner based on the signal from the temperature control components. 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 30 - Temp Sensor
48
Flame Safety Control
The second system to understand is the Flame Safety Control . The FSC is present only to monitor the flame, NOT to control temperature. The FSC uses a sensor mounted at the intake of the upper-most firing tube of the furnace to sense the existence of a flame. The FSC controls the opening of the redundant solenoid gas valves and the operation of the spark igniter to initiate a flame upon start up. When there is a call for heat, the LED on the FSC is energized indicating that the unit has power. Then, there is a one minute prepurge in which the power-vent blower on the furnace runs at full speed to
Figure 31 - Flame Safety
Controller exhaust any gas in the Heat-exchanger/Control Cabinet that may be present prior to trial for ignition. As soon as the pre-purge has initiated, the FSC checks that airflow is sensed by the power-vent airflow switch* and that the
High Limit and Roll-out switches are not tripped.
*NOTE: If, while trouble-shooting the unit, it is necessary to jumper-out this airflow switch, the jumpers must be applied to the contacts immediately after the power-vent motor is turned on and the FSC begins to check for airflow, otherwise the unit will go into lock-out mode.
Upon successful sensing of induced power-vent airflow and continuity of temperature limit and roll-out switches, the FSC initiates a 15 second ignition sequence. During this ignition sequence, the FSC opens the On/Off gas valves and allows gas to pass through to the gas manifold. At the same moment, the spark igniter begins to spark, causing the electrode on the burner to ignite the gas. This results in a flame at the lowest firing tube of the furnace which immediately ignites the flow of gas in each succeeding firing tube moving vertically until the entire furnace is lit. When the sensor detects the flame at the intake of the uppermost firing tube the FSC continues to power the On/Off gas valve until there is a loss of flame presence.
This is the normal operating mode.
Figure 32 – Ignition Sequence
Modulating Stage Sequence
As mentioned in the previous sections, every unit is equipped with a modulating furnace(s) located furthest downstream at the discharge of the heater module. The modulating stage(s) operates differently than the other On/Off staged furnaces in that instea d of being “On” or “Off”, the gas flow to this furnace is modulated up and down to account for varying calls for heat during the unit ’s operating period. In addition, the speed of its power-vent blower is varied as the gas flow changes in order to maintain constant combustion efficiency over the entire firing range.
Modulating furnace power-vent blower(s) are controlled by an onboard speed controller on the IBT that varies the output voltage to the motor. There is one Speed Controller per modulating furnace. (Two speed controllers per board.) The Output voltage (True RMS) to the motor varies non-linearly between 120V AC
@ 10V DC for high fire and 81.6V AC @ 0V DC for low fire.
49
IBT BOARD and High Fire Start
The IBT BOARD translates a difference between two sensor values and the set point or a 0-10V DC or
0-20 mA signal from an Analog Control to the modulating furnace(s). The signal is linearized such that input voltage is directly proportional to amount of gas being delivered to the modulating valve(s). If that signal is greater than a high voltage threshold for a certain interval it will relay 24V to the FSC on the next furnace. This will repeat if the heat capacity is still not enough and more stages will be turned on. If the call for heat is lower than a low voltage threshold for a certain period of time the IBT BOARD will cut power to the last stage that turned on, starting the post purge sequence and repeat the process for subsequent stages if needed. On furnaces that have two modulating burners the linearized signal is sent to one of these burners depending on the need for heat while the furnace not receiving the modulating signal is locked in to high fire, low fire or off.
In order to ensure proper light-off in all conditions, every unit’s IBT BOARD contains software that forces the modulating furnace(s) to light at high fire when that furnace’s main gas valve is first opened. There is a built in timer that allows it to send a constant 10V DC signal to the modulating gas valve(s) and powervent blower speed controller(s) and force the furnace(s) into high fire for a period of 17 seconds after the initial spark is sent by the FSC. After this forced high-fire light-off period has expired, the modulating furna ce’s power-vent blower and modulating gas valve will receive a modulating signal from the IBT BOARD as mentioned above.
NOTE: For in-depth board information, see
Re-Circulating Control Options
Manual Positioning Control
The dampers can be controlled from the HMI in the unit or from a space HMI if one is provided to any position from 0% to 100% fresh air. This is a 0-10V setting, which is available under user settings, 100%
Outdoor Air (0 volts), 100% Return Air (10 volts). This will allow manually setting the dampers to match the building ventilation requirements. On a power failure the return air damper will close by spring return.
Two Position Control
The dampers can be controlled by a two position switch (a field supplied switching device) to open the fresh air to 100%. The IBT board sends out a constant voltage. The field supplied switch will cut or allow the signal from the IBT board to the mixing box damper. On opening of the circuit, power failure, or if the unit is shutoff, the return air damper will close by spring return. If the circuit is closed, the IBT board will allow the return air damper to open per the set point.
Outdoor Air %
The dampers can be controlled from the HMI in the unit or from a space HMI if one is provided to any position from 0% to 100% fresh air. There is an outdoor air percentage setting which is available under user settings. This will allow the user to manually set the dampers to match the building ventilation requirements. The IBT board utilizes an internal algorithm to alter its 0-10V output to the mixing box damper in order to maintain an exact outdoor air percentage. When this mixing box option is selected, a mixing box deadband comes into play. This setting checks the delta T between outdoor and return air. If the difference between these two temperatures is less than or equal to the mixing box deadband setting, the IBT board will not alter its output to the mixing box damper (default setting is 5 degrees). On a power failure, or if the unit is turned off, the return air damper will close by spring return.
50
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 A306 outdoor sensor), and position the dampers to maintain the pressure setting on the controller. The controller has two set points and an indicator. The two set points 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 set points.
When building 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 static 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 A306 outdoor sensor.
Figure 33 – Photohelic Gauge
Static Pressure Controller Installation Instructions
Avoid locating the front of the static pressure controller in sunlight 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.
Use the supplied rubber tubing the high side of the static pressure controller should be plumbed to the inside of the building. The low side of the static pressure controller should be plumbed to the A306 outdoor sensor. See the A306 installation instructions.
Figure 34 – Static Pressure Controller
51
A306 Outdoor Sensor
The A306 senor is used in conjunction with the photohelic. Use the installation instructions shipped with the A306 outdoor sensor.
Figure 35 – Exploded View
Figure 36 – Outdoor Sensor Installed
Building Signal Damper Control
When this option is ordered, the supply and return dampers will modulate based on a 0-10V DC signal from the Building automation system.
Schedule Control
When this option is ordered, the supply and return damper will change based on the schedule. There are separate occupied and unoccupied outdoor air percentage settings located under user settings. The unit will maintain the appropriate outdoor air percentage based on the schedule state. When this mixing box option is selected, a mixing box deadband comes into play. This setting checks the delta T between outdoor and return air. If the difference between these two temperatures is less than or equal to the mixing box deadband setting, the IBT board will not alter its output to the mixing box damper (default setting is 5 degrees).
52
Network
For DDC descriptions, see Appendix B – IBT DDC Points (page
NOTE: The board will reboot when altering factory settings.
BACNET
BACNET IP or BACNET MS/TP compatibility can be implemented with this package through a Protocessor, which is a BTL listed embedded Gateway configured to give a Building Management
System (BMS) access to monitor and/or control a list of BACNET objects. The Protocessor is mounted and factory pre-wired inside the Electrical Control Panel. Field connections to the Building
Management System are shown to the right.
The Protocessor is pre-configured at the factory to use the field protocol of the Building Management System in the specific jobsite.
BACNET objects can only be accessed through the specified port and protocol.
1. Field Ethernet Connection for BACNET IP
2. Field RS485 Connection for BACNET MS/TP
Figure 37 - BACNET Wiring Reference
Figure 38 - BACNET
Connections
53
Changing Device Instance, MAC Address, Baud Rate
Some applications may require that the Protocessor have a specific Device Instance, the default device instance is 50,000. To change the Device Instance, you must access the Web Configurator by connecting a computer to the Ethernet port of the Protocessor. The computer used must be assigned a static IP address of 192.168.1.xxx and a subnet mask of 255.255.255.0.
To access the Web Configurator, type the IP address of the Protocessor in the URL of any web browser.
The default IP address of the Protocessor is 192.168.1.24. Once the landing page has loaded, if required, log in using “admin” for the username and password. If the default “admin” password does not work, the gateway should have a printed password on the module’s Ethernet port.
Go to the main configuration page, select “Configure” from the left-hand menu. Select “Profile
Configuration
,” the window shown in Figure 39
should appear.
The MAC address and Baud Rate, used by BACNET MTSP, are editable. The MAC address default is
127, and the Baud Rate default is 38400.
Figure 39 - Configuration Parameters Page
If any changes are made, click on the submit button for each individual change.
Each individual change will require the system to restart.
54
Changing the IP Address
Some BACNET IP applications may require changing the IP address of the Protocessor. In order to change the IP address, go to the internal server by typing the default IP address of the Protocessor,
192.168.1.24, in the URL field of any web browser. The computer used must have a static IP address of
192.168.1.xxx. The window shown in Figure 40
appears. Click on the “Diagnostics and Debugging” button on the lower right corner.
Click on “Setup” from the left hand side menu and select “Network Settings.” The window shown in
will appear. You can now modify the IP address to whatever is required in the application.
Once the IP address has been modified, click on “Update IP Settings.”
Figure 40 - Network Settings Page
After you have updated the IP settings, you will be prompted to restart the system. You can do so by clicking on the “System Restart” button at the bottom of the screen. Any time after this, you will have to type the new IP address of the Protocessor on the URL to gain access to the Web Configurator.
55
LonWorks
LonWorks compatibility can be implemented on control packages through the ProtoNode, a LonMark certified external Gateway configured to give a Building Management System access to monitor and/or control a list of Network Variables. The ProtoNode is mounted and factory pre-wired inside the Electrical
Control Panel. Field connections to the Building Management System is shown.
Figure 41 – LonWorks Adapter and Wiring Reference
Commissioning on a LonWorks Network
During the commissioning process by the LonWorks administrator (using a LonWorks
Network Management Tool), the user will be prompted to hit the Service Pin in the
ProtoNode. This pin is located in the front face, and it can be pressed by inserting a small screwdriver and tilting it towar ds the LonWorks Port. The location of the “Service
Pin” is shown in Figure 42 .
Figure 42 - Service Pin Location
NOTE: Insert Small Screwdriver. Tilt Toward LonWorks Port To Activate Service
Pin.
If an XIF file is required, it can be obtained by following these steps:
1. Set your computer’s static IP address to 192.168.1.xxx with a subnet mask of
255.255.255.0.
2.
Run a Cat 5 connection from the ProtoNode’s Ethernet port to your computer.
3. On any web browser’s URL field, type 192.168.1.24/fserver.xif
The web browser should automatically download the fserver.xif file or let you save it on your computer. Save it as fserver.xif.
56
SERVICE INFORMATION
Troubleshooting Flow-charts
57
Fault Codes
The following tables list causes and corrective actions for possible problems with indirect heater units.
Review these lists prior to consulting technical support.
Fire
Smoke
Fault
Gas PS High
Gas PS Low
Description
There is an input from the fire detector.
There is an input from the smoke detector.
The board is receiving an input on the gas pressure high terminal.
The board lost input on the
Gas Pressure Low terminal. There should be an input when gas
Possible checks
•
Check for short circuits in the wire.
•
Replace fire detector.
•
Verify the smoke detector is set up properly.
•
Check for short circuits in the wire.
•
Replace smoke detector.
•
Adjust regulator or add regulator.
•
Repair faulty wiring.
•
Replace switch.
•
See High Gas Pressure switch (page 65).
•
Low Gas pressure switch.
•
Repair broken or loose wiring connections.
•
Replace switch.
•
See Low Gas Pressure switch (page 65).
Exhaust Overload pressure is at the proper level.
Motor overload has tripped.
Supply Overload
Sensor missing
(Return, Outside,
Intake, Discharge)
Sensor broken
(Return, Outside,
Intake, Discharge)
Motor overload has tripped.
Temperature sensor is not connected
Temperature sensor is defective
•
Check motor for debris or bad bearings.
•
Check motor wiring connections.
•
Check overload reset button.
•
Check wiring to the contactor.
•
Check overload amperage setting.
•
Check motor for debris or bad bearings.
•
Check motor wiring connections.
•
Check overload reset button.
•
Check wiring to the contactor.
•
Check overload amperage setting.
•
Install, and wire sensor.
•
Check for faulty wiring.
•
See temperature sensor (page 64).
•
Check for faulty wiring.
•
See temperature sensor (page 64).
HMI Temp Sensor The HMI contains an internal temperature sensor.
RTC 1 Temp Sensor Real Time Clock (RTC) temperature sensor located on IBT board.
•
Verify there is no damage to the HMI, or wiring to HMI.
•
If space temperature is being utilized, make sure
HMI Averaging is set to ON for all space HMIs.
Refer to HMI Menu Tree (page 30) Factory
Settings – Unit Options.
•
Verify there is no damage to the IBT board.
•
Check wiring to the IBT board.
58
Fault
No supply air proving
(Air flow switch)
FSC1 High Temp
FSC1 Rollout
FSC Vent Proving
Freezestat lockout
Firestat lockout
DX Float detect
Modbus system communication
Master ROM CRC
Clogged filters
Check FPDK
Signal was not received from air switch when supply blower was running.
Description
The Flame Sensor Controller (FSC) continually and safely monitors, analyze, and controls the proper operation of the gas burner and inducer motor.
If flame-rollout is present, the switch de-energizes heater circuit on individual furnace. Must be manually reset by pressing small button on the switch. 325°F setpoint.
The FSC verifies that airflow is sensed by the induced draft air sensor.
The discharge temperature was too low for a long period of time.
Intake or discharge temperatures exceeded the firestat set point.
Input signal from the drain pan float switch
Software mismatch
Possible checks
•
Make sure the blower runs.
•
Check air switch wiring.
•
Check blower rotation.
•
Check damper operation.
•
See Air Flow Switch (page 63).
•
Check connector J7 on the IBT board. Make sure the connection is secure.
•
High limit switch failed open. There should be continuity.
•
Check wiring to the switches
•
Reset the switch.
•
Rollout switch failed open. There should be continuity.
•
Check for a blocked tube, low airflow, or low gas pressure.
•
Kinked/blocked/damaged hose.
•
Poor venting.
•
Blockage in vent system.
•
Clogged condensation drain.
•
Power vent motor.
•
Failed switch.
•
See Vent Proving switch (page 64).
•
Check gas pressure.
•
Check for proper burner firing.
•
Use the HMI to reset.
•
Use the HMI to reset.
•
Check for faulty regulators.
•
Check for faulty modulating valves.
•
Make sure the pan drain is clear and water is draining.
•
Check for shorted wires.
•
Replace float switch.
Contact technical support.
Software mismatch
Input from filter airflow switch.
Freeze Protection Drain Kit is not operating correctly.
HMI “x” Revision Wrong Software mismatch
HMI Config Error HMI is not connected, or HMI is assigned incorrectly
Contact technical support.
•
Clean or replace filters.
•
See Clogged Filter Switch (page 63).
•
Improper installation.
•
Not Installed.
Contact technical support to flash the appropriate software.
Install HMI or change HMI address using bottom 2 buttons on HMI. See
59
Airflow Troubleshooting Chart
Problem
Fan Inoperative
Motor Overload
Insufficient Airflow
Potential Cause
•
Blown fuse
•
Open circuit breaker
Corrective Action
•
Check amperage .
•
Check fuse, replace if needed
•
Check circuit breaker .
.
Disconnect switch in “Off” position Turn to “On” position .
Motor wired incorrectly
Check motor wiring. Verify connections with wiring diagram located on fan motor .
Broken fan belt
Motor starter overloaded
HMI set to “Blower Off”
Fan rotating in the wrong direction
Replace belt .
•
Check amperage .
•
Reset starter .
Set HMI to “Blower On” .
Verify the fan is rotating in the direction shown on rotation label.
Fan speed is too high
Motor wired incorrectly
Overload in starter set too low
Motor HP too low
Reduce fan RPM.
Check motor wiring. Verify connections with wiring diagram located on fan motor.
Set overload to motor FLA value.
Determine if HP is sufficient for job.
Duct static pressure lower than design
Reduce fan RPM.
Fan rotating in the wrong direction
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
Verify the fan is rotating in the direction shown on rotation label.
There should be a straight clear duct at the outlet.
Inspect damper linkage. If the linkage is damaged, replace damper motor.
Improve ductwork to eliminate or reduce duct losses.
Increase fan RPM. Do not overload motor.
Open and adjust.
Clean filters. Replace filters if they cannot be cleaned or are damaged.
Adjust belt tension.
Reduce fan RPM.
Install filters.
Excessive Airflow design
Excessive Vibration and Noise Misaligned pulleys
Damaged/unbalanced wheel
Fan is operating in the unstable region of the fan curve
•
Bearings need lubrication
•
Damaged bearing
Fan speed is too high
•
Dirty/oily belt
•
Belts too loose
•
Worn belt
Belt slippage
Blower speed too high
Filters not installed
Duct static pressure lower than
Reduce fan RPM.
Align pulleys.
Replace wheel.
Refer to performance curve for fan.
•
Lubricate bearings.
•
Replace bearings if damaged.
Reduce fan RPM.
•
Clean belts.
•
Inspect and replace if needed.
60
Furnace Troubleshooting Chart
Problem
Furnace Does
Not Light/Stay
Lit
Not Enough
Heat
Potential Cause
Main gas is off
Air in gas line
Corrective Action
Open main gas valve.
Purge gas line.
Dirt in burner orifices
Gas pressure out of range
ON/OFF gas valve is off
Spark Igniter Rod out of position
Excessive drafts
Safety device has cut power
Clean orifices with compressed air.
Adjust to proper gas pressure.
Turn ON/OFF gas valve on.
Relocate Spark Igniter Rod to proper area.
Re-direct draft away from unit.
Check limits.
Check Air Flow Switch (page 63)
.
Dirty flame sensor
Thermostat not calling for heat
No spark at igniter
Defective valve
Clean flame sensor.
Change heating set-points to call for heat.
See Flame Safety Control check (page 66).
See Gas valve / Modulating gas valve check (page
Loose valve wiring
Defective flame sensor
Shut off valve closed
See Gas valve / Modulating gas valve check (page
Replace flame sensor.
Open shut off valve.
Defective Flame Safety Controller
See Flame Safety Control check (page 66).
Increase airflow through furnace.
Unit cycling on high limit
Main gas pressure too low
Unit locked into low fire
Check gas pressure.
Increase main gas pressure
– do not exceed
14 in. w.c
. inlet pressure.
•
Check wiring.
•
Check Modulating Valve settings.
•
See High-Fire and Low-Fire Burner Adjustment
Too much airflow
Furnace undersized
Gas controls not wired properly
Thermostat setting too low
Decrease airflow if possible.
Check design conditions.
See Gas valve / Modulating gas valve check (page
Increase thermostat setting.
Thermostat malfunction
Too Much Heat Defective modulating gas valve
Thermostat setting too high
Lifting Flames or Flashback
Yellow Tipping
Flames
Floating Flames or Flame Rollout
Unit locked into high fire
Thermostat wired incorrectly
Too much primary air
Manifold pressure set too high
Dirty orifice
Orifice too large
Insufficient primary air
Misaligned orifice
Insufficient primary air
Orifice too large
Manifold Pressure too high
Blocked Vent
Misaligned orifice
Check thermostat.
Check/replace modulating valve.
Decrease thermostat setting.
•
Check Modulation Valve Settings, see Table 10
•
See High-Fire and Low-Fire Burner Adjustment
Check thermostat wiring.
Reduce primary air.
Reduce manifold pressure.
Check and clean orifice.
Check orifice size.
Increase primary air.
Check manifold alignment.
Increase primary air.
Check orifice size.
Decrease Manifold Pressure.
Check Venting System.
Check manifold alignment.
61
VFD Fault List
Fault Number
0
1
2
3
4
5
6
7
8
13
14
15
16
9
10
11
12
No Fault
Description
IGBT Temperature Fault
Output Fault
Ground Fault
Temperature Fault
Flying Start Fault
High DC BUS
Low DC BUS
Overload Fault
OEM Fault
Illegal Setup Fault
Dynamic Brake Fault
Phase Lost
External Fault
Control Fault
Start Fault
Incompatible Parameter Set
17
18-27
28
29
EPM Hardware Fault
Internal Fault
Remote Keypad Lost
Assertion Level Fault
30 - 33
34
Internal Fault
Comm. Module Failure
35 - 44 Network Fault
Refer to VFD manufacturer manual for further details.
62
Component Testing
Air flow switch (PS-09)
1. Verify the vent tube is connected to the high side port for standard supply fans. When the supply fan starts, the positive pressure will close the switch and allow the supply fan to run. A fault will occur if the switch does not close.
2. If the “No Supply Air Proving” fault is active: o Check the rotation of the supply fan. o Verify the electrical connections are secure and tight. Verify vent tube is not pinched or damaged. o When the unit is powered ON and the supply fan is running, there should be 24V AC at connector J13 pin 6 and J13 pin
13. If the voltage reading is incorrect at J13 pin 13, check the adjustment of the switch.
Air Flow Switch Field Adjustment
Figure 43 - Air Flow Switch and Wiring Reference
Follow these steps if performing a part replacement, or to calibrate the switch.
•
Install the switch. Install the vent tube to the correct port. Install the electrical connections.
•
Power the unit ON. Monitor the HMI screen.
•
Turn the adjustment screw until a fault appears on the screen, then turn the screw until the fault becomes inactive. Turn the screw two more full turns counterclockwise.
Clogged filter switch (PS-10)
1. The vent tube should be connected to the low side port. A fault will occur when the switch senses a negative pressure.
2. If the “Clogged Filters” fault is active: o Check the filters. If the filters are clogged or damaged, replace as needed. Check for any other obstructions in the unit. o Verify the electrical connections are secure and tight. Verify vent tube is not pinched or damaged. o When the unit is powered ON, there should be 24V AC at connector J13 pin 5 and 0V AC J13 pin 12. If there is voltage at pin 12, check the adjustment of the switch.
Clogged Filter Switch Field Adjustment
Figure 44 - Clogged Filter
Switch and Wiring Reference
Follow these steps if performing a part replacement, or to calibrate the switch.
1. Install the switch. Install the vent tube on the low side port. Install the electrical connections.
2. Use material suitable to block the filter. This will create a clogged filter symptom.
3. Power the unit ON. The switch should now be closed, and the ‘Clogged Filters’ fault should be active. Check for voltage at the following pins:
▪ Common pin to ground. There should be 24-28V AC .
▪ Normally open pin to ground. There should be 24-28V AC .
A. If the voltage reading is correct, remove the material blocking the filter. The fault should clear.
If the fault is present, adjust the switch until set properly.
B. If the voltage reading is incorrect, adjust the switch until the proper voltage is obtained at the pins. Block the filter, and monitor that the switch closes (clogged). Unblock the filter, and monitor that the switch opens (unclogged).
63
Intake (SN-03)/Return (SN-04)/Outdoor (SN-05)/Discharge (SN-06) Temperature sensor
1. Make sure the unit is OFF.
2. Make sure the wires are connected properly.
3. Measure the resistance of the temperature sensor
Figure 45 – Wiring Reference
Table 15 - Sensor
Ohm Reading at the IBT board connector J15.
•
SN-03 – pin 1 to pin 2
•
SN-04 – pin 3 to pin 4
•
SN-05 – pin 5 to pin 6
•
SN-06 – pin 7 to pin 8
Use the temperature/ohm chart to determine your readings.
A. If there is 0 ohms the sensor or wires are shorted.
B. If there is infinite (OL) ohms the sensor or wires are open.
If the sensor or wiring has failed, replace the sensor.
Vent Proving switch (PS-01)
1. Make sure the wiring is connected properly.
2. Verify the vent tubing is routed correctly, and the tube is not pinched or clogged.
3. Make sure the unit is OFF. Check the switch. Remove the electrical connections. Check for continuity between pins:
• Pin “C” to pin “NO”. There should be no continuity.
▪ If there is continuity, the switch has failed. Replace the switch.
▪ If there is no continuity, re-connect the electrical connections. Continue to the next step.
4. Connect a manometer between the pressure switch, and hose. Power the unit ON, and monitor the manometer. Verify the value ( w.c.
) on the switch is correct.
▪ If the reading is below the set point, there is an issue with the vacuum.
▪ If the reading is above the set point, continue to the next step.
5. With the unit ON. Check for voltage:
•
Back probe connector J7-pin 14 to ground. There should be 24-28V AC .
•
Back probe connector J7-pin 10 to ground. There should be 24-28V AC .
▪ If the voltage reading is incorrect, check the wiring for an open or short circuit. If the wiring check is good, the switch has failed. Replace the switch.
▪ If the voltage reading is correct, there may have been an intermittent fault.
Figure 46 - Vent Proving Switch and Wiring Reference
64
Low Gas Pressure switch (PS-05)
1. Power the unit ON. Verify the inlet pressure gauge is reading the correct pressure.
•
Natural gas - 7 in. w.c. – 14 in. w.c
.
•
Propane - 11 in. w.c. – 14 in. w.c.
Note: If the reading is incorrect, contact the gas supply company .
2. Reset the lever on the switch. Gas pressure must be higher in the chamber for the reset latch to be set properly.
▪ If the reset did not work, continue with the next step.
3. Remove the cover. Make sure the wiring is set up for Normally Open (N.O.) contact.
4. Check for voltage:
•
Back probe connector J13-pin 3 to ground. There should be 24-28V AC .
•
Back probe connector J13-pin 10 to ground. There should be 0V AC .
A. If the voltage reading is incorrect, check the wiring for an open or short circuit. If the wiring is correct, the switch has failed. Replace the switch
B. If the voltage reading is correct, and the switch reset corrected the fault, there may have been an intermittent fault.
Figure 47 - Low Gas Pressure and Wiring Reference
C
NO
High Gas Pressure switch (PS-07) (PS-08)
NC
1. Power the unit ON. Reset the lever on the switch. Gas pressure must be lower in the chamber for the reset latch to be set properly.
2. Remove the cover. Make sure the wiring is set up for Normally Closed (N.C.) contact.
3. Verify the On/Off gas valve, and modulating valve are set properly. See High-Fire and Low-Fire
4. Check for voltage:
•
Back probe connector J13-pin 3 to ground. There should be 24-28V AC .
•
Back probe connector J13-pin 10 to ground. There should be 24-28V AC .
A. If the voltage reading is incorrect, check the wiring for an open or short circuit. If the wiring is correct, the switch has failed. Replace the switch
B. If the voltage reading is correct, and the switch reset corrected the fault, there may have been an intermittent fault.
Figure 48 - High Gas Pressure and Wiring Reference
C
NO
NC
65
Flame Safety Control (FSC-01)
1. Make sure the wiring is connected properly.
2. Power the unit ON. Use the HMI to set the unit in test mode.
•
Service > Test Menu > Test Heating > Run Low Fire Test > Stages All
•
Refer to the operation of sequence, Flame Safety Control (page 49).
Determine the symptom below
:
Symptom
Control does not start
Thermostat ON – no spark
Action
-Check wiring
-Check for a 24V AC transformer failure
-Check circuit breaker
-Check LED light
-Check wiring to thermostat input (TH)
-Faulty thermostat
-Check LED light
-Check wiring
-Check for flame fault
Blower ON – no Trial For
Ignition (TFI) after purge delay
Valve ON
TFI
– no spark during
-Air Flow fault, see Air Flow Switch (page 63).
-Check connection at PSW terminal
-Faulty Control (Check voltage between L1 and IND. There should be
24V AC )
-Check wiring
-Shorted ignitor electrode
-Check cable to ignitor
Spark ON – valve OFF -Check wiring
-Valve coil open
-Check voltage at V1
-Check flame rod position Flame during TFI – no flame sensed after TFI -Check cable to flame rod
-Poor ground connection at burner
-Poor flame
3. Power the unit ON. If the LED is blinking, verify the fault:
•
Steady ON = Internal controller failure
•
1 flash = Airflow fault
•
2 flashes = Flame without call for heat
•
3 flashes = Ignition lock out
66
Modulating Gas Valve (VA-05) (VA-06)
1. Make sure the wiring is connected properly. Check the wiring using a multi-meter for open or short circuits.
•
Terminal 1 – Signal ( + ) to J7-pin 6/J8-pin 6
•
Terminal 2 – Signal ( ) to J7-pin 7/J8-pin 7
•
Terminal 3 – Power 24V DC ( + ) to H
•
Terminal 4 – Power ( ) to N
A. If any damaged wiring is found, repair or replace.
B. If any open or short circuits are found, repair or replace.
C. If any wiring is connected incorrectly, correct the wiring.
Note: The wiring connection is polarity sensitive.
1. Make sure the DIP switches are all in the OFF position (factory setting). This will set the valve to receive a 0-10V DC
signal. If the unit is set up for an analog control system, see Table 10 .
2. Make sure the valve has been adjusted properly. See High-fire and Low-fire burner adjustment
(page
3. If the unit has been running, restart the unit. Check for voltage:
•
Connector J7-pin 6/J8-pin 6 to ground. There should be 10V DC . The voltage reading will drop after the unit has been running.
•
Check for voltage between H to N on the terminal block. There should be 24-28V AC . This voltage reading will be constant.
A. If the voltage reading is incorrect, check voltage to the IBT control board.
B. If the voltage reading is correct, there may be an issue with the modulating valve.
Figure 49 - Modulating Gas Valve and Wiring Reference
Main (ON/OFF) Gas Valve (VA-01)
1. Make sure the wiring is connected properly.
2. Make sure the gas valve is ON.
3. Power the unit ON. Check for voltage. Check for voltage across the pins on the gas valve. There should be 24-28V AC .
A. If the voltage reading is incorrect, check the wiring for an open or short circuit.
B. If the voltage reading is correct, the gas valve may be faulty.
Figure 50 - Main Gas Valve and Wiring Reference
67
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 TURNED OFF.
General Maintenance
1. Fan inlet and approaches to ventilator should be kept clean and free from any obstruction.
2. Motors are normally permanently lubricated. Check bearings periodically. If they have grease fittings lubricate each season. Use caution when lubricating bearings, wipe the fittings clean, the unit should be rotated by hand while lubricating. Caution: Use care when touching the exterior of an operating motor. Motors normally run hot and may be hot enough to be painful or cause injury.
3. All fasteners should be checked for tightness each time maintenance checks are preformed prior to restarting unit.
4. Blowers 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.
5. Before each heating season, verify that the drain on the bottom of each common flue box of every furnace in the unit is clear.
Re-Setting of the Unit
If the flame safety control is locked out (Spark igniter fails or no gas supply), reset the unit by:
1. Turn OFF Power to the unit.
2. Turn Power to the unit back ON.
Emergency shutdown of unit
To shut down 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.
68
2 weeks after startup
1. Belt tension should be checked after the first 2 weeks of fan operation. 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 the power to the fan motor OFF. Loosen the fasteners that hold the blower scroll plate to the blower. Rotate the motor to the left or right to adjust the belt tension. Belt tension should be adjusted to allow 1/64” of deflection per inch of belt span. Exercise 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 preformed prior to restarting unit.
Every 3 months
1. Belt tension should be checked quarterly. See instructions in the previous maintenance section.
Over-tightening will cause excessive bearing wear and noise. Too little tension will cause slippage at startup 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.
Unit Size
1
2
3
4
5
Diagonal Filters
Filter Quantity
4
2
4
4
9
Table 16 - Filter Quantity Chart
Intake
Size 1 Sloped
Size 2 Sloped
Size 3 Sloped
Size 4 Sloped
Size 5 Sloped
Size 1 V-Bank
Size 2 V-Bank
Size 3 V-Bank
Size 4 V-Bank
16” x 20” 20” x 25”
3
6
3
10
8
3
8
15
8
12 Size 5 V-Bank
Table 17 - Optional Mixing Box Filters
Filter Size Unit Size
10 x 16
20 x 25
1
2
15 x 20
18 x 25
14.5 x 19
3
4
5
Vertical Filters
Filter Quantity
1
1
2
2
3
Filter Size
10 x 16
16 x 25
15 x 15
16 x 20
14.5 x 19
69
Yearly
1. Before each heating season, verify that the drain on the bottom of each common flue box of every furnace in the unit is clear.
2. Inspect bearings for wear and deterioration. Replace if necessary.
3. Inspect belt wear and replace torn or worn belts.
4. Inspect bolts and set screws for tightness. Tighten as necessary.
5. Inspect motor for cleanliness. Clean exterior surfaces only. Remove dust and grease from the motor housing to ensure proper motor cooling. Remove dirt and grease from the wheel and housing to prevent imbalance and damage.
6. The heat exchanger should be checked for cracks. The heat exchanger should be replaced immediately if cracks are detected.
7. Inspect the combustion blower motor for cleanliness. Clean exterior surfaces of the combustion blower motor only. Removing excess dust and grease guarantees proper motor cooling.
8. Before each heating season, examine the burner and gas orifices. Inspect burner ports for foreign debris, heat exchanger, and spark igniter for cleanliness.
70
Heat Exchanger Inspection
NOTE: Below is for size 1 and 2 units.
Figure 51 – Size 1 and Size 2 Heat Exchanger
1. To inspect the heat exchanger, remove the access door on backside side of unit.
2. Visually inspect the heat exchanger. Check for splits, cracks or holes in the tubes and joints. If damage is found, replace the heat exchanger.
NOTE: Below is for size 3-5 units.
1. To inspect the heat exchanger, remove the access door on backside side of unit. This will expose the insulated heat exchanger compartment.
2. Use a sharp razor knife to cut the reinforced silver tape around all four outer edges, and down the center of the two halves.
3. Remove the insulation. Silicone is used to adhere the insulation to the panel.
4. Remove the screws from the right side panel first. Then remove the screws from the left panel.
Remove both panels to expose the heat exchanger.
5. Visually inspect the heat exchanger. Check for splits, cracks or holes in the tubes and joints. If damage is found, replace the heat exchanger.
Figure 52 – Size 2 to Size 5 Heat Exchanger
71
Appendix A – IBT Board Electrical Connections
RJ45 Connectors
J1 Auxiliary slave port
J2 Programming port (service only)
J3 connects to HMI
J4 connects to VFD controller
J5 connects to Cat 5 converter for Compressor
Frequency Drive
J6 connects to electronic expansion controller
J7 (FSC-1) and J8 (FSC-2) connectors contain inputs and outputs for Flame Safety Controller
(FSC), furnace, and gas train. J7 comes standard as stage 1 furnace, J8 as stage 2 furnace.
Pin 1 - 24V AC output to Pressure Switch input
(PSW) on FSC
Pin 2 - 24V AC output to Thermostat input (TH/W) on FSC
Pin 3 - detects 24V AC presence from IND on
FSC
Pin 4 - 24V AC output to valve power (V1) on FSC
Pin 5 - 24V AC output to main gas valve
Pin 6 - 0-10V DC (+) to modulating gas valve or
Electric Heater (option)
Pin 7 - 0-10V DC ( –) to modulating gas valve
Pin 8 - modulating gas valve shield
Connector J9 contains 120V AC connections
Pin 9 - ground to main gas valve
Pin 10 - detects 24V AC presence from vent proving switch
Pin 11 - 24V AC output (L1) on FSC
Pin 12 - 24V AC supply power (R) on FSC
Pin 13 - 24V AC out to high limit switch
Pin 14 - 24V AC out to vent proving switch
Pin 15 - detects 24V AC presence from roll out switch
Pin 16 - detects 24V AC presence from high limit switch
Pin 17 - 24V AC out to roll out switch
Pin 18 - valve ground (V2) on FSC
Pin 1 - 120V AC input
Pin 2 - tied to Pin 1 internally to the board
Pin 3 - detects 120V AC presence for fire condition
Pin 4 - 120V AC out to damper
Pin 5 - 120V AC presence from damper end limit
Pin 6 - 120V AC out to drain heater
Pin 7 - 120V AC out to cabinet heater
Pin 8 - 120V AC neutral
72
Connector J10 contains 120V AC connections
Pin 1 - detects 120V AC from evap cooler pressure switch
Pin 2 - detects 120V AC from evap cooler float switch
Pin 3 - 120V AC out to evap cooler water solenoid
Pin 4 - 120V AC out to evap cooler 3 way drain valve
Pin 5 - detects 120V AC from supply overload
Pin 6 - 120V AC out to supply starter coil
Pin 7
-
120V AC out to exhaust starter coil
Pin 8 - 120V AC from exhaust overload
Connector J11 contains low voltage screw terminal connections
Pin 1 - is an auxillary input
Pin 2 - is an auxiliary input
Pin 3 - is an auxiliary input
Pin 4 - Analog Control/DDC heat select input
Connector J12 contains low voltage sensor screw terminal connection
Pin 5 - Analog Control/DDC cool select input
Pin 6 - Analog Control/DDC call for blower input
Pin 7 - Analog Control/DDC occupied override input
Pin 8 - Analog Control/DDC isolated common
Pin 1 - smoke detector 24V AC out
Pin 2 - smoke detector 24V AC out
Pin 3 - smoke detector input
Pin 4 - smoke detector 24V AC common
Connector J13 contains low voltage connections
Pin 5 - air quality 24V AC out
Pin 6 - air quality 0-10V DC input
Pin 7 - air quality 0-10V DC common
Pin 8 - air quality 24V AC common
Pin 1 - 24V DC (+) for 4-20mA current sensor
Pin 2 - PWM (+) out for ECM motor
Pin 3 - 24V AC out for low gas pressure switch
Pin 4 - 24V AC out for high gas pressure switch
Pin 5 - 24V AC out for clogged filter switch
Pin 6 - 24V AC out for air flow switch
Pin 7 - 24V AC for board power
Pin 8 - 24V DC (-) for 4-20mA current sensor
Pin 9 - PWM ( –) out for ECM motor
Pin 10 - detects 24V AC for low gas pressure switch
Pin 11 - detects 24V AC for high gas pressure switch
Pin 12 - detects 24V AC for clogged filter switch
Pin 13 - detects 24V AC for air flow switch
Pin 14 - Ground
73
Connector J14 contains screw terminal connections for relative humidity sensors
Pin 1 - 24V DC (+) to humidity sensor
Pin 2 - 0-10V DC input from humidity sensor
Pin 3 - 0-10V DC common from humidity sensor
Pin 4 - 24V DC common to humidity sensor
Connector J15 contains screw terminal connections for 10k temperature thermistors only
Pin 5 - 24V DC + to humidity sensor
Pin 6 - 0-10V DC input from humidity sensor
Pin 7 - 0-10V DC common from humidity sensor
Pin 8 - 24V DC common to humidity sensor
Pins 1 and 2 - for intake sensor
Pins 3 and 4 - for return sensor
Pins 5 and 6 - for outdoor sensor
Connector J16 contains low voltage screw terminal connections for BAS/DDC/Space
Pins 7 and 8 - for discharge sensor
Pins 9 and 10 - for space temperature sensor
Pin 1 - Analog Control /DDC 0-10V DC input
Pin 2 - Analog Control /DDC 4-20mA input
Pin 3 - Analog Control /DDC analog input common
Pin 4 - Analog Control /DDC shield
Connector J17 triac output for power vent 2
Pin 5 - aux in for unit interlock
Pin 6 - 24V AC out
Pin 7 - 24V AC out
Pin 8 - common
74
Connector J18 contains low voltage connections
Pin 1 - 24V DC (+) spare output
Pin 2 - 0-10V DC (+) for modulating damper
Pin 3 - 0-10V DC (+) spare
Pin 4 - dx float switch output
Pin 5 - 24V AC out spare unit interlock
Pin 6 - unused connection
Pin 7 - unused connection
Connector J19 triac output for second power vent 2
Pin 8 - 24V DC ( –) spare output
Pin 9 - 0-10V DC ( –) for modulating damper
Pin 10 - 0-10V DC ( –) spare
Pin 11 - dx float switch common
Pin 12 - 24V AC common spare unit interlock
Pin 13 - unused connection
Pin 14 - unused connection
Connector J20 triac neutral for second power vent
Connector J21 triac neutral for first power vent
Connector J22 (Y1) contains 24V AC condenser 1 outputs
Pin 1 - 24V AC out
Connector J23 (Y2) contains 24V AC condenser 2 outputs
Connector J24 (Y3) contains 24V AC condenser 3 outputs
Pin 1 - 24V AC out
Connector J25 factory programming only, Zilog
ZDI microcontroller debug/programming interface
Pin 1 - 3.3V DC
Pin 2 - reset
Pin 3 - Gnd
Pin 2 - 24V AC common
Pin 2 - 24V AC common
Pin 4 - DBG input
Pin 5 - Gnd
Pin 6 - NC
75
Appendix B – IBT DDC Points
Full External Control Points:
BACNET OBJECT
NAME
HeatCommand
CoolCommand
BACNET
OBJECT
ID
1
2
BACNET
DATA
TYPE
Binary
Value
Binary
Value
LON SNVT NAME nviHeatCommand nviCoolCommand
SNVT TYPE
SNVT_count
SNVT_count
FUNCTION
Control
Control
DEFAULT
0
0
RANGE
0-1
0-1
DESCRIPTION
OFF(0) / ON(1)
OFF(0) / ON(1)
Binary
FanCommand 3 nviFanCommand SNVT_count Control 0 0-1 OFF(0) / ON(1)
Value
•
Use only if Heati ng and/or Cooling tempering mode has been set to “DDC” through the unit’s HMI.
• Setting the Heating and Cooling modes to “DDC” disables temperature based activation of these functions . The preferred heating and cooling activation method is to use space and/or intake temperatures along with unit set points.
•
Heating and Cooling cannot be called for at the same time.
•
The Fan Control point will only work if the heating or cooling mode is set to DDC.
For factory settings and temperature set points BACNET and LON points are displayed on to the BMS as raw values. The BMS must scale these points when reading and/or writing based on the point description.
For example, temperature sensor values must be divided by 10 after they are read. Likewise, when writing to a set point, the intended value must be multiplied by 10 before being sent to the controller.
Factory Settings:
BACNET OBJECT NAME
NumberofHMIs
BACNET
OBJECT ID
4
BACNET
DATA TYPE
Analog Value
LON SNVT NAME nviNumberofHMIs
SNVT
TYPE
SNVT_ count
FUNCTION
Monitor/Control
DEFAULT
1
RANGE
1-5
DESCRIPTION
HMI1 is always the cabinet HMI
IncludeHMIAvg
SetHeatStages
SetCondenserStages
5
6
7
Analog Value
Analog Value
Analog Value nviIncludeHMIAvg nviSetHeatStages nviSetCondStages
SNVT_ count
SNVT_ count
SNVT_ count
Monitor/Control
Monitor/Control
Monitor/Control
2
0
0
1-31 odd
0-4
0-5
Bitfield, if bit=1 that HMI is read only
One IBT Board can support 2 stages
Distinction between the number of condensers and the number of condenser cooling stages
FreezestatTime 8 Analog Value nviFstatTime
SNVT_ count
Monitor/Control 10 1-10 Time in Minutes
EvapSprayONTime
EvapSprayOFFTime
9
10
Analog Value
Analog Value nviEvSprayONt nviEvSprayOFFt
SNVT_ count
SNVT_ count
Monitor/Control
Monitor/Control
Set By
Plant
Set By
Plant
0-60
0-500
Time in Seconds
Time in Seconds
MinVFDFreqOccupied 11 Analog Value nviMinVFDFreqO
SNVT_ count
Monitor/Control 0 0-MaxVFDFreq Freq(Hz)*10
MaxVFDFreqOccupied
MinOAPercentOccupied
MaxOAPercentOccupied
12
13
14
Analog Value
Analog Value
Analog Value nviMaxVFDFreqO nviMinOAPercentO nviMaxOAPercentO
SNVT_ count
SNVT_ count
SNVT_ count
Monitor/Control
Monitor/Control
Monitor/Control
80
0
100
MinVFDFreq-
800
0-Max Outdoor
Air %
Min Outdoor Air
%-100
Freq(Hz)*10
Minimum Percentage of Outdoor
Air
Maximum Percentage of Outdoor
Air
MinPWMOccupied
MaxPWMOccupied
SchedulingEnable
15
16
17
Analog Value
Analog Value
Binary Value nviMinPWMO nviMaxPWMO nviSchedEnable
SNVT_ count
SNVT_ count
SNVT_ count
Monitor/Control
Monitor/Control
Monitor/Control
0
100
0
0-Max PWM
Min PWM-100
0-1
ECM Minimum Speed
ECM Maximum Speed
Disabled (0) / Enabled (1)
CoolDXLowTempLimit
EvapDrainValveSP
EvapDrainValveSPDiff
EvapCoolingDiff
18
19
20
21
Analog Value
Analog Value
Analog Value
Analog Value nviCoolDLowTLim nviEvapDValveSP nviEvapDVlvSPDif nviEvapCoolDif
SNVT_ count
SNVT_ count
SNVT_ count
SNVT_ count
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
550°F
130°C
400°F
40°C
20°F
20°C
30°F
20°C
400-700°F
40-210°C
350-1100°F
20-100°C
10-50°F
10-30°C
10-100°F
10-60°C
Temperature*10
Temperature*10
Temperature*10
Temperature*10
MinOAPercentUnoccupied
MaxOAPercentUnoccupied
MinVFDFreqUnoccupied
MaxVFDFreqUnoccupied
MinPWMUnoccupied
MaxPWMUnoccupied
22
23
24
25
26
27
Analog Value
Analog Value
Analog Value
Analog Value
Analog Value
Analog Value nviMinOAPercentU nviMaxOAPercentU nviMinVFDFreqU nviMaxVFDFreqU nviMinPWMU nviMaxPWMU
SNVT_ count
SNVT_ count
SNVT_ count
SNVT_ count
SNVT_ count
SNVT_ count
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
0%
100%
30Hz
60Hz
0%
100%
0-Max %
Min-100%
0-VFD Max
VFD Min-800
0-Max PWM
Min PWM - 100
Percentage of outdoor air
Percentage of outdoor air
Freq (Hz) *10
Freq (Hz) *10
Motor speed %
Motor speed %
CoolEvapLowTempLimit 28 Analog Value nviCoolELowTLim SNVT_ Monitor/Control 800°F 60-100°F count
Temperature*10
38°C 16-38°C
•
Writing to any of these registers will trigger a system reboot. Avoid writing to these on a regular basis.
•
The Scheduling Enable point tells the unit whether scheduling is allowed or not. It is NOT an occupancy command.
76
Temperature Set Points:
BACNET OBJECT NAME
BACNET
OBJECT
ID
BACNET
DATA
TYPE
LON SNVT NAME SNVT TYPE FUNCTION DEFAULT RANGE DESCRIPTION
InHeatOccSP
SpaceHeatOccSP
MinDischHeatSP
DischHeatOccSP
MaxDischHeatOccSP
InCool1OccSP
IntakeCoolOccStageDiff
SpaceCoolOccStageDiff
SpaceCoolOccSP
EvapCoolOccSP
InHeatUnoccSP
SpaceHeatUnoccSP
MinDischHeatUnoccSP
DischHeatUnoccSP
MaxDischHeatUnoccSP
InCool1UnoccSP
IntakeCoolUnoccStageDiff
SpaceCoolUnoccStageDiff
SpaceCoolUnoccSP
EvapCoolUnoccSP
InFirestatSP
DischFirestatSP
CabinetHeatSP
FreezestatSP
FurnaceDrainHeatSP
RoomOverrideSP
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value nviInHeatOccSP nviSpaceHOccSP nviMinDischHSP nviDischHOccSP nviMaxDischHOcSP nviInCool1OccSP nviInCOccStgDif nviSpCOccStgDif nviSpaceCOccSP nviEvapCoolOccSP nviInHeatUnoccSP nviSpaceHUnoccSP nviMinDisHUnocSP nviDischHUnoccSP nviMaxDisHUnocSP nviInC1UnoccSP nviInCUnocStgDif nviSpCUnocStgDif nviSpaceCUnoccSP nviEvapCUnoccSP nviInFirestatSP nviDischFstatSP nviCabinetHeatSP nviFreezestatSP nviFurnDrainHSP nviRoomOrideSP
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
450°F
70°C
700°F
210°C
600°F
160°C
600°F
160°C
1200°F
490°C
850°F
290°C
100°F
60°C
30°F
20°C
740°F
230°C
850°F
290°C
450°F
70°C
700°F
210°C
600°F
160°C
600°F
160°C
1200°F
490°C
850°F
290°C
100°F
60°C
30°F
20°C
740°F
230°C
850°F
290°C
1350°F
570°C
2400°F
1160°C
0°F
-180°C
350°F
20°C
350°F
20°C
900°F
310°C
350-1100°F
20-430°C
Intake Heat SP + Intake Heat
Diff < Intake Cool SP
350-1100°F
20-430°C
Space Heat SP + Space Heat
Diff < Space Cool SP
400°F-DischHeatOccSP
40°C-DischHeatOccSP
MinDischHeatSP-
MaxDischHeatOccSP
DischHeatOccSP-1500°F
DischHeatOccSP-660°C
550-1000°F
130-380°C
Intake Cool SP - Intake Cool
Hyst > Intake Heat SP
0-200°F
0-110°C
0-200°F
0-110°C
500-900°F
100-320°C
Space Cool SP - Space Cool
Hyst > Space Heat SP
550-1000°F
130-380°C
350-1100°F
20-430°C
350-1100°F
20-430°C
400°F-DischHeatUnoccSP
40°C-DischHeatUnoccSP
MinDischHeatUnoccSP-
MaxDischHeatUnoccSP
DischHeatUnoccSP-1500°F
DischHeatUnoccSP-660°C
550-1000°F
130-380°C
0-200°F
0-110°C
0-200°F
0-110°C
500-900°F
100-320°C
550-1000°F
130-380°C
1000-3000°F
380-1490°C
1000-3000°F
380-1490°C
0-400°F
(-180)-40°C
(-400)-750°F
(-400)-24°C
350-450°F
20-70°C
600-1200°F
160-490°C
Temperature*10
Temperature*10
Temperature*10
Temperature*10
Temperature*10
Temperature*10
Temperature*10
Temperature*10
Temperature*10
Temperature*10
Temperature*10
Temperature*10
Temperature*10
Temperature*10
Temperature*10
Temperature*10
Temperature*10
Temperature*10
Temperature*10
Temperature*10
Temperature*10
Temperature*10
Temperature*10
Temperature*10
Temperature*10
Temperature*10
•
The preferred method for DDC control is through set point manipulation. Use the set points shown above along with the “DDC Occupied Override” point in the Runtime settings section to control the blower and to determine when to heat or cool.
• Temperatures can be in degrees F or degrees C, depending on the “Temp Units” point in the factory settings.
77
Runtime Settings and Indicators:
BACNET OBJECT NAME
VFDFrequencySettingOcc
PWMRateOccupied
MixBoxUnoccOAPercent
MixBoxOccOAPercent
BACNET
OBJECT
ID
55
56
57
58
BACNET
DATA
TYPE
Analog
Value
Analog
Value
Analog
Value
Analog
Value
LON SNVT NAME nviVFDFrequencyO nviPWMRateO nviMBoxUnocOAPer nviMBoxOcOAPer
MixingDamperVolts
DDCOccupiedOverride
FSC1GasON
FSC2GasON
FSC3GasON
FSC4GasON
59
60
61
62
63
64
Analog
Value
Binary
Value
Binary
Input
Binary
Input
Binary
Input
Binary
Input nviMDamperV nviDDCOccupOride nvoFSC1GasON nvoFSC2GasON nvoFSC3GasON nvoFSC4GasON
SNVT TYPE
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
FUNCTION
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor/Control
Monitor
Monitor
Monitor
Monitor
DEFAULT
Set By
Plant
Set By
Plant
0
100
0
0
0
0
0
0
RANGE
VFD Min Freq-VFD Max
Freq
Min PWM-Max PWM
Min Outdoor Air %-
Max Outdoor Air %
Min Outdoor Air %-
Max Outdoor Air %
0-1000
0-1
0-1
0-1
0-1
0-1
DESCRIPTION
Running VFD Frequency
Running PWM Rate
Percentage of Outdoor Air
Unoccupied
Percentage of Outdoor Air
Occupied
Volts*100
Override Off(0)
– Override
On(1)
Off(0)
– On(1)
Off(0)
– On(1)
Off(0)
– On(1)
Off(0)
– On(1)
VFDFrequencySetting
Unoccupied
PWMRateUnoccupied
CoolingOutputY1
CoolingOutputY2
CoolingOutputY3
AirQuality
AnalogHeatControl 0-10V
65
66
67
68
69
70
71
Analog
Value
Analog
Value
Binary
Input
Binary
Input
Binary
Input
Analog
Value
Analog
Value nviVFDFreqU nviPWMRateU nvoCoolOutY1 nvoCoolOutY2 nvoCoolOutY3 nvoAirQuality nviAVHeat0-10V
SNVT_count Monitor/Control
Set By
Plant
VFD Min Freq-VFD Max
Freq
SNVT_count Monitor/Control
Set By
Plant
Min PWM-Max PWM
SNVT_count
SNVT_count
SNVT_count
SVNT_count
SNVT_count
Monitor
Monitor
Monitor
Monitor
Monitor/Control
0
0
0
0
0
0-1
0-1
0-1
0-1000
0-1000
Unoccupied Running
Unoccupied Running
Off(0) – On(1)
Off(0)
– On(1)
Off(0)
– On(1)
Volts*100
Volts*100
• Use the “DDC Occupied Override” point to switch between occupied and unoccupied settings and set points. Make sure that all timeslots in the unit’s internal schedule are set to “Unoccupied” in order to avoid conflicting commands. This can be verified through the unit’s HMI.
• To control the blower through the “DDC Occupied Override” point, set the blower mode to
“ON/AUTO/OFF” during occupied and unoccupied times, depending on the required sequence of operations.
•
FSC1-4 points can be used as indicators that the unit is attempting to heat. Cooling Outputs Y1-3 points can be used as indicators that the unit is attempting to cool.
• Analog heat control can only be used if the heating tempering mode is set to “DDC”.
78
Sensor Values and Alerts:
BACNET OBJECT NAME
DamperPositionReference
SupplySpeedReference
OATemp
ReturnTemp
DischargeTemp
IntakeTemp
SpaceTemp
RTCTemp
HMI1Temp
HMI2Temp
HMI3Temp
HMI4Temp
HMI5Temp
AlertCode1
AlertCode2
AlertCode3
AlertCode4
AlertCode5
AlertCode6
BACNET
OBJECT
ID
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
BACNET
DATA
TYPE
Analog
Input
Analog
Input
Analog
Input
Analog
Input
Analog
Input
Analog
Input
Analog
Input
Analog
Input
Analog
Input
Analog
Input
Analog
Input
Analog
Input
Analog
Input
Analog
Input
Analog
Input
Analog
Input
Analog
Input
Analog
Input
Analog
Input
LON SNVT NAME nvoDamperPos nvoSupSpeedRef nvoOATemp nvoReturnTemp nvoDischargeTemp nvoIntakeTemp nvoSpaceTemp nvoRTCTemp nvoHMI1Temp nvoHMI2Temp nvoHMI3Temp nvoHMI4Temp nvoHMI5Temp nvoAlertCode1 nvoAlertCode2 nvoAlertCode3 nvoAlertCode4 nvoAlertCode5 nvoAlertCode6
SNVT TYPE
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
SNVT_count
FUNCTION
Monitor
Monitor
Monitor
Monitor
Monitor
Monitor
Monitor
Monitor
Monitor
Monitor
Monitor
Monitor
Monitor
Monitor
Monitor
Monitor
Monitor
Monitor
DEFAULT
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
RANGE
0-1000
0-1000
(-64)-302°F
(-53)-150°C
(-64)-302°F
(-53)-150°C
(-64)-302°F
(-53)-150°C
(-64)-302°F
(-53)-150°C
(-64)-302°F
(-53)-150°C
(-40)-185°F
(-40)-85°C
(-40)-257°F
(-40)-125°C
(-40)-257°F
(-40)-125°C
(-40)-257°F
(-40)-125°C
(-40)-257°F
(-40)-125°C
(-40)-257°F
(-40)-125°C
0-87
0-87
0-87
0-87
0-87
DESCRIPTION
Volts*100
Volts*100
Temperature*10
<Min = Disconnected
>Max = Broken
<Min = Disconnected
>Max = Broken
<Min = Disconnected
>Max = Broken
<Min = Disconnected
>Max = Broken
<Min = Disconnected
>Max = Broken
<Min = Disconnected
>Max = Broken
<Min = Disconnected
>Max = Broken
<Min = Disconnected
>Max = Broken
<Min = Disconnected
>Max = Broken
<Min = Disconnected
>Max = Broken
UnitStatus 91
Analog
Input nvoUnitStatus
SNVT_count
SNVT_count
Monitor
Monitor
-
-
0-87
0-3
0= Idle
1= Heating
2= Cooling
3 = Blower Only
• Temperatures can be in degrees F or degrees C, depending on the “Temp Units” point in the factory settings.
•
Values should be scaled by the Building Management System (see point description).
Variable Frequency Drive Information (Read-Only):
BACNET OBJECT
NAME
VFDActualFrequency
VFDAmperage
VFDPower
BACNET
OBJECT
ID
92
93
94
BACNET
DATA TYPE
Analog Input
Analog Input
Analog Input
LON SNVT NAME nvoVFDActFreq nvoVFDAmps nvoVFDPower
SNVT TYPE
SNVT_count
SNVT_count
SNVT_count
FUNCTION
Monitor
Monitor
Monitor
DEFAULT
-
-
-
RANGE
0-65535
0-1000
0-65500
DESCRIPTION
Frequency*10
Amperage*10 kiloWatts*100
79
IBT DDC Fault Codes
23
24
25
26
27
28
29
30
15
16
17
18
19
20
21
22
7
8
9
10
11
12
13
14
Code
0
1
2
3
4
5
6
39
40
41
42
43
44
45
46
31
32
33
34
35
36
37
38
47
48
49
50
Description
No Fault
Fire
Smoke
Gas PS High (Master)
Gas PS Low (Master)
IBT to IBT Comm Fail
Gas PS High (Slave)
Gas PS Low (Slave)
Exhaust Overload
Supply Overload
VFD571 IGBT Temp
VFD571 Output
VFD571 Ground
VFD571 Temp
VFD571 Flying Start
VFD571 High DC Bus
VFD571 Low DC Bus
VFD571 Overload
VFD571 OEM
VFD571 Illegal Setup
VFD571 Dynamic Brake
VFD751 Phase Lost
VFD751 External
VFD751 Control
VFD571 Start
VFD571 Incompat Param Set
VFD571 EPM HW
VFD571 Internal 1
VFD571 Internal 2
VFD571 Internal 3
VFD571 Internal 4
VFD571 Internal 5
VFD571 Internal 6
VFD571 Internal 7
VFD571 Internal 8
VFD571 Personality
VFD571 Internal 10
VFD571 Remote Keypad Lost
VFD571 Assertion Level
VFD571 Internal 11
VFD571 Internal 12
VFD571 Internal 13
VFD571 Internal 14
VFD571 Comm Module
VFD571 Network
VFD571 Network 1
VFD571 Network 2
VFD571 Network 3
VFD571 Network 4
VFD571 Network 5
VFD571 Network 6
80
74
75
76
77
78
79
80
81
66
67
68
69
70
71
72
73
Code
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
90
91
92
93
94
82
83
84
85
86
87
88
89
Description
VFD571 Network 7
VFD571 Network 8
VFD571 Network 9
Return Sensor Missing
Return Sensor Broken
Outside Sensor Missing
Outside Sensor Broken
Intake Sensor Missing
Intake Sensor Broken
Discharge Sensor Missing
Discharge Sensor Broken
HMI Temp Sensor
RTC 1 Temp Sensor
RTC 2 Temp Sensor
No Damper End
No Supply Air Proving
FSC1 High Temp
FSC2 High Temp
FSC3 High Temp
FSC4 High Temp
FSC1 Rollout
FSC2 Rollout
FSC3 Rollout
FSC4 Rollout
FSC1 Vent Proving
FSC2 Vent Proving
FSC3 Vent Proving
FSC4 Vent Proving
Freezestat Lockout
Firestat Lockout
Evap Water PS
Evap Float Detect
DX Float Detect
Modbus SysInfo Comm
Master ROM CRC
Slave ROM CRC
Clogged Filters
HMI 1 Version Wrong
HMI 2 Version Wrong
HMI 3 Version Wrong
HMI 4 Version Wrong
HMI 5 Version Wrong
Modbus Supply Vfd Comm
Modbus HMI Comm
Definitions
MVL – Modulating Voltage Low – (.2V for 0-10V input, 2.1V for 2-10V input, .4mA for 0-20mA input, or
4.2mA for a 4-20mA input) - If the voltage stays below this set value for a certain amount of time the current relay will open.
MVH – Modulating Voltage High – (9.60V for either 0-10V or 2-10V, or 19.2mA for either 0-20mA or 4-
20mA) - If the voltage stays above this set value for a certain amount of time the next relay will close.
RCT – Relay Close Time – The amount of time that the input voltage must stay above MVH before the next relay will close.
ROT – Relay Open Time – The amount of time that the input voltage must stay below MVL before the current relay will open.
RTT – Relay Tentative Time – The amount of time after a new relay has closed that the voltage must not drop or else the newly closed relay will open again.
Number of Stages - This will set the number of stages that are on the IBT.
Resolution – The resolution changes how often a sample is take and recorded from the input.
Cycle Time – The cycle time is the amount time that is stored in the history.
The number of samples that is stored in the history is calculated by ( Cycle Time/Resolution) .
Stage Operation
During stage 1 the first burner is modulating the full range of the input, whether it be a 0-10V signal or a
2-10V signal. Once the input voltage has been above MVH for time RCT, a pre-purge cycle starts on the next burner.
If the input voltage still remains high and has not lowered for the entire 1 minute pre-purge, the second burner will then light and go into high-fire for 17 seconds. Stage 2 begins after the 17 seconds. During this stage the input is split into two sets of linearization data. Burner one will modulate from 0-10V from the first half of the input signal. Burner two will modulate from 0-10V from the second half.
For example, if the input is a 0-10V signal and has a value of 7V, burner one will be at max output of 10V and burner two will be around 4V (based on the current set of linearization data). If the input signal is a 2-
10V signal and the value is 6V, burner one will be at 10V and burner two will be at 0V. This is because
6V is the very middle of the 2-10V scale for the input. If the input signal is a 0-10V signal and has a value of 1V, the first burner will have an output around 2V and the second burner will have an output of 0V.
This modulating scheme remains throughout the rest of the stages. If the input remains above MVH for time RCT after the preceding relay has closed, the third burner will begin its 1 minute pre-purge followed by 17 seconds of high fire and Stage 3 will be entered. After this 17 seconds the third burner will remain at high-fire while the first two burners continue to modulate. The fourth burner acts in the same manner as the third. If the input voltage ever remains below MVL for time ROT, then the last relay will be opened and that stage will shut off.
81
Modulation Sequence
Input V < MVL for time ROT
STAGE 1
1 Modulating Burner that is linearized based on the input. Stays in stage 1 for as long as V < MHV
Input V > MVH for time RTT
STAGE 2
2 Modulating Burners with split linearization. Stays in stage 2 for as long as MVL <V < MVH
Input V < MVL for time ROT
Input V < MVL for time ROT
Input V > MVH for time RTT
STAGE 3
2 Modulating Burners with split linearization and 1 Fixed Burner.
Stays in stage 3 for as long as MVL
< V < MVH
Input V > MVH for time RTT
STAGE 4
2 Modulating Burners with split linearization and 2 Fixed Burners.
Stays in stage 4 for as long as MVL
< V
RCT
Stage Total # of stages
1 2 3 4
First 0 0 0 0
Second x 120 90 90
Third x x 120 90
Fourth x x x 120
45
45
45
45
Relay 2 closes
Second Burner -> 1 Minute prepurge followed by 17 second High-
Fire
If input V lowers during
RTT
Input V > MVH for time RCT
60
60
60
60
Input V > MVH for time
RCT
If input V lowers during
RTT
ROT
(Seconds)
Relay 3 closes
Third Burner -> 1 Minute pre-purge followed by 17 second High-Fire
Input V > MVH for time RCT
If input V lowers during
RTT
Relay 4 closes
Fourth Burner -> 1 Minute prepurge followed by 17 second High-
Fire
RTT
(Seconds)
82
83
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 Field Measured Information
Model Number Motor Voltage
Serial Number
Motor Volts
Motor Hertz
Motor Phase
Motor FLA
Motor HP
Blower Pulley
Motor Pulley
Belt Number
Gas Type
Min. Btu/Hr
Max. Btu/Hr
Motor Amperage**
RPM
Gas Type
High Fire Inlet Gas Pressure
Low Fire Manifold Gas Pressure
High Fire Manifold Gas Pressure
Thermostat Set-Point
Temperature Control
Airflow Direction in. w.c. in. w.c. in. w.c.
Discharge
Space
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: 1-919-554-9374
84
advertisement
Related manuals
advertisement