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Weather-Rite XT112 Installation, Operation & Service Manual

Xt-series direct, gas-fired, industrial air handler
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FOR YOUR SAFETY
If you smell gas:
1. Open windows.
2. DO NOT try to light any appliance.
3. DO NOT use electrical switches.
4. DO NOT use any telephone in
your building.
5. Extinguish any open flame.
6. Leave the building.
7. Immediately call your local gas
supplier after leaving the building.
Follow the gas supplier's
instructions.
8. If you cannot reach your gas
supplier, call the Fire Department.
WARNING
Fire Hazard
Keep all flammable objects, liquids and
vapors the minimum required clear-
ances to combustibles away from
equipment.
Some objects will catch fire or explode
when placed close to equipment.
Failure to follow these instructions can
result in death, injury or property
damage.
WARNING
Improper installation, adjustment, alteration, service
or maintenance can result in death, injury or
property damage. Read the Installation, Operation
and Service Manual thoroughly before installing or
servicing this equipment.
Installation must be done by a contractor qualified
in the installation and service of gas-fired heating
equipment or your gas supplier.
CANADA: 100% OUTSIDE AIR ONLY
© 2017 Weather-Rite LLC
Weather-Rite
Direct, Gas-Fired, Industrial
NOT FOR RESIDENTIAL USE
™
Installation, Operation &
Service Manual
Installer
Please take the time to read and understand
these instructions prior to any installation.
Installer must give a copy of this manual to the owner.
Keep this manual in a safe place in order to provide
your service technician with necessary information.
Weather-Rite LLC
1100 Seven Mile Road NW
Comstock Park, MI 49321
Telephone: +1.612.338.1401
Fax: +1.616.784.0435
Toll Free: 800.589.3691
www.weather-rite.com
XT-Series
Air Handler
XT112
XT115
XT118
XT125
XT130
Owner
P/N WR121100NA Rev F 2/17

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  • Page 1 NOT FOR RESIDENTIAL USE Weather-Rite LLC 1100 Seven Mile Road NW Comstock Park, MI 49321 Telephone: +1.612.338.1401 Fax: +1.616.784.0435 Toll Free: 800.589.3691 CANADA: 100% OUTSIDE AIR ONLY www.weather-rite.com P/N WR121100NA Rev F 2/17 © 2017 Weather-Rite LLC...
  • Page 3 Conçus pour les applications non-résidentielles Weather-Rite LLC 1100 Seven Mile Road NW Comstock Park, MI 49321 Téléphone: +1.612.338.1401 Fax: +1.616.784.0435 Numéro sans fraís: 800.589.3691 Canada: seulement avec www.weather-rite.com 100% d’air externe P/N WR121100FC Rev F 2/17 © 2017 Weather-Rite LLC...

  • Page 5: Table Of Contents

    ™ XT-Series Start-Up Proce- SECTION 12: Dampers ............30 dures ..................87 12.1 Discharge Damper ..........31 SECTION 25: The WEATHER-RITE ™ XT-Series Warranty .. 89 12.2 Inlet Damper ............31 SECTION 13: Discharge Heads and Splash Plates .... 32 13.1 Three-Way Discharge Head Installation ....
  • Page 6 © 2017 Weather-Rite LLC Printed in the U.S.A.

  • Page 7: Section 1: Air Handler Safety

    LLC. Cover the air handler to protect it from the Gas-fired equipment is not designed for use in environment. Weather-Rite LLC will not be held atmospheres containing flammable vapors or dust or responsible for any damages that may occur from atmospheres containing chlorinated or halogenated outdoor storage.

  • Page 8: Safety Labels And Their Placement

    In accordance with California Proposition 65 require- ments, a warning label must be placed in a highly visible location on the outside of the equipment (i.e., near equipment's serial plate). To order additional labels, please contact Weather-Rite LLC or your ™ WEATHER-RITE independent distributor.

  • Page 9: Section 2: Installer Responsibility

    • To provide access to air handler for servicing. • To provide the owner with a copy of this Weather-Rite LLC cannot be responsible for ensuring Installation, Operation and Service Manual. that all appropriate safety measures are undertaken prior to installation;...

  • Page 10: National Standards And Applicable Codes

    XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL 2.3 National Standards and Applicable Codes All equipment must be installed in accordance with the latest revision of the applicable standards and national codes. This refers also to the electric, gas and venting installation. Note: Additional standards for installation in public garages, aircraft hangars, etc.

  • Page 11: Section 3: Critical Considerations

    SECTION 3: C RITICAL ONSIDERATIONS SECTION 3: CRITICAL CONSIDERATIONS 3.1 Required Clearances to Combustibles WARNING Clearances are the required distances that combustible objects must be away from the air handler to prevent fire hazards. Combustibles are materials that may catch on fire and include common items such as wood, paper, rubber, fabric, etc.

  • Page 12: Purge Of Supply Duct

    XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL 3.2 Purge of Supply Duct Table 1: Recommended Torque Settings If this heating unit is to be installed indoors, and its outdoor air supply ducted from outdoors, ANSI Standards Z83.4/CSA 3.7, Z83.18 and Z83.25/CSA Bolt Head 3.19 require that all supply duct shall be purged a Grade Marking...

  • Page 13: Section 4: National Standards And Applicable Codes

    SECTION 4: N ATIONAL TANDARDS AND PPLICABLE ODES SECTION 4: NATIONAL STANDARDS AND APPLICABLE CODES 4.4 Parking Structures and Repair Garages 4.1 Gas Codes Installation in garages must be in accordance with the following codes: The type of gas appearing on the nameplate must be the type of gas used.

  • Page 14: Section 5: Specifications

    XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 5: SPECIFICATIONS attached ductwork. See Page 9, Table 4 and Table 5 for static pressure accessories. If more external static Estimated weight table apply to both upright and pressure is required, this needs to be requested with horizontal units of the same model.
  • Page 15 SECTION 5: S PECIFICATIONS Table 4: Estimated Pressure Drop of Accessory Components Inlet Hood with Inlet Hood with Airflow Range Inlet Hood with Filters Filter Section Model Moisture Limiters Bird Screen in wc (mbar) in wc (mbar) in wc (mbar) in wc (mbar) in wc...

  • Page 16: Section 6: Lifting An Air Handler

    XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 6: LIFTING AN AIR HANDLER • Verify that the lifting lugs are intact undamaged and secured to the air handler. WARNING • Ensure factory-installed hardware is torqued as specified. 4. Prepare the installation location to be ready to accept the air handler (i.e.
  • Page 17 SECTION 6: L IFTING AN ANDLER 6.1.3 Lifting an Upright Air Handler Step 2: Remove the lifting lugs on the inlet end of the air handler and re-install hardware. All air handlers are shipped in the horizontal position. Step 3: Use all four lifting lugs on the discharge end Prior to lifting an upright air handler, the following of the air handler to enable the air handler to be lifted steps must be performed (See Page 11, Figure 2):...

  • Page 18: Section 7: Roof Curb

    Failure to follow these instructions can result in death, injury or property damage. Roof curbs are shipped unassembled and require field assembly. NOTE: Before installation, verify that you have the correct roof curb and that all required components are present. If any are missing, contact your WEATHER-RITE ™ independent distributor.
  • Page 19 SECTION 7: R FIGURE 3: Roof Curb Assembly ***Cross Brace Caulk required for outside perimeter ***Side panels are split of roof curb at bolted joints. Top Mounting Flange Side Panel End Panel (Inlet or Discharge) Dimensions Weight* Weight** Model (in) 24.3 80.2 21.3...

  • Page 20: Air Handler Mounting To Roof Curb

    XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL 7.2 Air Handler Mounting to Roof Curb After the curb has been installed, the air handler may be placed on the curb. See Page 14, Figure 4. After the air handler is in place, the installer must fasten the air handler to the curb. This is accomplished by drilling holes down through the floor of the air handler and into the curb.

  • Page 21: Section 8: Legs For Horizontal Mounting

    SECTION 8: L ORIZONTAL OUNTING SECTION 8: LEGS FOR HORIZONTAL MOUNTING WARNING Crush Hazard Falling Hazard Severe Injury Hazard Cut/Pinch Hazard Use proper lifting Use proper safety Use proper lifting Wear protective gear equipment and equipment and prac- practices and equip- during installation, practices.

  • Page 22: Section 9: Upright Installation

    XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 9: UPRIGHT INSTALLATION WARNING Crush Hazard Falling Hazard Severe Injury Hazard Cut/Pinch Hazard Use proper lifting Use proper safety Use proper lifting Wear protective gear equipment and equipment and prac- practices and equip- during installation, practices.
  • Page 23 SECTION 9: U PRIGHT NSTALLATION Step 1: Assemble using the provided hardware: 3/8" bolts, nuts and lock washers. Assemble the legs with the top upside down on a flat surface. See Page 17 , Figure 5. FIGURE 5: Step 1 Step 2: Attach the mounting feet to each leg using supplied hardware.
  • Page 24 XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 3: With the top frame upside down, insert and attach the first two legs. Note: All legs are identical and not all the holes will be used on each leg. See Page 18, Figure 7. FIGURE 7: Step 3...
  • Page 25 SECTION 9: U PRIGHT NSTALLATION Step 4: Next attach the horizontal support(s), and repeat process for the other two remaining legs. See Page 19, Figure 8. FIGURE 8: Step 4...
  • Page 26 XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 5: Attach remaining support braces taking note of the support location to proper orient for your air handler's configuration. See Page 20, Figure 9. FIGURE 9: Step 5 Control Side Return Filter Access...

  • Page 27: Section 10: Filter Section

    SECTION 10: F ILTER ECTION SECTION 10: FILTER SECTION WARNING Crush Hazard Falling Hazard Severe Injury Hazard Cut/Pinch Hazard Use proper lifting Use proper safety Use proper lifting Wear protective gear equipment and equipment and prac- practices and equip- during installation, practices.

  • Page 28: Filter Section Installation - Horizontal Air Handlers

    XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL 10.2 Filter Section Installation - Horizontal Air 10.3.2 Filter Installation Handlers Install the proper filters as required for the air 10.2.1 Filter Section Installation handler’s configuration. See Page 22, Table 6. Table 6: Filter Quantities For installation directly onto the inlet of the air Permanent Aluminum Mesh Pleated / Polyester* handler, foam tape (provided by others) must be...

  • Page 29: Section 11: Inlet Hood

    Page 6, Table 1. In addition, all seams must be caulked (provided by others). NOTE: Check to be sure that all required components are present. If any are missing, contact your ™ WEATHER-RITE independent distributor. 11.1 Inlet Hood Assembly FIGURE 12: Inlet Hood with Filter Racks...
  • Page 30 XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 13: Inlet Hood Roof Left Panel Right Panel Rain Gutter X2 Bottom For an air handler supplied with a filter section a single hood is provided. For an air handler with inlet hood mounted filters, two hoods are provided.
  • Page 31 SECTION 11: I NLET Step 11.2.3 Attach the upper hood roof with the provided TEK screws along the left and right side and upper edge to the air handler. Step 11.2.4 Attach the bottom filter rail for the upper inlet hood to the hood using the provided rivets.
  • Page 32 XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 11.2.5 Mount the lower inlet hood right and left side (flanges will be facing out), with the bolts and wash- ers provided and the upper edge of these sides to the lower portion of the upper hood with the TEK screws provided.
  • Page 33 SECTION 11: I NLET Step 11.2.7 Attach the lower hood roof with the provided TEK screws along the left and right side.
  • Page 34 XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 11.2.8 Attach the remaining filter rails and the rain gutters to the upper and lower hood sides with the provided rivets. Step 11.2.9 Attach filter retaining latches with the provided rivets. Step 11.2.10 Caulk seam between air handler and inlet hood.
  • Page 35 SECTION 11: I NLET Step 11.3 Inlet Hoods for Air Handler with Filter Section Step 11.3.1 Seal around the perimeter of the inlet of the filter section with the provided foam gasket tape. Step 11.3.2 Attach the left and right side of the inlet hood (flanges facing in) to the top of the inlet hood using the TEK screws provided.

  • Page 36: Section 12: Dampers

    XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 12: DAMPERS WARNING Crush Hazard Falling Hazard Severe Injury Hazard Cut/Pinch Hazard Use proper lifting Use proper safety Use proper lifting Wear protective gear equipment and equipment and prac- practices and equip- during installation, practices.

  • Page 37: Discharge Damper

    SECTION 12: D AMPERS 12.1 Discharge Damper Discharge dampers are shipped loose. Discharge dampers are designed to be mounted downstream of the air handler in ductwork. A qualified contractor/installer must make appropriate allowances for duct connections. To install the discharge damper on an interior wall, drill holes every 8" (20.5 cm) in the flanges on all four sides of the discharge damper to accommodate lag bolts (provided by others).

  • Page 38: Section 13: Discharge Heads And Splash Plates

    XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 13: DISCHARGE HEADS AND SPLASH PLATES WARNING Crush Hazard Falling Hazard Severe Injury Hazard Cut/Pinch Hazard Use proper lifting Use proper safety Use proper lifting Wear protective gear equipment and equipment and prac- practices and equip- during installation, practices.

  • Page 39: Splash Plate Installation

    SECTION 13: D ISCHARGE EADS AND PLASH LATES 13.2 Splash Plate Installation The splash plate is designed to hang directly from a horizontal air handler with a bottom discharge. Before the splash plate can be installed on the air handler, first drill four holes in the air handler floor. These holes to be centered over the entire blower discharge opening.
  • Page 40 XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 17: Mounting Hole Locations Blower Discharge Centerline Model (in) 24.6 22.5 XT-112 (cm) 62.5 57.1 (in) 32.1 34.0 XT-115 (cm) 81.5 86.4 (in) 36.6 36.8 XT-118 (cm) 93.0 93.4 (in) 40.6 40.3 XT-125 (cm)

  • Page 41: Section 14: Duct Considerations

    SECTION 14: D ONSIDERATIONS SECTION 14: DUCT CONSIDERATIONS Dh: hydraulic diameter H: rectangular duct inside height WARNING W: rectangular duct inside width The air handler is not designed to support the weight of ductwork. Ductwork must be constructed in a fashion that is self-supporting.

  • Page 42: Section 15: Gas Piping

    XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 15: GAS PIPING regulator will be required to assure that the correct gas pressure is supplied to the regulator. Pressure WARNING should be measured between the high pressure gas regulator and safety shut off valve. Minimum gas pressure as indicated on data plate must be measured with the burner operating in high fire.
  • Page 43 SECTION 15: G IPING FIGURE 18: ANSI/FM/XL-Compliant Manifolds (XT-112) Alternate Inlet High Gas Pressure Regulator (Optional For ANSI-Compliant Manifolds and supplied for FM and XL-Compliant Manifolds) Vent to Atmosphere (FM and XL Manifold) Regulator With Dual Safety Shut Off Valve Inlet Manual Gas Modulating Valve...
  • Page 44 XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 20: FM-Compliant Manifold (XT-115 - XT-130) Alternate Inlet High Gas Pressure Regulator (Optional) Safety Shut Safety Shut Off Valve Off Valve Vent to Atmosphere Inlet Visual Indicator Manual Gas Vent to Atmosphere Valve (Main) Modulating Valve With Union...

  • Page 45: Gas Piping

    SECTION 15: G IPING 15.4 Gas Piping FIGURE 22: Plug Tapping (XT-112) The gas manifold extends through the side of the Modulating Valve control cabinet for models XT-112 - XT-130. The Plugged Taping factory piping terminates with a female pipe To Measure Burner Pressure connection in the manual gas valve.

  • Page 46: Section 16: Electrical

    XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 16: ELECTRICAL DANGER Electrical Shock Hazard Disconnect electric before service. More than one disconnect switch may be required to disconnect electric from equipment. Equipment must be properly grounded. Failure to follow these instructions can result in death or electrical shock.

  • Page 47: Disconnect Fuse Sizing

    SECTION 16: E LECTRICAL 16.1 Disconnect Fuse Sizing The fuse classification must be determined by the service disconnect rating plate and all applicable codes. Fuse sizing is determined by the motor size, control current and supply voltage. Fuses that are being replaced must be replaced with the same type, size and class of fuse that was supplied with the air handler.

  • Page 48: Control Current Draw

    Weather-Rite LLC. Refer to Page 42, Table 10 for a brief description of each safety device, its location and its switching voltage.
  • Page 49 SECTION 16: E LECTRICAL 16.6.4 Flame Control 16.6.5 Discharge Temperature Sensor This device will check for both pilot flame and main This device senses the discharge temperature of the flame within the burner. When a flame signal from the air at the blower. The discharge temperature sensor pilot flame is available, it will allow the main gas valve reports the discharge temperature to the temperature to open.
  • Page 50 XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 25: Interconect Wiring 2...

  • Page 51: Interlocks

    SECTION 16: E LECTRICAL 16.7 Interlocks setpoint, after the 5 minute establishing period, the air handler fan will be turned off. If there is a failure of 16.7.1 Carbon Dioxide Interlocks the exhaust fan to activate the field supplied airflow All air handlers that recirculate air from the heated switch, after the 5 minute establishing period, the air space require either a control to limit the temperature...
  • Page 52 XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL 16.8.9 Single Point Connection 16.8.10 Service Receptacle Powered by Others (Wired) When a variable frequency drive or auxiliary motor starter (both used for controlling an exhaust fan) or This option provides a service receptacle. It includes an enclosure heater or ground fault interrupt (GFI) ground-fault interrupter (GFI) receptacle mounted on receptacle are ordered, the installer/service...

  • Page 53: Section 17: Sequence Of Operation

    SECTION 17: S EQUENCE OF PERATION SECTION 17: SEQUENCE OF OPERATION 17.1.2 Fixed Recirculation (FR) Style The FR style air handler has a constant speed DANGER blower that is designed to deliver a constant volume of air to the heated space. In all cases, however, the air being delivered directly over the burner for combustion must always be 100% outside air.
  • Page 54 XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL Table 11: Configuration Chart Air Handler Air Flow Air Volume Control Configuration Make Up Air (MUA) 100% Outside Air Constant Non-adjustable ratio of Fixed Recirculation (FR) 20% outside air and Constant 80% return air Adjustable ratio of 20% outside air and 80% Building Pressure...

  • Page 55: Hvac Remote Panels And Panel Options

    SECTION 17: S EQUENCE OF PERATION 17.2 HVAC Remote Panels and Panel Options The remote panel should be mounted in the conditioned space in a convenient location for controlling the air handler. Do not locate a remote panel that contains temperature sensing equipment in an area directly affected by the air handler or another heat source as it may interfere with the operation of the air handler.
  • Page 56 XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL Selectrastat dial. The 7-day programmable touchscreen thermostat provides nighttime setback for unoccupied space heating. AUTO/WINTER Mode: Occupied time: Blower and burner cycle operate continuously to maintain a constant space temperature as selected on the Selectrastat dial. The burner flame fully modulates and varies the discharge air temperature to maintain the space temperature.

  • Page 57: Basic Air Handler Sequence Of Operation

    Discharge temperature monitoring and modulation valve adjustment are completed by the customer supplied control system. For optimum efficiency, Weather-Rite LLC suggests to limit the discharge temperature to 160 °F. 17.3 Basic Air Handler Sequence of Operation While the control transformer is energized, the secondary side supplies 115 VAC to the control circuit.
  • Page 58 XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL 2. Air Flow - This indicator comes on at the same • When the flame sensor detects a pilot flame, the time as the one above. This is because the signal is sent back to the safeguard control. The actual circuit is not used and is jumped out.
  • Page 59 SECTION 17: S EQUENCE OF PERATION the system. The trial for ignition must be (PTFI) timing, and recycle or non-recycle operation. delayed by 7 seconds while the blower in the See Page 53, Figure 28. unit is running. This is to guarantee that there are no combustible gases or vapors present in Purge Timing the air stream during burner ignition and light...
  • Page 60 XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL Pilot Trial for Ignition • At the same time that the contact in step b closes, the electronic network opens a contact, which • Jumpers JP6 and JP7 are used by the factory powers terminal #4.

  • Page 61: Section 18: Direct Fired Burner

    SECTION 18: D IRECT IRED URNER SECTION 18: DIRECT FIRED BURNER WARNING DANGER Explosion Hazard Carbon Monoxide Hazard Burn Hazard Electrical Shock Hazard Leak test all compo- Heaters installed Allow heater to cool Disconnect electric nents of gas piping unvented must be before service.

  • Page 62: Direct Fired Burner Ignition

    The gas flowing out the ports The burner that is used in the Weather-Rite LLC unit in the pilot gas tube is ignited by this arc. The arc will is equipped with a pilot assembly.

  • Page 63: Direct Fired Burner Flame Proving (Flame Rod)

    SECTION 18: D IRECT IRED URNER 18.2 Direct Fired Burner Flame Proving (Flame Rod) The flame rod in the burner is constructed of a material that produces a signal when heated. This signal is measured as a direct current micro amp. The path of the signal is from the flame rod to the burner.

  • Page 64: Section 19: Direct Fired Process Air Heaters

    XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 19: DIRECT FIRED PROCESS AIR HEATERS DANGER Electrical Shock Hazard Severe Injury Hazard Disconnect electric before service. Do not enter equipment while in operation. More than one disconnect switch may be Equipment may start automatically.

  • Page 65: Direct Fired Process Air Heater Models

    SECTION 19: D IRECT FIRED PROCESS AIR HEATERS the process air heater in compliance with: 4. Instructions must be provided to require peri- odic inspection and cleaning of the recircula- United States: Refer to NFPA 86 - latest revision, tion air duct. The installer must supply this Ovens and Furnaces /ANSI Z83.25 - latest revision, information.

  • Page 66: Installer's Responsibility For Process Heaters Connected To Paint Booths

    XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 31: Burn Hazard 19.3 Installer's Responsibility for Process Heaters Connected to Paint Booths WARNING If the exhaust control system is not supplied by the Process Heater, then the installer must electrically interlock the exhaust system with the heater.

  • Page 67: Section 20: Start-Up Procedures

    SECTION 20: S TART ROCEDURES SECTION 20: START-UP PROCEDURES DANGER Electrical Shock Hazard Severe Injury Hazard Disconnect electric before service. Do not enter equipment while in operation. More than one disconnect switch may be Equipment may start automatically. required to disconnect electric from equipment.

  • Page 68: Installation Of Recirculating Air Handler

    /h) of outside air per 1,000 Btu/h (0.293 kW). qualified in the installation and service of equipment Before installation, check that the local distribution sold and supplied by Weather-Rite LLC and conform condition, nature of gas and pressure, and the ™...

  • Page 69: Electrical

    SECTION 20: S TART ROCEDURES 20.2.2 Belt Tension 20.3 Electrical • Belt tension should be checked with a belt-tension Check motor starter for proper overload set- tings. The overload setting should meet full gauge when one is available. Follow the belt load amps (FLA) of motor.

  • Page 70: Gas Piping And Initial Pressure Settings

    XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL adjustment. 20.5 Gas Piping and Initial Pressure Settings Perform a pressure test on all gas supply lines to the air handler per applicable codes. Table 15: Motor Sheave Drive Torque Make sure to isolate all gas controls before Specifications pressure testing the system.
  • Page 71 SECTION 20: S TART ROCEDURES 5. Adjust air handler high fire gas pressure. • Reconnect any wires that were removed for adjustment. • Determine the high fire gas pressure by adding the manifold pressure for maximum Maximum discharge temperature is 160° F input (from the rating plate) and the burner (71°...

  • Page 72: Safety Shut Off Valve Check

    XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL Set BMS to max fire or remove input wires from Remove from terminal SC11 Signal terminals #6 and #5 and #1 on the Conditioner connect a 9VDC battery to signal conditioner the signal conditioner Remove wire from ter- Disconnect selector ribbon Series 94...
  • Page 73 SECTION 20: S TART ROCEDURES FIGURE 35: MR 212 Valve SIDE VIEW NOTE: For high fire adjustment, turn clockwise to increase manifold pressure; turn counter clockwise to decrease manifold pressure. Inlet Pressure Outlet Pressure (Burner Pressure)
  • Page 74 XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 36: M611 Valve NOTE: Modulating only. Gas Inlet Low Fire Adjustment Gas Outlet (under cap) FIGURE 37: Regulator (XT-112) Regulator Adjustment Below (High Fire Adjustment Cap) Gas Flow Gas Flow Outlet Pressure Inlet Pressure Tap-1/8 NPT Tap-1/8 NPT...

  • Page 75: Section 21: Maintenance

    SECTION 21: M AINTENANCE SECTION 21: MAINTENANCE DANGER Electrical Shock Hazard Severe Injury Hazard Disconnect electric before service. Do not enter equipment while in operation. More than one disconnect switch may be Equipment may start automatically. required to disconnect electric from equipment.

  • Page 76: General

    OSHA regulations and allow ample qualified in the installation and service of equipment time for the air handler to cool. After maintenance is sold and supplied by Weather-Rite LLC and conform performed or air handler is serviced, the air handler ™...
  • Page 77 SECTION 21: M AINTENANCE Drive Belts and Sheaves Check for belt ride in the groove. In multiple groove drives, belt ride should be uniform. Check groove wear area for wear. Side wall of groove should be straight, not dished out. Bottom of groove should show no signs of belt contact.
  • Page 78 Repeat this same operation after 1 week of service. Consult Weather-Rite LLC or the motor manufacturer for fur- ther recommendations on grease compatibility.

  • Page 79: Manifold And Controls

    SECTION 21: M AINTENANCE 21.4 Manifold and Controls Manifold Periodically check gas control assembly and internal and external piping for leaks. Relief vent lines to outdoors on gas controls should be checked to ensure against blockage caused by insects or any other substance. Clean as required.

  • Page 80: Optional Equipment

    NOTE: When using Weather-Rite LLC supplied disposable polyester filters, they must be inserted with the white media side facing the inlet of filter sec- tion. When using Weather-Rite LLC supplied permanent aluminum mesh or disposable filters, they must be inserted with the arrow on the filter pointing in the direction of airflow (toward the air handler).

  • Page 81: Section 22: Replacement Parts

    DANGER Electrical Shock Hazard Explosion Hazard Carbon Monoxide Hazard Fire Hazard Use only genuine WEATHER-RITE ™ replacement parts per this installation, operation and service manual. Failure to follow these instructions can result in death, electric shock, injury or property damage.
  • Page 82 XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL Table 20: Control Panel Spare Parts Description Models Part Number Pressure Switch Low Airflow All models 28892 Pressure Switch High Airflow All models Maxitrol 1014U (Temp Control Amp) 07432 Maxitrol 1044 (Temp Control Amp) 07431 Mixing Tube All models...
  • Page 83 SECTION 22: R EPLACEMENT ARTS Table 22: Blower Spare Parts Model XT-112 XT-115 XT-118 XT-125 XT-130 1000-2000 CFM 2000-4000 CFM Blower 62924 62923 P-000315 P-000316 P-000317 P-000318 Bearing P-000627 P-000630 P-000633 P-000636 Shaft P-000628 P-000631 P-000634 P-000637 Wheel P-000629 P-000632 P-000635 P-000638 Table 23: Remote Spare Parts...
  • Page 84 XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL 208/3/60 Overload 28709 28708 28708 28711 28712 28713 28714 28716 28717 28718 28719 28720 28720 Starter 33810 33810 33810 33811 33812 33813 33814 33816 33817 33818 33819 33819 33820 Fuse 25120 25094 25094 25095 25096...

  • Page 85: Section 23: Troubleshooting

    SECTION 23: T ROUBLESHOOTING SECTION 23: TROUBLESHOOTING DANGER Electrical Shock Hazard Severe Injury Hazard Disconnect electric before service. Do not enter equipment while in operation. More than one disconnect switch may be Equipment may start automatically. required to disconnect electric from equipment.

  • Page 86: Initial Checks

    XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL 23.1 Initial Checks When encountering any abnormal operation or fault conditions of the equipment, all troubleshooting should start with the following initial checks. If a problem is discovered in these initial checks it must be corrected before moving on in the trouble shooting.

  • Page 87: Burner

    SECTION 23: T ROUBLESHOOTING 23.3 Burner PROBLEM POSSIBLE CAUSE SOLUTION Auxiliary contact not closed. Properly mount contact or replace Flame control Burner/winter switch closed? Replace switch does not try for ignition High temp limit switch tripped? Manually reset or replace Check blower operation Reconnect tubes to pressure switch Low airflow pressure switch contacts not made.

  • Page 88: Temperature Controls

    XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL Burner (continued) PROBLEM POSSIBLE CAUSE SOLUTION Manual shut off valve closed Open manual shut off valve Check wiring from burner control to SSOV Safety Shut Off Valve not operating. Is there Verify inlet gas pressure positive gas pressure downstream of SSOV? Replace SSOV Verify minimum gas supply pressure as per data...

  • Page 89: A1014 Amplifier - Field Checklist

    SECTION 23: T ROUBLESHOOTING 23.5 A1014 Amplifier - Field Checklist SYMPTOM POSSIBLE CAUSE No Gas Flow 1. Modulating valve improperly installed. Continuous Low Fire (electronics problem). 2. Short circuit or no voltage to the amplifi er. 3. Open circuit in TD114. Remote Temperature Selector circuit or wiring. 4.
  • Page 90 XT I ERIES NSTALLATION PERATION AND ERVICE ANUAL FIELD TEST REMEDY 1. Arrow on side of Valve should point in direction of gas fl ow. 1. Install properly. 2. Check for 24VAC at amplifi er terminals 7 & 8. 2. Prove the power source. 3.

  • Page 91: A44 Amplifier - Field Service Checklist

    23.6 A44 Amplifier - Field Service Checklist SYMPTOM POSSIBLE CAUSE No gas fl ow. 1. Valve improperly installed. Continuous low fi re (electronics ok). 2. Open circuit in modulator coil. 3. Plunger missing, jammed or improperly installed. 4. Ruptured main or balancing diaphragm. Continuous Low Fire (electronics problem) 5.
  • Page 92 FIELD TEST REMEDY 1. Arrow on side of valve should point in direction of gas fl ow. 1. Install properly. 2. Remove wires connected to amplifi er terminals 6 & 7 and mea- 2. If proper resistance values are not observed, replace modulator head or sure resistance.

  • Page 93: Section 24: Weather-Rite Xt-Series Start-Up Proce- Dures

    Address: ________________________________ Phone: __________________________________ Phone: __________________________________ Fax: ____________________________________ Fax: ____________________________________ Notice: Please return a completed copy to Weather-Rite™ LLC. If this document is not returned, the manufacturing date will be used as the warranty start date. WARNING Explosion Hazard Falling Hazard...
  • Page 94 (P/N RP121100NA). Contact the local WEATHER-RITE ™ according to the rating plate inlet gas pressure specifica- tions. independent distributor or Weather-Rite LLC for a manual. Fuel Type: _______ Pressure: ___________. Only after performing steps 1-3, open the main gas valve At Start-up:...

  • Page 95: Section 25: The Weather-Rite ™ Xt-Series Warranty

    Should you need Replacement Parts or have additional questions, call or write: Weather-Rite LLC will require the part in question to be returned to the factory. Weather-Rite LLC will, at its sole discretion, repair or replace after determining the nature of Weather-Rite LLC the defect and disposition of part in question.

This manual is also suitable for:

Xt115Xt118Xt125Xt130

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