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Installation, Operation, and Maintenance Manual
Modular Direct Fired Heater
Direct Fired Module
The use and storage of gasoline or other flammable vapors and liquids in open containers in the
vicinity of this appliance is hazardous.
Upon receiving unit, check for any interior and exterior damage, and if found, report it
immediately to the carrier. Also check that all accessory items are accounted for and are
damage free. Turn the blower wheel by hand to verify free rotation and check the damper (if
supplied) for free operation.
Improper installation, adjustment, alteration, service or maintenance can cause property
damage, injury or death.
thoroughly before installing or servicing this equipment. ALWAYS disconnect power and gas
prior to working on heater.
Save these instructions. This document is the property of the owner of this equipment and is
required for future maintenance. Leave this document with the owner when installation or
service is complete.
Standard and Modular Direct Fired Heaters
If you smell gas:
1.
2.
3.
4.
FOR YOUR SAFETY
RECEIVING AND INSPECTION
WARNING!!
Read the installation, operating and maintenance instructions
Standard Direct Fired Heater
FOR YOUR SAFETY
Open windows.
Don't touch electrical switches.
Extinguish any open flames.
Immediately call your gas supplier.
May 2008 Rev. 11
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Table of Contents
Troubleshooting
Related Manuals for Energy Tech Laboratories MR212
Summary of Contents for Energy Tech Laboratories MR212
- Page 1 Standard and Modular Direct Fired Heaters Installation, Operation, and Maintenance Manual Modular Direct Fired Heater Standard Direct Fired Heater FOR YOUR SAFETY If you smell gas: Open windows. Don’t touch electrical switches. Extinguish any open flames. Immediately call your gas supplier. Direct Fired Module FOR YOUR SAFETY The use and storage of gasoline or other flammable vapors and liquids in open containers in the...
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Page 3: Table Of Contents
TABLE OF CONTENTS WARRANTY ..............................4 INSTALLATION ............................. 5 Mechanical ..............................5 Site Preparation ............................ 5 Assembly .............................. 5 Curb and Ductwork ..........................5 Roof Mount Installation ......................... 6 Installation with Exhaust Fan ........................ 6 Direct Fired Module Installation ......................7 Indoor (INLINE) Installation ........................ -
Page 4: Warranty
WARRANTY This equipment is warranted to be free from defects in materials and workmanship, under normal use and service, for a period of 12 months from date of shipment. This warranty shall not apply if: 1. The equipment is not installed by a qualified installer per the MANUFACTURER’S installation instructions shipped with the product, 2. -
Page 5: Installation
INSTALLATION It is imperative that this unit is installed and operated with the designed airflow, gas, and electrical supply in accordance with this manual. If there are any questions about any items, please call the service department at 1-866-784-6900 for warranty and technical support issues. Mechanical WARNING: DO NOT RAISE VENTILATOR BY THE INTAKE HOOD, BLOWER OR MOTOR SHAFT, OR BEARINGS –... -
Page 6: Roof Mount Installation
through vertical portion of the ventilator base Recommended Supply Ductwork Sizes assembly flange using a minimum of eight (8) lug Blower Size Duct Size Straight Duct Length screws, anchor bolts, or other suitable fasteners (not 14 x 14 48 in. furnished). -
Page 7: Direct Fired Module Installation
Direct Fired Module Installation Indoor (INLINE) Installation Heat Module Add-On Installation Modular heat units shipped to add heat onto existing blower only applications require field mechanical and wiring installation. 1. Remove existing filter intake and lifting lugs from blower section intake side. 2. -
Page 8: Gas
Installation of gas piping must conform with local building codes, or in the absence of local codes, with the National Fuel Gas Code, ANSI Z223.1 (NFPA 54) – latest edition. In Canada, installation must be in accordance with CAN/CGA-B149.1 for natural gas units and CAN/CGA-B149.2 for propane units. WARNING: INLET GAS PRESSURE MUST NOT EXCEED PRESSURE INDICATED ON NAMEPLATE. -
Page 9: Electrical
Electrical Before connecting power to the heater, read and understand this WARNING!! entire section of this document. As-built wiring diagrams are Disconnect power before furnished with each fan by the factory, and are attached to the installing or servicing fan. High door of the unit. -
Page 10: Remote Control Panel
Remote Control Panel On units shipped with the optional remote control panel, an electrical drop containing the panel wiring is provided with the heater. There is a terminal strip inside the remote panel that matches the terminals in the heater unit. The remote panel should be wired as shown below. Fire System Microswitch Fan to Building Wiring Connection... -
Page 11: Operation
OPERATION Prior to starting up or operating the heater, check all fasteners for tightness. In particular, check the set screw in the wheel hub, bearings and the fan sheaves (pulleys). With power and gas to the heater OFF or prior to connecting ventilator to power, turn the fan wheel by hand to be sure it is not striking the inlet or any obstacles. -
Page 12: Main Burner Adjustment
Main Burner Adjustment Mod Valve Voltage Summary 1. Once the pilot has been properly established, the manifold gas pressure or temperature rise should be Volts DC Firing Mode adjusted to jobsite conditions. The gas pressure 0 to 5 VDC Low Fire regulator (integral to the combination gas control on size 5 to 15 VDC Modulation... -
Page 13: Heater Start Up Summary
Heater Start Up Summary Is incoming gas pressure Adjust 7"-14"? incoming gas (7"-5 psi. for size 4-5 units) pressure. Adjust pilot flame. Setting incoming pressure: Presure must be measured at first "T" in supply gas line before the first gas valve. Adjusting the pilot: The pilot DC signal should be 12 VDC minimum. -
Page 14: Final Start Up Procedure
Final Start Up Procedure 1. With the air and burner systems in full operation and all ducts attached, measure the system airflow. Motor sheave (pulley) is variable pitch, and allows for an increase or decrease of the fan RPM to adjust the airflow, as shown in the illustration below. For your convenience, a RPM chart is included in the following pages. -
Page 15: Pulley Combination Chart
Pulley Combination Chart Motor RPM 1725 1/3 to 1-1/2 HP MOTOR PULLEY AX BELTS 1VL34 Open TURNS ON MOTOR PULLEY Closed BLOWER PULLEY DATUM DIAMETER PITCH DIAMETER 4 1/2 3 1/2 2 1/2 1 1/2 AK114 11.2 1/3 to 2 HP MOTOR PULLEY AX BELTS 1VL40... -
Page 16: Sequence Of Operation
Sequence of Operation The direct-fired heater is most easily understood when broken down into smaller individual systems. There are two main systems, a make-up air fan and a heater. The make-up air fan consists of a blower and motor. The heater may be further broken down into two control systems, the Flame Safety Control (FSC) and the Modulating Gas System (MGS). -
Page 17: Modulating Gas System
airflow switch to close. The high airflow switch protects against profile plate failures that cause excessive airflow through the burner. In the event that the pressure drop across the burner is not in the range of the airflow switch, gas flow to the burner is stopped by the Flame Safety Control. The graphs below illustrate the approximate cfm going through the unit vs. -
Page 18: Optional Remote Panel Circuit
Begins Pilot Trial For Ignition and turns on PTFI LED The pilot gas solenoid valve is opened, the spark igniter begins sparking, and the flamerod sensor watches for flame initiation When flame is established, the FLAME LED is illuminated and main valve opens and the FSC powers the Maxitrol system and gas flow begins modulating The FSC monitors the flame while the Maxitrol system adjusts to the selected temperature •... -
Page 19: Components
Components The following image and list outlines the typical direct fired heater components and their functions. 1. Gas Inlet – Main gas supply connection 2. Motor Starter – Contactor with overload protection to start and protect motor. 3. Freeze-Stat Thermostat (Optional) – De-energizes blower motor if the discharge air temperature falls below the set point. -
Page 20: Remote Panel Option
Remote Panel Option The Remote Panel is a device used to control the operation of the heater from a remote location. This unit is available in both a “2 Position” or “3 Position” configuration and with or without a cooling output. It also will accommodate both the Maxitrol discharge temperature dial and the Maxitrol space sensing Selectrastat. -
Page 21: Troubleshooting
Troubleshooting The following tables list causes and corrective actions for possible problems with direct fired heater units. Review these lists prior to consulting manufacturer. Airflow Troubleshooting Chart Problem Potential Cause Corrective Action Fan Inoperative Blown fuse or open circuit breaker Replace fuse or reset circuit breaker and check amps Disconnect switch in “Off”... -
Page 22: Burner Troubleshooting Chart
Burner Troubleshooting Chart Problem Potential Cause Corrective Action Pilot Does Not Light/Stay Lit Main gas if off Open main gas valve Air in gas line Purge gas line Dirt in pilot orifice Clean orifice with compressed air Gas pressure out of range Adjust to proper gas pressure Pilot valve is off Turn pilot valve on... -
Page 23: Remote Panel Troubleshooting Chart
Remote Panel Troubleshooting Chart Light Indication Condition Possible Cause No Lights Power not available to Remote Panel Bad voltage to unit Main disconnect in “OFF” Position Circuit breaker tripped Bad main transformer POWER Light Only Proper unit Off Operation No problem No power to motor starter Manual/Off/Auto Switch in “Off”... -
Page 24: Troubleshooting Flowcharts
Troubleshooting Flowcharts Adjust Blower runs Is the air flow LED Adjust pulley to Is Overload Reset & measure FLA Nothing but there is on Flame Saftey achieve proper tripped on of motor. Is it higher Happens change no heat illuminated? airflow. -
Page 25: Maintenance
MAINTENANCE To guarantee trouble free operation of this heater, the manufacturer suggests following these guidelines. Most problems associated with fan failures are directly related to poor service and maintenance. Please record any maintenance or service performed on this fan in the documentation section located at the end of this manual. -
Page 26: Weeks After Startup
2 weeks after startup 1. Belt tension should be checked after the first 2 weeks of fan operation. Belts tend to stretch and settle into pulleys after an initial start-up sequence. Do not tension belts by changing the setting of the motor pulley, this will change the fan speed and may damage the motor. To re- tension belts, turn the power to the fan motor OFF. -
Page 28: Start-Up And Maintenance Documentation
Airflow Maxitrol 14 Switch amplifier Start-Up and Maintenance Documentation START-UP AND MEASUREMENTS SHOULD BE PERFORMED AFTER THE SYSTEM HAS BEEN AIR BALANCED AND WITH THE HEAT ON (Warranty will be void without completion of this form) Job Information Job Name Service Company Address Address...