Weather-Rite TT Series Installation, Operation & Service Manual
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Weather-Rite TT Series Installation, Operation & Service Manual

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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 fuel
supplier after leaving the building.
Follow the fuel supplier's
instructions.
8. If you cannot reach your fuel
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 registered installer/
contractor qualified in the installation and service of
gas/oil-fired heating equipment or your fuel supplier.
NOT FOR RESIDENTIAL USE
© 2017 Weather-Rite LLC
WEATHER-RITE™ TT-Series
Industrial Air Handler
Installation, Operation &
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
Direct, Gas Fired,
Service Manual
TT112
TT115
TT118
TT212
TT215
TT218
Installer
Owner
P/N WR161100NA Rev B 09/17
TT221
TT224
TT230
TT233
TT236

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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 www.weather-rite.com P/N WR161100NA Rev B 09/17 © 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 www.weather-rite.com P/N WR161100NA Rev B 09/17 © 2017 Weather-Rite LLC...

  • Page 5: Table Of Contents

    All rights reserved. No part of this work covered by the copyrights herein may be reproduced or copied in any form or by any means - graphic, electronic, or mechanical, including photocopying, recording, taping or information storage and retrieval systems - without the written permission of Weather-Rite LLC. Printed in U.S.A.
  • Page 6 27.6 Series 44 - Preliminary Circuit Analysis ....164 27.7 Series 94 - Preliminary Circuit Analysis ....168 27.8 Series MP - Trouble Shooting ......... 172 27.9 Flame ® Safeguard........... 186 27.10 WEATHER-RITE ™ TT-Series Start-Up Procedure. 191 SECTION 28: The WEATHER-RITE ™ TT-Series Warranty . 195...

  • Page 7: Section 1: Air Handler Safety

    If the air handler must be temporarily stored, (i.e. job For additional copies of the Installation, Operation site is not ready for installation of the air handler), the and Service Manual, please contact Weather-Rite air handler should be set on 4" x 4" (10 cm x 10 cm) LLC.

  • Page 8: Safety Labels And Their Placement

    Figure 8. Page 3, Figure 2 for label location. Avoid placing label on areas with extreme heat, cold, corrosive chemicals or other elements. To order additional labels, please contact Weather-Rite LLC or your ™ WEATHER-RITE independent distributor. 1.5 Label Placement...
  • Page 9 SECTION 1: A ANDLER AFETY FIGURE 2: TT224-TT236 Horizontal Item Part Number Description 91070002 Danger - Severe Injury Logo 91070001 Danger - Electric Shock 91070004 Warning - Fire 91070006 Warning - Burn 91070005 Warning - Fall 19162 Rotation 19030 Recommended Entry 91010427 Vent Outdoors 14302333...
  • Page 10 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 4: TT224-TT236 Upright 10 10 Item Part Number Description 91070002 Danger - Severe Injury Logo 91070001 Danger - Electric Shock 91070004 Warning - Fire 91070006 Warning - Burn 91070005 Warning - Fall 19162 Rotation 19030...
  • Page 11 SECTION 1: A ANDLER AFETY FIGURE 5: TT118 Upright Item Part Number Description 91070002 Danger - Severe Injury Logo 91070001 Danger - Electric Shock 91070004 Warning - Fire 91070006 Warning - Burn 91070005 Warning - Fall 19162 Rotation 19030 Recommended Entry 91010427 Vent Outdoors 14302333...
  • Page 12 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 7: 2" NPT or Smaller Gas Train Control Panel Interior Exterior Interior Item Part Number Description 91070001 Danger - Electric Shock 91070005 Warning - Fall 14302333 Installation Manual Enclosed Serial Data Plate Electrical Schematic 91070016 California Proposition 65...
  • Page 13 SECTION 1: A ANDLER AFETY FIGURE 9: Remote Panel Item Part Number Description 91070001 Danger - Electric Shock 91070032 Danger - Electric Shock 910700033 Danger - Electric Shock FIGURE 10: Aux Control Panel Item Part Number Description 91070001 Danger - Electric Shock 91070032 Danger - Electric Shock 910700033...

  • Page 14: Section 2: Installer Responsibility

    The installer is responsible for the following: in product damage. • To install and commission the air handler, as well Weather-Rite LLC cannot be responsible for ensuring as the gas and electrical supplies, in accordance that all appropriate safety measures are undertaken with applicable specifications and codes.
  • Page 15 SECTION 2: I NSTALLER ESPONSIBILITY • Pipe wrenches sized appropriately for the gas train components • Drill motor and various drills ® • U-tube manometer or Magnehelic gauge (0 to 1.0" w.c.) • U-tube manometer or gas pressure gauge (0 to 5# and 0 to 30"...

  • Page 16: Section 3: Critical Considerations

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 3: CRITICAL CONSIDERATIONS for access is 48" (122 cm). Minimum clearance for accessibility applies to the control enclosure, WARNING blower access panel and filter access panel (when equipped). The stated clearances to combustibles represent a surface temperature of 90 °F (50 °C) above room temperature (90 °F [50 °C] plus ambient temperature).

  • Page 17: Section 4: National Standards And Applicable Codes

    SECTION 4: N ATIONAL TANDARDS AND PPLICABLE ODES SECTION 4: NATIONAL STANDARDS AND APPLICABLE CODES All appliances must be installed in accordance with 4.5 Electrical the latest revision of the applicable standards and Electrical connection to air handler must be in national codes.

  • Page 18: Section 5: Specifications

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 5: SPECIFICATIONS The legend below is a list of abbreviations used in this section and applies to Page 12, Figure 11 Dimension and estimated weight tables apply to both through Page 23, Figure 22. upright and horizontal air handlers of the same model.
  • Page 19 SECTION 5: S PECIFICATIONS FIGURE 12: Upright Model Dimensions (Models TT112 and TT115) SIDE VIEW VIEW Table 5: Estimated Shipping Weights (Models TT112 and TT115) Roof Curb Double Burner/ Four-Way Filter Inlet Discharge/ Service Deflection Model Blower Weatherizing Legs Stand Discharge Burner/ Filter...
  • Page 20 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 13: Horizontal Model Dimensions (Model TT118) PLAN VIEW MOTORIZED MOTORIZED INLET HOOD FILTER / BURNER DISCHARGE BLOWER SECTION INLET DAMPER WITH BIRDSCREEN SECTION DAMPER (OPTIONAL) (OPTIONAL) (OPTIONAL) SIDE VIEW NOTE: *'S' dimension reflects curb angle for horizontal orientation.
  • Page 21 SECTION 5: S PECIFICATIONS FIGURE 14: Upright Model Dimensions (Model TT118) SIDE VIEW VIEW Table 9: Estimated Shipping Weights (Models TT118) Roof Curb Burner/ Discharge/ Four-Way Double Deflection Inlet Serivce Model Blower Weatherizing Inlet Legs Stand Discharge Discharge Burner/ Filter Hood Platform Section...
  • Page 22 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 15: Horizontal Model Dimensions (Models TT212 - TT221) PLAN VIEW MOTORIZED MOTORIZED INLET HOOD FILTER SECTION DISCHARGE BURNER / BLOWER SECTION INLET DAMPER WITH BIRDSCREEN (OPTIONAL) DAMPER (OPTIONAL) (OPTIONAL) (OPTIONAL) SIDE VIEW NOTE: *'U' dimension reflects curb angle for horizontal orientation.
  • Page 23 SECTION 5: S PECIFICATIONS FIGURE 16: Upright Model Dimensions (Models TT212 and TT221) SIDE VIEW VIEW NOTE: Model TT221 has 1.5" (3.91 cm) mounting channel above curb angle. Table 13: Estimated Shipping Weights (Models TT212 - TT221) Roof Curb Double Burner/ Four-Way Filter...
  • Page 24 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 17: Horizontal Model Dimensions (Models TT224 and TT230) PLAN VIEW MOTORIZED MOTORIZED INLET HOOD FILTER SECTION DISCHARGE BURNER / BLOWER SECTION INLET DAMPER WITH BIRDSCREEN (OPTIONAL) DAMPER (OPTIONAL) (OPTIONAL) (OPTIONAL) SIDE VIEW NOTE: *’Z’...
  • Page 25 SECTION 5: S PECIFICATIONS FIGURE 18: Upright Model Dimensions (Models TT224 - TT230) SIDE VIEW VIEW Table 17: Estimated Shipping Weights (Models TT224 - TT230) Roof Curb Double Burner/ Discharge/ Four-Way Filter Inlet Service Deflection Model Blower Weatherizing Inlet Legs Stand Discharge Burner/ Filter...
  • Page 26 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 19: Non-Recirculating Horizontal Model Dimensions (Models TT233 and TT236) PLAN VIEW MOTORIZED MOTORIZED INLET HOOD FILTER SECTION DISCHARGE BURNER / BLOWER SECTION INLET DAMPER WITH BIRDSCREEN (OPTIONAL) DAMPER (OPTIONAL) (OPTIONAL) (OPTIONAL) SIDE VIEW NOTE: *’Z’...
  • Page 27 SECTION 5: S PECIFICATIONS FIGURE 20: Non-Recirculating Upright Model Dimensions (Models TT233 and TT236) SIDE VIEW VIEW Table 21: Estimated Shipping Weights (Models TT233 and TT236) Roof Curb Double Burner/ Four-Way Filter Inlet Discharge/ Service Deflection Model Blower Weatherizing Legs Stand Discharge Burner/ Filter...
  • Page 28 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 21: Recirculating Horizontal Model Dimensions (Models TT-233 and TT-236) PLAN VIEW MOTORIZED MOTORIZED INLET HOOD BURNER FILTER SECTION DISCHARGE BLOWER SECTION INLET DAMPER WITH BIRDSCREEN SECTION (OPTIONAL) DAMPER (OPTIONAL) (OPTIONAL) (OPTIONAL) SIDE VIEW NOTE: *'AA' dimension reflects curb angle for horizontal orientation.
  • Page 29 SECTION 5: S PECIFICATIONS FIGURE 22: Recirculating Upright Model Dimensions (Models TT233 and TT236) SIDE VIEW VIEW Table 25: Estimated Shipping Weights (Models TT233 and TT236) Roof Curb Double Burner/ Discharge/ Four-Way Filter Inltet Service Deflection Model Blower Weatherizing Inlet Legs Stand Discharge Burner/...
  • Page 30 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Table 27: Blower Motor Horsepower Selection Total Static Pressure AIRFLOW Outlet Percent- .50 in wc / .75 in wc / 1.00 in wc / 1.25 in wc / 1.50 in wc / 1.75 in wc / 2.00 in wc / 2.25 in wc 2.50 in wc...
  • Page 31 SECTION 5: S PECIFICATIONS Total Static Pressure AIRFLOW Outlet Percent- .50 in wc / .75 in wc / 1.00 in wc / 1.25 in wc / 1.50 in wc / 1.75 in wc / 2.00 in wc / 2.25 in wc 2.50 in wc Velocity age of...
  • Page 32 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Total Static Pressure AIRFLOW Outlet Percent- .50 in wc / .75 in wc / 1.00 in wc / 1.25 in wc / 1.50 in wc / 1.75 in wc / 2.00 in wc / 2.25 in wc 2.50 in wc Velocity...

  • Page 33: Section 6: Lifting An Air Handler

    If the equipment arrives by Flat Bed truck: Models TT112 through TT218 are shipped vertically Weather-Rite LLC strongly recommends using a on skids and must be turned into the proper position crane to unload the air hander. Lift the equipment for lifting into place.
  • Page 34 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 3. The hook labeled #1 is attached to the eyebolt and free from the skid, remove the skid. The air labeled #1. handler will be hanging at a slight angle. 4. Remove the lag bolts attaching the air handler 6.
  • Page 35 SECTION 6: L IFTING AN ANDLER 6.1.3 Lifting an Upright Air Handler If the air handler is shipped as two pieces, lift the two pieces separately and then assemble. See Page 30, Lift the air handler into place using all four 0.75" Section 7 for assembly instructions.

  • Page 36: Section 7: Air Handler Assembly

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 7: AIR HANDLER ASSEMBLY splits. Once caulk has been applied to outdoor models TT233-TT236 (pitched roof is standard), the All air handlers, except the TT118 and the provided roof seam cover should be screwed over recirculating TT233-TT236, have the blower and the caulked seam every 12"...
  • Page 37 SECTION 7: A ANDLER SSEMBLY FIGURE 27: Air Handler Assembly - Recirculating Horizontal (Models TT233 and TT236) TYPICAL ROOF SEAM DETAIL INSTALL DRILL SCREWS APPROX. 1" FROM EACH END TO SECURE SEAM STRIP TO ROOF CONNECTING FLANGES SEAM STRIP PITCHED ROOF (REF) CAULK END OF SEAM &...
  • Page 38 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 28: Air Handler Assembly - Recirculating Upright (Models TT233 and TT236) BLOWER BOLT SECTION FLAT WASHER FLAT WASHER BURNER SECTION LOCK WASHER TYPICAL FOR ALL CONNECTIONS Quantity of 1/2" Nuts, Model Bolts, Flat/Lock Washers TT233 14 sets TT236...

  • Page 39: Section 8: Vibration Isolation

    SECTION 8: VIBRATION ISOLATION SECTION 8: VIBRATION ISOLATION Vibration isolation isolates the support / mounting structure / building from vibrations that the air handler equipment may generate. The type of isolation is determined by the application and or specifications of the equipment on order.
  • Page 40 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 30: Pad Isolator Installation C-Channel (Check Unit Dimensions Unit For More Detail) Waffle Pad Isolator 2" (5.08 cm) x 2" (5.08 cm) 2” Duct Flange or Case Curb Angle Curb 34 of 198...

  • Page 41: Neoprene Or Spring Isolators For Hanging-Mounted Air Handler

    SECTION 8: VIBRATION ISOLATION 8.2 Neoprene or Spring Isolators for Hanging- Equipment should be hung at its proper eleva- Mounted Air Handler tion by using temporary fixtures that can be removed after vibration isolators are installed The hanger style isolator, available in neoprene or and adjusted.
  • Page 42 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 33: Hanger Rods’ Installation instructions (Model TT112-TT218) FLAT WASHER LOCK WASHER (HARDWARE BY OTHERS) 36 of 198...
  • Page 43 SECTION 8: VIBRATION ISOLATION FIGURE 34: Hanger Rods’ Installation (Model TT221) FLAT WASHER LOCK WASHER (HARDWARE BY OTHERS) 37 of 198...
  • Page 44 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 35: Hanger Rods’ Installation Instructions (Model TT224-TT236) FLAT WASHER LOCK WASHER (HARDWARE BY OTHERS) 38 of 198...

  • Page 45: Neoprene Or Spring Isolators For Pad-Mounted Air Handlers

    SECTION 8: VIBRATION ISOLATION 8.3 Neoprene or Spring Isolators for Pad- Mounted Air Handlers The pad style isolator, which is available in either a neoprene version or spring version, is used to support the air handler from a base pad or structural frame.
  • Page 46 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 37: Pad Mounting Installation Instructions for Neoprene Isolator (Models TT112-TT218) 40 of 198...
  • Page 47 SECTION 8: VIBRATION ISOLATION FIGURE 38: Pad Mounting Installation Instructions for Neoprene Isolator (Model TT221) 41 of 198...
  • Page 48 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 39: Pad Mounting Installation Instructions for Neoprene Isolator (Models TT224-TT236) 42 of 198...
  • Page 49 SECTION 8: VIBRATION ISOLATION 8.3.2 Spring Mount Isolator The spring mount isolator includes a rectangular steel housing which incorporates the spring and load tensioning adjustment bolt. It is equipped with neoprene stabilizers to provide lateral control without binding. See Page 43, Figure 40. Spring style is normally selected when the equipment requires up to 1"...
  • Page 50 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 41: Pad Mounting Installation Instructions for Spring Isolator (Models TT112-TT218) 44 of 198...
  • Page 51 SECTION 8: VIBRATION ISOLATION FIGURE 42: Pad Mounting Installation Instructions for Spring Isolator (Model TT221) 45 of 198...
  • Page 52 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 43: Pad Mounting Installation Instructions for Spring Isolator (Model TT224-TT236) 46 of 198...

  • Page 53: Section 9: Roof Curb

    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 representative. 9.1 Roof Curb Assembly and Installation Assemble roof curb according to the assembly drawing on Page 48, Figure 44.
  • Page 54 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 44: Roof Curb B1/B2 NOTES: Curb is shipped unassembled. All dimensions are outside dimensions. Curb material is galvanized steel of 14ga to 12ga based on model. Nuts and bolts are (3/8" x 1") are furnished. Caulk (by others) all joints before assembling.

  • Page 55: Air Handler Mounting To Roof Curb

    The installer is responsible for tying the air handler to the curb per all applicable codes. See Page 49, Figure 45 for details. FIGURE 45: Installation of Legs DRILL SCREW LEGS INTO SIDE OF CABINET. 1.500 (TYP) WEATHER-RITE UNIT "B" DRILL SCREW CROSS 6.000 4.019 MEMBER TO LEGS.

  • Page 56: Section 10: Upright Stand

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 10: UPRIGHT STAND 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 57 SECTION 10: U PRIGHT TAND FIGURE 46: Upright Stand Detail Model Weight 36.0 36.0 28.0 TT112 & 91.4 91.4 71.1 56.7 TT115 36.0 60.0 30.0 TT118 91.4 152.4 76.2 63.5 36.0 60.0 28.0 TT212 91.4 152.4 71.1 63.5 36.0 72.0 28.0 TT215 91.4...
  • Page 58 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 47: Attaching Air Handler to Mounting Stand (TT112-TT221) BOLT FLAT WASHER FLAT WASHER LOCK WASHER TYPICAL FOR ALL CONNECTIONS Connecting Point (TYP Both Sides) Quantity of 1/2" Nuts, Model Bolts, Flat/Lock Washers 52 of 198...
  • Page 59 SECTION 10: U PRIGHT TAND FIGURE 48: Attaching Air Handler to Mounting Stand (TT224-TT236) BOLT FLAT WASHER FLAT WASHER LOCK WASHER TYPICAL FOR ALL CONNECTIONS Connecting Point (TYP Both Sides) Quantity of 1/2" Nuts, Model Bolts, Flat/Lock Washers 53 of 198...
  • Page 60 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 49: Stand Mounting Hole Detail for Floor/Slab (Models TT221-TT236) Short Sides of Air Handler Long Sides of Air Handler Model (in) 43.5 101.5 TT221 (cm) 110.5 257.8 (in) 53.5 113.0 TT224 (cm) 135.9 287.0 (in)

  • Page 61: Section 11: Vertical Mounting Legs

    SECTION 11: V ERTICAL MOUNTING SECTION 11: VERTICAL MOUNTING LEGS 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 62 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 51: Mounting Legs Installation Instructions DRILL SCREW LEGS INTO SIDE OF CABINET. 1.500 (TYP) WEATHER-RITE UNIT "B" DRILL SCREW CROSS 6.000 4.019 MEMBER TO LEGS. 2.500 4.334 9.000 SECTION A-A 9.500 9.500 LAG BOLT HOLES FOR FLOOR MOUNTING.

  • Page 63: Section 12: Filter Section

    Failure to follow these instructions can result in death, injury or property damage. All filter sections are shipped assembled. The TT118 filter section is an integral part of the burner section. NOTE: Check to be sure that all required components are present. If any are missing, contact your WEATHER-RITE ™ independent distributor.

  • Page 64: Filter Section Installation - Horizontal Air Handlers

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 12.1 Filter Section Installation - Horizontal Air Handlers For installation directly onto the inlet of the air handler, use the supplied hardware and bolt the filter section to the air handler through the pre-drilled holes. Supplied hardware must be torqued to recommended specifications on Page 10, Table 1.

  • Page 65: Filter Section Installation - Upright Air Handlers

    SECTION 12: F ILTER ECTION 12.2 Filter Section Installation - Upright Air Handlers For installation directly onto the inlet of the air handler, use the supplied hardware and bolt the filter section to the air handler through pre-drilled holes. If the air handler and filter section are to be set on a stand, mount the filter section to the stand first and then install the air handler.

  • Page 66: Section 13: Inlet Hoods

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 13: INLET HOODS 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 67: Inlet Hood Installation (Models Tt112 - Tt215)

    SECTION 13: I NLET OODS 13.1 Inlet Hood Installation (Models TT112 - TT215) Inlet hoods for models TT112 - TT215 are shipped in one piece. To install the inlet hood on the cabinet of the air handler, use the supplied hardware. See Page 61, Figure 54. To install the inlet hood on an exterior wall, drill holes every 8"...

  • Page 68: Inlet Hood Assembly (Models Tt218 And Tt221)

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 13.2 Inlet Hood Assembly (Models TT218 and TT221) Inlet hoods for standard TT218 and TT221 are shipped in two pieces. To install the inlet hood on the cabinet of the air handler, use the supplied hardware. See Page 62, Figure 55. To install the inlet hood on an exterior wall, drill holes every 8"...

  • Page 69: Inlet Hood Installation (Models Tt224 And Tt230)

    SECTION 13: I NLET OODS 13.3 Inlet Hood Installation (Models TT224 and TT230) Inlet hoods for standard TT224 and TT230 are shipped in five pieces. To install the inlet hood on the cabinet of the air handler, use the supplied hardware. See Page 63, Step 13.3.1. To install the inlet hood on an exterior wall, drill holes every 8"...
  • Page 70 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 13.3.2 1/2" Bolt Lock Washer Washer and Washer 1/2" Nut Step 1: Attach assembly made on Page 63, Step 13.3.1 to inlet section of air handler using supplied hardware. Quantity of 1/2" Nuts, Caulk mating surfaces Model Bolts, Flat/Lock Washers...
  • Page 71 SECTION 13: I NLET OODS Step 13.3.4 Step 1: Use supplied drill screws to attach assembly made on Page 64, Step 13.3.3 to the larger section of the inlet hood that was attached to the air handler on Page 64, Step 13.3.2. Drill Screws Caulk mating surfaces 65 of 198...
  • Page 72 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 13.3.5 Step 1: Drill screw factory supplied hood support channel through side of support and side flanges of inlet hood. Drill Screws NOTE: This view shown with half of the hood hidden to show support. Step 13.3.6 Step 1: Drill screw factory supplied hood support to bottom flange at base of unit.

  • Page 73: Inlet Hood Installation (Models Tt233 And Tt236)

    SECTION 13: I NLET OODS 13.4 Inlet Hood Installation (Models TT233 and TT236) Inlet hoods for standard TT233 - TT236 are shipped in two sections. To install the inlet hood on the cabinet of the air handler, use the supplied hardware. See Page 67 , Figure 56. To install the inlet hood sections on an exterior wall, drill holes every 8"...

  • Page 74: Section 14: Service Platform

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 14: SERVICE PLATFORM 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 75 SECTION 14: S ERVICE LATFORM FIGURE 57: Service Platform Upright Unit / Models TT224 through TT236 Upright Unit / Models TT112 through TT221 Horizontal Unit / All Models Table 30: Service Platform Model Weight TT112 & 48.0 36.0 42.0 TT115 121.9 91.4 106.7...

  • Page 76: Section 15: Dampers

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 15: 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 77: Inlet Damper Installation

    SECTION 15: D AMPERS FIGURE 58: Discharge Damper DRILL SCREWS (SUPPLIED BY OTHERS) Quantity of 1/4" Model Drill Screws 112-115 118-212 215-218 224-230 233-236 Table 31: Lag Bolts Model Quantity of Lag Bolts Recommended TT112 & TT115 TT118 & TT212 TT215 &...
  • Page 78 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 59: Inlet Damper Drill Screws or Lag Bolts (supplied by others) 72 of 198...

  • Page 79: Section 16: Discharge Plenum And Discharge Louvers

    SECTION 16: D ISCHARGE PLENUM AND ISCHARGE OUVERS SECTION 16: DISCHARGE PLENUM AND DISCHARGE LOUVERS 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 80: Double Deflection Discharge Louver Installation

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 16.2 Double Deflection Discharge Louver Installation All discharge louvers are shipped assembled. The discharge louvers are designed for mounting to the cabinet of the air handler (covering the discharge opening) or to an interior wall. To install the discharge louvers to the cabinet of the air handler, drive sheet metal screws or pop rivets (supplied by others) through the flanges into the air handler cabinet every 8"...

  • Page 81: Section 17: Duct Considerations

    SECTION 17: D ONSIDERATIONS SECTION 17: DUCT CONSIDERATIONS Proper engineering methods need to be employed when calculating duct and component static pressure WARNING (i.e. 2009 ASHRAE Handbook - Fundamentals, Chapter 21). The system ductwork must comply with Sheet Metal and Air Conditioning Contractors Nationals Association (SMACNA) or any other recognized standards.

  • Page 82: Inlet Air Duct

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 17.1 Inlet Air Duct Table 33: Minimum Discharge Duct Connection Size Inlet duct work height and width must be no smaller Model Height Width than the air handler inlet height and width and supply (in) 19.5 only uncontaminated air to the air handler.

  • Page 83: Section 18: Gas Piping

    SECTION 18: G IPING SECTION 18: GAS PIPING Table 34: Gas Train Capacities 18.1 Gas Manifolds Inlet Gas Pressure Manifold Size All gas piping to the air handler must comply with: Minimum Maximum Up to 999 1" 1 PSI United States: Refer to NFPA 54/ANSI Z223.1 - latest 7"...

  • Page 84: Gas Manifold Venting

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 18.3 Gas Manifold Venting • Use as short a vertical run of pipe as possible. • Do not run pipe from a high point to a lower point Vent valves fitted on XL-compliant manifolds on indoor installed air handlers must be piped to the to avoid obstacles.
  • Page 85 SECTION 18: G IPING FIGURE 63: ANSI Manifold 1000 - 5000 MBH - 1"-2" NPT HIGH GAS PRESS. SWITCH PROTECTS AGAINST EXCESSIVE GAS PRESSURE BLOCK GAS SOLENOID VALVE. SECONDARY BACK-UP VALVE TO PREVENT GAS FROM REACHING BURNER DURING SHUTDOWN. METERING VALVE. CONTROLS THE FLOW OF MAIN GAS SOLENOID VALVE.
  • Page 86 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 65: FM Manifold 700 MBH Less than 1000 MBH 1" NPT HIGH GAS PRESS. SWITCH PROTECTS AGAINST EXCESSIVE GAS PRESSURE POSITION INDICATING BLOCK GAS SOLENOID VALVE. e ll e y w H o n SECONDARY BACK-UP VALVE TO PREVENT GAS FROM REACHING BURNER DURING SHUTDOWN.
  • Page 87 SECTION 18: G IPING FIGURE 67: FM Manifold above 3000 MBH 2 ½" to 3" NPT HIGH GAS PRESS. SWITCH PROTECTS AGAINST EXCESSIVE GAS PRESSURE LOW GAS PRESS. SWITCH PROTECTS AGAINST INSUFFICIENT GAS PRESSURE. SHUT-OFF COCK. MANUAL SHUT OFF THAT ISOLATES THE GAS TRAIN ASSEMBLY FROM THE BURNER.
  • Page 88 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 69: XL Manifold 1000 - 5000 MBH 1" - 2" NPT VENT VALVE. HIGH GAS PRESS. SWITCH PROTECTS AGAINST EXCESSIVE GAS VENTS GAS THAT IS TRAPPED PRESSURE IN THE MANIFOLD BETWEEN THE MAIN & BLOCK VALVES, ON POSITION INDICATING BLOCK SHUTDOWN, TO THE OUTDOORS.

  • Page 89: Gas Piping

    SECTION 18: G IPING FIGURE 70: XL Manifold above 3000 MBH 2 ½" - 3" NPT HIGH GAS PRESS. SWITCH PROTECTS AGAINST EXCESSIVE GAS PRESSURE LOW GAS PRESS. SWITCH PROTECTS AGAINST INSUFFICIENT GAS SHUT-OFF COCK. PRESSURE. MANUAL SHUT OFF THAT ISOLATES THE GAS TRAIN ASSEMBLY FROM THE BURNER.

  • Page 90: Line Pressure Test - Leak Testing

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 71: Gas Pressure Taps (Manifold) 18.5.2 Burner Gas Pressure - 1/8" NPT A pressure tap is used to measure negative airflow at the burner and to set high fire gas pressure. The pressure tap is located on an elbow between the modulating valve and the burner.

  • Page 91: Section 19: Electrical

    SECTION 19: E LECTRICAL SECTION 19: ELECTRICAL 19.2 Remote Panel The remote panel must be wired as shown on the DANGER electrical schematic. All power supply and motor wiring must be type THWN - or equivalent, minimum with a 167 °F (75 °C) temperature rise.

  • Page 92: Safety Systems

    2,500 MBH and XL compliant gas trains above sold and supplied by Weather-Rite LLC. See Page 400 MBH) and are also available as an option on the 86, Figure 36 for a brief description of each safety others.

  • Page 93: Section 20: Sequence Of Operation

    SECTION 20: S EQUENCE OF PERATION SECTION 20: SEQUENCE OF OPERATION 20.1 Air Handler Configuration Based on the air handler application, the air handler DANGER may be configured in any of the following styles to achieve the described functionality. These configurations are available on all air handlers.

  • Page 94: Remote Panel Options

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 20.1.1 Make-Up Air (MUA) Style FIGURE 73: Air Handler Configurations The MUA style air handler has a constant speed Make-Up Air (MUA) blower that is designed to deliver a constant volume of air to the heated space. This style air handler supplies 100% outside air to the heated space and is not capable of supplying return air.
  • Page 95 SECTION 20: S EQUENCE OF PERATION Flame Failure Indicator: The burner control module burner for summer ventilation. has experienced a fault and will need to be reset. The Winter position: The blower and burner will operate burner control module must be reset at the air as needed for the application to maintain airflow and handler.

  • Page 96: Basic Sequence Of Operation

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 76: 8.3LS Remote Panel RMTC Summer/Off/Winter switch on the remote panel in the SUMMER position, power is supplied to the blower motor starter coil, allowing the blower motor to start. The burner circuit is NOT energized. Winter (Blower &...
  • Page 97 SECTION 20: S EQUENCE OF PERATION compliance requirements (ANSI, CSA, FM and XL). 2. The MEP100 and MEP 230-programmer mod- ule determines the operational characteristics of the control. It also has mounted on its exte- 20.4.1 Fireye ® MicroM Flame Safeguard rior, five (5) lights which indicate the operating This control is located in the center of the main status of the control.
  • Page 98 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 4. Flame On - This indicator comes on after the • Terminal #3 powers up the equipment's pilot gas flame safeguard has proven out the flame sig- solenoid valve which opens allowing gas to flow. nal.
  • Page 99 SECTION 20: S EQUENCE OF PERATION provided in the flame safeguard control. There is a stored within the programmer's eeprom memory after specified time for pre-purge, trial for ignition, and non 8 hours of continuous electrical operation. recycle. To set the dipswitches for their appropriate setting use the following procedure.
  • Page 100 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL network. illuminated at this time will be the OPERATING CONTROL. Thirty seconds after the lockout has • All interlocks, control relays and safety limits are activated, the alarm circuit is powered up, closed. Power is supplied to terminals #1 and #7 illuminating the ALARM LED.
  • Page 101 SECTION 20: S EQUENCE OF PERATION 3. PTFI - This acronym stands for Pilot Trial For This shuts off the power to the ignition module, Ignition. This indicator is on only during the trial which stops the spark at the burner. The for ignition period.
  • Page 102 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL tinuing activating the spark electrode if a haz- • Jumpers JP1 through JP5 are used to select the ardous malfunction takes place. purge timing for the M4RT1. The available purge timing selections are 5, 7, 30, 60, and 240 3.
  • Page 103 SECTION 20: S EQUENCE OF PERATION • All interlocks, control relays and safety limits are illuminated at this time will be the OPERATING CONTROL. Thirty seconds after the lockout has closed. Power is supplied to terminal #7 of the activated, the alarm circuit is powered up, flame safeguard.
  • Page 104 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 2. Pilot - this indicator comes on when power is the main fuel valve, terminal 9, is powered. If present at terminals #8 and #10 of the flame a flameout occurs, the flame safeguard safeguard.

  • Page 105: Air Volume Control Options

    SECTION 20: S EQUENCE OF PERATION options; See Page 98, Figure 85 and Page 98, Table indicating that the demand is satisfied or a limit has 39. If necessary, clip the site-configurable jumpers opened. with side cutters and remove the resistors from the relay module.
  • Page 106 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL (master/slave operation). As the VFD speeds the When switched to the low speed position, the blower blower up, the profile damper opens proportionally to motor switches to low speed providing low Air maintain the proper pressure drop across the burner. Volume operation.

  • Page 107: Night Setback Options

    SECTION 20: S EQUENCE OF PERATION 20.5.6 Space Pressure Controller With Minimum This option provides automatic control of occupied and unoccupied cycles, operated by an electric time clock. It includes a seven-day electronic time clock This option uses a building pressure sensor (for DDC (mounted on the remote panel).

  • Page 108: Other Control Options

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 20.7 Other Control Options run for a timed period (adjustable 1 to 100 minutes) after burner shutdown. It includes timer (mounted on 20.7.1 Exhaust Fan Interlock - Exhaust Fan Starts air handler). Air Handler This option provides an interlock between an exhaust fan and an air handler.
  • Page 109 SECTION 20: S EQUENCE OF PERATION This option provides a service receptacle. It includes ground-fault interrupter (GFI) receptacle (mounted on the air handler). Power to the receptacle is supplied by a 7A power source from the air handler itself. 20.7.14 UL-Listed Flame Control Panel This option provides for the air handler's control panel to be built to Underwriters Laboratories (UL) standards.

  • Page 110: Section 21: Temperature Controls

    NOTE: This is a field-installed device and location is critical. Make sure this sensor in mounted in the The ones used on Weather-Rite LLC equipment are; area of ductwork that has the most amount of air Series 14, 44, 94 and "M".
  • Page 111 SECTION 21: T EMPERATURE ONTROLS FIGURE 86: Series 14 Components 21.1.2 System Components For Series 44 area of ductwork that has the most amount of air moving through it. Recommended distance from • Space Temperature Sensors / Selectors air handler is 6 to 16 feet. These are combined temperature sensing / selection devices used to control the space to the •...
  • Page 112 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 21.1.3 System Components For Series 94 moving through it. Recommended distance from air handler is 6 to 16 feet. • Dual Temperature Selectors with LED Display These are non-temperature-sensing controls • Amplifier which set the temperature required in the spray This is a solid state control that receives its input cycle and in the dry cycle, while displaying the signal from the temperature selectors and...
  • Page 113 SECTION 21: T EMPERATURE ONTROLS that its resistance increases as its temperature be entered and stored while the standard MP2 increases. RTD is an acronym for Resistance amplifier only allows one program to be entered. Temperature Detector. As its name implies, the •...

  • Page 114: Section 22: Direct Fired Burner

    Failure to follow these instructions can result in death, electric shock, injury or property damage. The burner used by Weather-Rite is manufactured by Midco International ® , Inc., Model HMA-2A. The HMA- 2A is used for natural gas and propane (LP). The burner combines the two main ingredients needed for proper combustion air (oxygen) and fuel (gas whether natural or manufactured).

  • Page 115: Direct Fired Burner Ignition

    URNER FIGURE 90: Midco HMA-2A Burner 22.1 Direct Fired Burner Ignition The burner that is used in the Weather-Rite LLC unit is equipped with a pilot assembly. The pilot assembly consists of a pilot gas tube, spark electrode or rod and either a flame rod with grounding assembly or UV scanner.

  • Page 116: Direct Fired Burner Flame Proving (Flame Rod)

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 22.2 Direct Fired Burner Flame Proving (Flame Rod) The length the flame rod extends into the burner is The flame rod in the burner is constructed of a determined by the insulator surrounding the rod. This material that produces a signal when heated.

  • Page 117: Direct Fired Burner Flame Proving (Ultra Violet Scanner)

    SECTION 22: D IRECT IRED URNER 22.3 Direct Fired Burner Flame Proving (Ultra energized continuously by a high voltage. During Violet Scanner) combustion, UV radiation ionizes the gas, causing current pulses to flow between the electrodes. These The UV tube is made of quartz and is filled with a gas current pulses result in a flame signal which is that ionizes when struck by UV radiation from the transmitted to the amplifier in the control where it is...

  • Page 118: Section 23: Direct Fired Process Air Heaters

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 23: 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. required to disconnect electric from equipment.

  • Page 119: Direct Fired Process Air Heater Models

    These filters must be approved by the Process Heater, that can be used by personnel authority having jurisdiction of the installation. to enter the space. If additional burn hazard warnings are needed, contact Weather-Rite 113 of 198...

  • Page 120: Installer's Responsibility For Process Heaters Connected To Paint Booths

    FUSE F3 • The installer must ensure that the Outside Air FUSE F1 120 V Damper, when supplied by Weather-Rite LLC, is CONTROL TRANSFORMER set to provide proper airflow for combustion and to make sure the recirculation air is properly diluted...

  • Page 121: Weather-Rite

    TERMINAL LOCATED ON REMOTE STATION from operating for a minimum of 3 minutes or FIELD WIRING at least 4 air changes of the space. See Page 115, Figure 98. 23.4 WEATHER-RITE ™ Control Packages Various control packages are available to FIGURE 98: Purge Circuit complement the process heaters.
  • Page 122 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL • Booth Lighting On/Off Switch, fusing and • Switch in "Summer" position for fan only or contactor (supply power for lights by others). "Winter" position for fan and burner. • Process Heater's discharge damper opens to 2.Operation: 100% open position.
  • Page 123 SECTION 23: D IRECT FIRED PROCESS AIR HEATERS FIGURE 101: WRP-2 • Booth lights operated by on/off switch. • Booth balancing pot provides fine tune adjustment of exhaust fan speed to maintain booth pressure. DRY CYCLE START LIGHTS 3.Operation - Dry Mode: HOLD BLOWER •...
  • Page 124 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 23.4.4 WRP - 3R Remote Control Station - 100% • Temperature based on Dry temperature set Ventilation Air and 90/10 Recirculating Cure Sys- point. tem - VFD Exhaust • When Dry cycle is completed, cool-down cycle 1.
  • Page 125 SECTION 23: D IRECT FIRED PROCESS AIR HEATERS adjusts exhaust fans to maintain booth FIGURE 104: WRP-4 pressure. 2.Operation - Paint Mode: • Switch in "Summer" position for fan only or DRY CYCLE START LIGHTS "Winter" position for fan and burner. HOLD BLOWER •...
  • Page 126 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL • Dry mode: • NEMA1 hinged control panel. • Activate switch to either "Summer" or "Winter" • System On & Off Push Buttons, Cure Push position Button & Heat Auto/On Switch. • Turn Dry Cycle Start Timer to desired time •...
  • Page 127 SECTION 23: D IRECT FIRED PROCESS AIR HEATERS • During cool-down cycle, the Process Heater and exhaust fan revert to 100% airflow position (operating as if in paint mode). • Process Heater and exhaust fan shut down after cool-down cycle. 4.Cure Mode (90/10 Recirculating Cure system): •...

  • Page 128: Section 24: Start-Up Procedures

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 24: 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 129: Installation Of Recirculating Air Handler

    This procedure should be Correct Alignment completed by the commissioning contractor and returned to Weather-Rite LLC. If the document is not returned, the manufacturing date will be used as the warranty start date. 24.1 Installation of Recirculating Air Handler...

  • Page 130: Electrical

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL V-belt and a motor sheave measuring an ammeter. Measure the system current draw again after the burner adjustments are made between 5.8" (1.59 cm) and 8.6" (21.84 cm), and with the burner and blower both on. the belt will have proper tension if a 5/8"...
  • Page 131 SECTION 24: S TART ROCEDURES 24.4.1.1 Differential Pressure Adjustment Manual pressure and away from burner to decrease Profiles pressure. Check pressure over the full operating range of the unit when done. See Page 124, Figure To adjust the differential pressure that was measured in the step above, use the profile damper adjustment quadrants located above and below the burner access panel for horizontal configuration or on either...
  • Page 132 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL NOTE: Open the burner observation port and • After the burner has ignited and run for 30 examine the burner flame. The flame should be a seconds, measure the discharge temperature. brilliant blue with short (approx. 1" to 2") yellow •...

  • Page 133: Gas Piping And Initial Pressure Settings

    SECTION 24: S TART ROCEDURES finger tips. critical items to consider before adjusting low fire: A. Low fire adjustment does not regulate gas 24.5 Gas Piping and Initial Pressure Settings pressure. Perform a pressure test on all gas supply lines B.
  • Page 134 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 112: Pilot Pressure Tap PILOT PRESSURE TAP. PILOT SOLENOID VALVE. ALLOWS GAS TO FLOW TO THE BURNER PILOT. PILOT GAS REGULATOR CONTROLS THE AMOUNT OF GAS FLOW TO THE PILOT SHUT-OFF COCK BURNER'S PILOT TUBE.
  • Page 135 SECTION 24: S TART ROCEDURES FIGURE 113: Maxitrol MR212 Valve Low Fire Adjustment (loosen locking screw before adjustment) High Fire Adjustment 129 of 198...
  • Page 136 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 114: Regulator RV61 130 of 198...

  • Page 137: Safety Shut Off Valve Check

    SECTION 24: S TART ROCEDURES FIGURE 115: Maxitrol M611 Valve Gas Inlet Low Fire Adjustment Gas Outlet (under cap) 24.6 Safety Shut Off Valve Check profile linkage range. See Page 125, Section 24.4.2.1. After the initial start up and gas pressure adjustment, verify gas soundness of each SSOV (Safety Shut Off •...
  • Page 138 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL • Recheck air pressure drops across burner on high • Take air pressure drop across burner profiles. and low airflow settings. • If below recommended setting, decrease the • Minimum motor speed is factory set and should profile linkage range of travel without altering the not be adjusted unless specifically directed to do high speed position.

  • Page 139: Section 25: Maintenance

    SECTION 25: M AINTENANCE SECTION 25: 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 140: General

    WEATHER-RITE ™ equipment sold and supplied by Weather-Rite LLC and conform and perform service where necessary, using only ™ replacement parts sold and supplied by Weather-Rite to all requirements set forth in the WEATHER-RITE LLC.
  • Page 141 SECTION 25: 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 con- tact.
  • Page 142 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 143: Motor And Drive Components

    SECTION 25: M AINTENANCE 25.4 Motor and Drive Components Gain access to the blower and motor by removing the belt guard or weather- proof cover. First, release tension on the belts by adjusting the motor base closer to the blower pulley. Remove the belts. To remove the motor pulley, first loosen the adjustment set screws and count the number of turns to fully close the pulley (this number will be required to reinstall the pulleys to the previous adjustment).

  • Page 144: Supply Blower

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 25.5 Supply Blower The supply air is handled by DWDI (double width, double inlet) blower wheel(s) mounted on either a solid or tubular shaft. The blower wheel(s) are attached to this shaft via two setscrews or two clamps (tubular shaft style) (one on each side of the wheel).

  • Page 145: Burner

    SECTION 25: M AINTENANCE 25.7 Burner An annual inspection of the burner and components must be made to ensure proper and safe operation. For the most part, the burner is self cleaning. However, if the application is extremely dirty or dusty, it may become neces- sary to periodically clean the burner.
  • Page 146 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 12. If your flame sensor is a scanner, clean the lens with a clean damp soft rag. A flame rod's metal rod should be clean and free of dirt and carbon. Like the spark rod igniter, the porcelain on the flame rod must be intact as well.

  • Page 147: Section 26: Replacement Parts

    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. See warnings and important information before removing or replacing parts. After any maintenance or repair work, always test fire the heater in accordance with the start-up instructions on Page 122, Section 24 to help ensure all safety systems are in working order before leaving the heater to operate.
  • Page 148 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Model Description Part Number Quantity BEARING 81900000 BEARING DRIVE END 81900110 TT233 SHAFT 30315702 WHEEL 82000073 BEARING 81900000 BEARING DRIVE END 81900116 TT236 SHAFT 30315900 WHEEL 82000083 26.1.2 Bushing, Fixed Pulley Description Size (in) Part Number 82200580 1 3/16...
  • Page 149 SECTION 26: R EPLACEMENT ARTS 26.1.3 Fixed Pulley Description Part Number 1B X 11.0 1-3/16 82105120 1B X 11.0 PD SDS 14093210 1B X 12.4 1-3/16 82105140 1B X 12.4 PD SDS 14189300 1B X 13.6 1-3/16 82105150 1B X 13.6 PD SDS 82105160 1B X 16.0 PD SDS 82100270...
  • Page 150 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Description Part Number 3B X 20.0 PD SF 82100950 3B X 25.0 PD SF 82100960 3B X 30.0 PD SF 82100970 3B X 31.5 PD SH 14120900 3B X 4.4 PD SD 82100700 3B X 4.6 PD SD 82100710 3B X 4.8 PD SD...
  • Page 151 SECTION 26: R EPLACEMENT ARTS Description Part Number 1B x 5.0-6.5 1-3/8" 82105930 1B x 6.0-7.4 1-1/8" 82101630 1B X 6.3-7.3 1-1/8" 14128900 2B X 3.5-4.9 1-3/8" 82101810 2B X 3.5-4.9 7/8" 82101790 2B X 4.3-5.3 1-3/8" 82101890 2B X 4.3-5.4 1-3/8 14228905 2B X 4.5-5.9 1-5/8"...
  • Page 152 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 26.1.5 Belts Description Part Number B-036 33689436 B-040 33689440 B-041 33689441 B-042 33689402 B-043 33689443 B-044 33689444 B-045 33689445 B-046 33689446 B-047 33689447 B-048 33689448 B-050 33689450 B-052 33689452 B-053 33689453 B-054 33689454 B-057 33689457 B-058...

  • Page 153: Damper Components

    SECTION 26: R EPLACEMENT ARTS Description Part Number B-120 33689420 B-128 33689428 B-150 33689411 B-154 33689413 BX-49 33689549 BX-50 33689550 BX-51 33689551 BX-52 33689552 BX-62 33689562 BX-64 33689564 BX-65 33689565 BX-67 33689567 BX-70 33689570 BX-72 33689572 BX-76 33689576 BX-77 33689577 BX-78 33689578 BX-80...

  • Page 154: Burner Components

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Description Part Number MODULATING FOOT MOUNT WITH END SWITCH 83400051 24V NO SW SPRING RETURN 14321500 24V WITH SW ZERO SPAN SPRING RETURN 14321501 24V NO SW ZERO SPAN SPRING RETURN 14321502 20V WITH SW SPRING RETURN 14321510 120V WITH SW SPRING RETURN 14321511...

  • Page 155: Manifold Components

    SECTION 26: R EPLACEMENT ARTS 26.4 Manifold Components Description Part Number SOLENOID VALVE - 3/8" (PILOT) 14036400 SOLENOID VALVE - 1" 82500031 SOLENOID VALVE - 1.25" 82500040 SOLENOID VALVE - 1.5" 10762900 SOLENOID VALVE - 2" 82500060 Description Part Number SOLENOID VALVE - POSITION INDICATION - 1"...
  • Page 156 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL HIGH GAS PRESSURE SWITCH 83100070 IGNITION CABLE (PER FOOT) 81400400 IGNITION CABLE BOOT 81150420 IGNITION CABLE SNAP FITTING 81150440 FIREYE ULTRA VIOLET SCANNER 83500022 HONEYWELL ULTRA VIOLET SCANNER 15159701 PILOT OFF TIMER 14197700 150 of 198...

  • Page 157: Electrical Components

    SECTION 26: R EPLACEMENT ARTS 26.5.2 Flame Safeguards Description Part Number FLAME SAFEGUARD RELAY MODULE 15159600 FLAME RELAY SUB-BASE 15160001 AMPLIFIER - FLAME ROD 15159802 AMPLIFIER - ULTRAVIOLET 15159801 PURGE TIMER 7 SEC 15159701 FLAME SAFEGUARD RELAY MODULE 14169810 FLAME RELAY SUB-BASE 83500010 PROGRAMMER - RECYCLE 14170010...
  • Page 158 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 26.6.2 Contactors Description Part Number 18 AMPS 14320703 25 AMPS 14320704 32 AMPS 14320705 40 AMPS 14320706 50 AMPS 14320707 65 AMPS 14320708 80 AMPS 14320709 115 AMPS 14320710 150 AMPS 14320711 26.6.3 Overloads Description Part Number .4-.63 AMPS...
  • Page 159 SECTION 26: R EPLACEMENT ARTS 26.6.5 Miscellaneous Electrical Components Description Part Number CLOGGED FILTER PRESSURE SWITCH 8024206082 83100006 INDICATOR LIGHT - NEON - AMBER - 120 VAC 14297311 INDICATOR LIGHT - NEON - GREEN - 120 VAC 14297313 INDICATOR LIGHT - NEON - RED - 120 VAC 14297310 INDICATOR LIGHT - NEON - WHITE - 120 VAC 14297312...

  • Page 160: Miscellaneous Mechanical Components

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 26.7 Miscellaneous Mechanical Components Description Part Number Door Handle - Control Panel, Slotted, Compression 14303506 Door Handle - Cabinet Doors, Latch 10500401 Profile Quadrants #640 81100030 Volumatic Outdoor Pressure Sensor, Static Pressure Sensor Kit 33628800 Cabinet Door Gasket, Gasketing 1/2"...
  • Page 161 SECTION 26: R EPLACEMENT ARTS 2 x 20 x 20 82400160 Permanent 2 x 20 x 25 82400170 2 x 20 x 20 82400070 Disposable 2 x 20 x 25 82400080 2 x 20 x 20 82402870 TT224 30% Pleated 2 x 20 x 25 82402860 20 x 20...

  • Page 162: Section 27: Troubleshooting

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 27: 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 163: Initial Checks

    SECTION 27: T ROUBLESHOOTING The following is divided into two basic categories - fan problems and burner problems. In some cases, they interrelate. In order to use this effectively, you should familiarize yourself with both categories. 27.1 Initial Checks When encountering any abnormal operation or fault conditions of the equipment, all troubleshooting should start with the following initial checks.

  • Page 164: Burner

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 27.3 Burner PROBLEM POSSIBLE CAUSE SOLUTION Flame control does not try Auxiliary contact "M1" not closed? Properly mount contact or replace for ignition Replace switch High temp limit switch tripped? Manually reset or replace Low airflow pressure switch contacts not made? Check blower operation Reconnect tubes to pressure switch...

  • Page 165: Temperature Controls

    SECTION 27: T ROUBLESHOOTING Burner (continued) PROBLEM POSSIBLE CAUSE SOLUTION No main flame Manual shut off valve closed Open manual shut off valve Safety Shut Off Valve not operating. Is there Check wiring from burner control to positive gas pressure downstream of SSOV? SSOV Verify inlet gas pressure Replace SSOV...
  • Page 166 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 5. After test, remove the test resistor and recon- • Proceed slowly with the above steps so as nect the Discharge Air Sensor to terminals 3 to allow the temperature measuring and 4. If Remote Temperature Selector has instrument to catch up with the change in been moved return it to its original position.
  • Page 167 SECTION 27: T ROUBLESHOOTING 161 of 198...
  • Page 168 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 27.5.4 Series 14 - Field Service 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.
  • Page 169 SECTION 27: T ROUBLESHOOTING 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 170: Series 44 - Preliminary Circuit Analysis

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 27.6 Series 44 - Preliminary Circuit Analysis to check operation of sensing and selecting components. If proper operation is not observed, see This Preliminary Circuit Analysis will provide Field Service Checklist to test M or MR valves and identification of faulty components, improper wiring or connecting wiring.
  • Page 171 SECTION 27: T ROUBLESHOOTING • If hunting is encountered (rapid oscillation), Discharge Air Temperature Selector. Set the Discharge Air Temperature Selector for the rotating the sensitivity control counterclockwise desired room temperature. Because of the may dampen the oscillation, stabilizing the flame. large space being heated, wait at least one half •...
  • Page 172 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 27.6.4 Series 44 - 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.
  • Page 173 SECTION 27: T ROUBLESHOOTING 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 174: Series 94 - Preliminary Circuit Analysis

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 27.7 Series 94 - Preliminary Circuit Analysis 27.7.1.1 Calibration of Spray Temperature Selector In order to diagnose the cause of problems in this system it is necessary to determine certain values. It NOTE: Calibration can not be done if room is helpful to have a volt/ohm multimeter.
  • Page 175 SECTION 27: T ROUBLESHOOTING 169 of 198...
  • Page 176 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 27.7.2 Series 94 - Field Service Checklist 170 of 198...
  • Page 177 SECTION 27: T ROUBLESHOOTING 171 of 198...

  • Page 178: Series Mp - Trouble Shooting

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 27.8 Series MP - Trouble Shooting The MP2 and MP2+ have built in diagnostics; refer to the following programming guides for setup and troubleshooting information. Thoroughly read entire MP Section to guarantee proper usage of MP2 or MP2+ system. MP2+ system requires initial programming before accessing process menu.
  • Page 179 SECTION 27: T ROUBLESHOOTING Example 80° F -5° F 75° F 1. Program Offset to -5° F 2. Program Process Set Point (desired space temperature) to 75° F. 3. Therefore discharge air temperature = 80° F. (Required [MP2 or MP2+] discharge air temperature to maintain desired space temperature.) 4.
  • Page 180 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 27.8.1.2 Operation Menu Max Proc Temp This feature limits the maximum temperature for each Process. It has a range of 60 °F (15 °C) to 240 °F (115 °C). It does not allow the Process Set Point to be set in excess of the Maximum Process Temperature setting.
  • Page 181 SECTION 27: T ROUBLESHOOTING Looping Mode The looping mode feature is used to select the controllers default position on startup and (TM02 after the last process of a program is completed. applications Selecting "READY" only) Power up: "READY" is displayed. Requires a momentary switch closure to move the controller to the first process.
  • Page 182 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Soft Start Off, Slow, Medium, Fast Max Valve VDC 7 to 25 VDC Max Ramp VDC 5 to 24 VDC Total Bandwidth 5 °F(2.8 °C) to 15 °F (8.3 °C) Offset Temp Offset Temp Process #(1 - 8) -10 °F(-5.6 °C) to + 10 °F(5.6 °C) Ramping Ramping Process #(1 - 8) Off, 60 Deg/hr to 900 Deg/...
  • Page 183 SECTION 27: T ROUBLESHOOTING Press and release once to switch to the next Process or to move the controller from the "READY" position to the First Process. Press twice or hold for 10 seconds to abort a timed process. Table 46: Screen Indicators Display Description **STORED**...
  • Page 184 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 27.8.3 Series MP2+ Select User Information The initial programming has a maximum of 8 programs available. Each program has a maximum of 8 processes set points. The program and process set point in use is displayed as P(1-8) S#(1-8). Programs utilize global settings.
  • Page 185 SECTION 27: T ROUBLESHOOTING Max Valve VDC (Global Setting for MP2+ system) 2 Scroll to max valve VDC, press 3 Max Valve VDC, set voltage value (7 V to 25 V), press 4 **Stored** will flash 4 times to confirm entry. Max Ramp VDC 2 Scroll to Max Ramp VDC, press...
  • Page 186 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 3 Maximum Temp Process #, scrol to Set Points #, press 4 Max T Proc #, set Temp value (60 °F (15 °C) to 240 °F (115 °C), press 5 **Stored** will flash 4 times to confirm entry. 6 Repeat steps 2 - 5 for Set Points #(2-8) Min Proc Temp (Global Setting for MP2+ system) 2 Scroll...
  • Page 187 SECTION 27: T ROUBLESHOOTING 27.8.5 Series MP Operation 27.8.5.1 MP2 Process Control System Push and release Button 1 on dial face (See Page 176, Table 45 (programming buttons) ) or momentarily latch (make) a set of contacts wired to the TB1 terminal (i.e. typically accomplished by a momentary ON (normally open) switch) to proceed to the next Pro- cess.
  • Page 188 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 27.8.6 Switching to the Next Programmed Process: Timed Nothing is required. The MP2+ system will immediately proceed to the next programmed Processes process after timing out. NOTE: If the last Process of a program is timed, it will proceed either to the "READY" posi- tion or to the First Process.
  • Page 189 SECTION 27: T ROUBLESHOOTING Short circuit in TS194(Q) Dis- Check TS194(Q) for internal short cir- charge Air Sensor circuit or wir- cuit. See Temperature Sensor Function ing. of Preliminary Circuit Analysis. Continuous high fire Perform remedy for possible cause 1 (electronic problem) and 2 above.
  • Page 190 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Observed Problem Possible Cause Remedy Increase bandwith setting. See Opera- tion Menu programming in MP2(+) User's Programming Guide. If flame 1 Hunting stabilizes, reduce bandwith to the mini- mum setting where a stable flame can be maintained.
  • Page 191 SECTION 27: T ROUBLESHOOTING Remove power. Disconnect and recon- Bad cable connection between nect cable securely. Restore power. If dial and amplifier. "Ready…" remains, replace or consult Maxitrol Company. Dial cable disconnected and Remove and restore power. If reconnected with system pow- "Ready…"...

  • Page 192: Flame Safeguard

    TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 27.9 Flame ® Safeguard 27.9.1 Fireye ® MicroM FIGURE 117: Fireye ® Micro M Service Guide Page 1 LOCKOUT INTRLCK PTFI FLAME MESSAGE CTRL ● ❍ ❍ ● LINE FREQUENCY NOISE ❍ ● ●...
  • Page 193 SECTION 27: T ROUBLESHOOTING FIGURE 118: Fireye ® Micro M Service Guide Page 2 187 of 198...
  • Page 194 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL second PFEP selection. It also allows for pilot 27.9.2 Fireye ® M4RT1 turn-down test and other burner adjustments. This The Fireye ® M4RT1 is a self contained version of the activates a fifteen-second flameout timer that MicroM flame safeguard.
  • Page 195 SECTION 27: T ROUBLESHOOTING Code 3-1 Running or Lockout 1. Check wiring; correct any errors. *Running/ Interlock fault during 2. Inspect the fan; make sure there is no air intake blockage and that it is supplying air. Interlock Switch Prepurge. 3.
  • Page 196 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Code 5-3 Man-Open Switch, Start 1. Check wiring and correct any errors. *Man-Open Sw.; Start Switch or Control On in 2. Make sure that the Manual Open Valve Switch, Start Switch and Control are operating properly. Sw.

  • Page 197: Weather-Rite

    SECTION 27: T ROUBLESHOOTING 27.10 WEATHER-RITE ™ TT-Series Start-Up Procedure WEATHER-RITE™ TT-SERIES START-UP Start Up Date: Model: Serial No: Installation Name: Start Up Contractors Name: Phone No: Name of Technician Doing Start Up: Type of Gas: Nat: Check installation site to ensure all codes and engineering specifications are correct.
  • Page 198 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 192 of 198...
  • Page 199 SECTION 27: T ROUBLESHOOTING START-UP "HEAT" Note ambient air temperature, with the unit running in the "no heat" mode. Ambient air temperature: __________ deg. F Check to see that only the pilot shut off valve is open. Reset the optional low gas pressure switch if the unit is equipped with it.
  • Page 200 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL The following items should be completed during final walk through with the customer. Personnel Training Review: It is important that everyone concerned with the operation and maintenance of the equipment be trained in the safety procedures contained in the operation and maintenance manuals.

  • Page 201: Section 28: The Weather-Rite

    616 North 5th Street Minneapolis, MN 55401-1236 Weather-Rite LLC will require the part in question to be returned to the factory. Weather-Rite LLC will, at its sole Telephone: +1.612.338.1401 discretion, repair or replace after determining the nature of Fax: +1.612.338.6783...
  • Page 202 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 196 of 198...
  • Page 203 SECTION 28: T WEATHER-RITE ™ TT-S ERIES ARRANTY 197 of 198...
  • Page 204 TT-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 198 of 198...
  • Page 205 To help facilitate optimum performance and safety, Weather-Rite LLC recommends that a qualified contractor conduct, at a minimum, annual inspections of your WEATHER-RITE ™...

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