Applied Air GAS-FIRED HEATERS Installation & Operation Instruction

Indirect gas-fired heaters including units with ddc controls

Hide thumbs

Table Of Contents

Table of Contents

Quick Links

Download this manual

INSTALLATION, OPERATION AND MAINTENANCE

MANUAL FOR INDIRECT GAS-FIRED HEATERS

INCLUDING UNITS WITH DDC CONTROLS

ATTENTION: READ THIS MANUAL AND ALL LABELS ATTACHED TO THE UNIT CAREFULLY BEFORE

ATTEMPTING TO INSTALL, OPERATE OR SERVICE THESE UNITS! CHECK UNIT DATA PLATE FOR

TYPE OF GAS AND ELECTRICAL SPECIFICATIONS AND MAKE CERTAIN THAT THESE AGREE WITH

THOSE AT POINT OF INSTALLATION. RECORD THE UNIT MODEL AND SERIAL No.(s) IN THE SPACE

PROVIDED. RETAIN FOR FUTURE REFERENCE.

The use and storage of gasoline or other ﬂ ammable vapors and liquids in open contain-

ers in the vicinity of this appliance is hazardous.

L'utilisation et l'entreposage d'essence ou d'autres liquides ou produits émettant des vapeurs

inﬂ ammables dans des récipients ouverts à proximité de cet appareil est dangereux.

FOR YOUR SAFETY

If you smell gas:

1. Open Windows

2. Don't touch electrical switches.

3. Extinguish any open ﬂ ame.

4. Immediately call your gas supplier.

WARNING: Improper installation, adjustment, alteration, service or maintenance can

cause property damage, injury or death. Read the installation, operating and maintenance

instructions thoroughly before installing or servicing this equipment.

AVERTISSEMENT : Une installation déﬁ ciente, de même qu'un mauvais réglage,

modiﬁ cation, entretien ou maintenance peuvent occasionner des dommages matéri-

els, corporels voire causer la mort. Lire attentivement les instructions d'installation,

d'utilisation et d'entretien avant d'installer ou d'intervenir sur cet appareil.

Install, operate and maintain unit in accordance with manufacturer's instructions to avoid

exposure to fuel substances or substances from incomplete combustion which can cause

death or serious illness. The state of California has determined that these substances

may cause cancer, birth defects, or other reproductive harm.

Installer Please Note: This equipment has been test ﬁ red and inspected. It has been shipped

free from defects from our factory. However, during shipment and installation, problems such as

loose wires, leaks or loose fasteners may occur. It is the installer's responsibility to inspect

and correct any problems that may be found.

FOR YOUR SAFETY

POUR VOTRE SÉCURITÉ

WARNING

INSTALLER'S RESPONSIBILITY

4830 Transport Drive, Dallas, TX 75247 Phone: 214-638-6010 Fax: 214-905-0806

www.appliedair.com

POUR VOTRE SÉCURITÉ

Si vous sentez une odeur de gaz :

1. Ouvrez les fenêtres.

2. Ne pas actionner d'interrupteur.

3. Éteindre toute ﬂ amme ouverte.

4. Appelez immédiatement votre

fournisseur de gaz.

IOMIF-1

Table of Contents

Need help?

Do you have a question about the GAS-FIRED HEATERS and is the answer not in the manual?

Questions and answers

Summary of Contents for Applied Air GAS-FIRED HEATERS

Page 1 IOMIF-1 INSTALLATION, OPERATION AND MAINTENANCE MANUAL FOR INDIRECT GAS-FIRED HEATERS INCLUDING UNITS WITH DDC CONTROLS ATTENTION: READ THIS MANUAL AND ALL LABELS ATTACHED TO THE UNIT CAREFULLY BEFORE ATTEMPTING TO INSTALL, OPERATE OR SERVICE THESE UNITS! CHECK UNIT DATA PLATE FOR TYPE OF GAS AND ELECTRICAL SPECIFICATIONS AND MAKE CERTAIN THAT THESE AGREE WITH THOSE AT POINT OF INSTALLATION.
Page 2: Table Of Contents
Clearly mark any shutoff devices. * IMPORTANT NOTICE * Applied Air assumes no responsibility for loss or dam- CONCEALED DAMAGE IN TRANSIT age in transit; therefore, you should protect yourself Sometimes transit damage is not noticed until the goods by following these instructions.
Page 3: Section Ii: General Information
Due to insure all items have been received. All equipment to the custom nature of Applied Air equipment, not all (and any optional accessories) should be checked possibilities are addressed in this manual. The customer carefully for physical damage in the presence of the or installer can obtain information from Applied Air’s...
Page 4: Section Iii: Installation
SECTION III - INSTALLATION FOR CANADIAN INSTALLATIONS ONLY During transit, unloading and setting of the unit; bolts 1. All installations must conform with local building codes, and nuts may have become loosened, particularly in the or in the absence of local codes, with current CAN/CGA- pillow block ball bearing assemblies in the fan section.
Page 5 B. Locating the Unit In addition to the combustible clearances listed above, Prior to locating the unit, authorities having jurisdiction access for service should be allowed around the unit. should be consulted before installations are made. Approval The recommended minimum access clearance is permits should be checked against the unit received.
Page 6 – 6 –...
Page 7 – 7 –...
Page 8 – 8 –...
Page 9 – 9 –...
Page 10 LIFTING LUG GRILLS 3 DIRECTION DISCHARGE BOX (4 DIRECTION OPTIONAL) GASKET PROP FAN SECTION ALIGNMENT FLANGE CAP GASKET COOLING SECTION (OPTIONAL) ALIGNMENT FLANGE CAP GASKET V-BANK AND INLET SECTION DISCHARGE BOX GASKET PLENUM EXTENSION SHEET METAL SCREW IN PLACE C000712 –...
Page 11 DIRECTIONS FOR FIELD ASSEMBLING AND WEATHERPFOOFING SECTIONS 1. Apply gasket material to the end of the ﬁ rst section 4. Apply caulking material along the top of both sides of (blower, discharge, heater, ets). (See Fig. 1.) the standing roof seam (Fig.4). Place roof cap (Fig. 4) on top of the seam and secure it with two rows of TEK NOTE: One roof cap is attached to a standing seam screws (one down each side), spaced approximately...
Page 12 D. Location of Accessories If optional disconnect is not furnished with heater, the Where applicable, standard or optional accessories will ﬁ eld provided disconnect must be of the proper size be placed inside the fan section of the unit for shipment, and voltage.
Page 13 – 13 –...
Page 14 APPROVED SIDE WALL VENT DEVICE SIDE WALL VENTING APPROVED SIDE WALL VENT DEVICE DIMENSIONS SIZE "H" "W" 6-1/4 6-3/8 6-1/4 6-3/8 H X W 6-1/4 6-3/8 6-1/4 6-3/8 7-3/8 SEE NOTE 4 7-3/8 EXHAUSTER 7-3/8 7-3/8 9-3/8 BUILDING WALL 9-3/8 9-3/8 9-3/8 RAIN...
Page 15 Pitch horizontal pipes downward ¼ inch per foot toward The appliance and its individual shutoff valve must outlet for condensate drainage. Support horizontal runs be disconnected from the gas supply piping system as required to prevent sagging. during any pressure testing of that system at test pressures in excess of ½...
Page 16 RP-10 RP-10 SECOND STAGE COOLING FIRST STAGE COOLING COIL 'A' COIL 'B' RP-16 RP-17 RP-12A RP-12B RP-11 RP-11 RP-09 RP-09 RP-18 RP-18 RP-13A RP-13B RP-11A TO RP-11A RP-09 RP-09 RP-18 RP-18 RP-19 SEE NOTE #12 12" SECOND STAGE SUCTION 24" FIRST STAGE SUCTION A-FRAME COIL ASSEMBLY END ELEVATION THE ABOVE PIPING SCHEMATIC SHOULD BE USED AS A GUIDE ONLY.
Page 17 Evaporator Coil – Draw Through I. Locating Temperature Controls The room or outdoor thermostats should be mounted where The cooling coil section can be located in the unit so they will not be subjected to direct impact of the heated air that supply air is drawn through the evaporative coil(s).
Page 18 SUGGESTED P-TRAP DESIGN FOR CONDENSATE DRAIN PANS UNDER A NEGATIVE PRESSURE 90° LONG RADIUS PVC ELBOW NIPPLE 90° LONG RADIUS PVC ELBOW DRAIN PAN DRAIN PVC ADAPTER FITTING FPT x SLIP PVC PIPE NIPPLE NOTE: PVC PIPE 'H' TO BE A MINIMUM OF NIPPLE 1/2"...
Page 19: Section Iv: Pre-Start Up
SECTION IV – PRE START-UP bubble solution. The most common types of problems Do not attempt start-up without completely reading and understanding this manual, along with the found relative to the gas train itself is free of foreign material within the gas piping. This will interfere with Digital Control System user manual (if applicable).
Page 20 SUGGESTED TOOLS AND INSTRUMENTS U-Tube Manometer (0 – 10" W.C.) Two Required Volt/Ohm meter Flue Gas Test Equipment Tachometer Standard Hand Tools Stack & Temperature Thermometer D.C. Volt Meter Gas Pressure Gauge (0 – 35 lbs.) BAC View 6 for DDC Controls (if applicable) Ammeter/Amprobe (or equal) SUGGESTED CONTROLS SETTINGS FL-01 Fan Control………..…...……..…95...
Page 21: Section V: Unit Start Up Without Ddc Controls
SECTION V – UNIT START-UP WITHOUT DDC CONTROLS Open pilot and ﬁ rst main gas shut-off valves slowly. Before attempting to start the heater read and understand the sequence of operations, electrical Last main gas shut-off valve before the burner must schematic, gas train, burner, and ﬂ...
Page 22 NOTE: Pilot regulator adjustment may be needed if CAUTION: If main ﬂ ame does not light within a few the adjustment of the needle valve does not yield seconds after pilot ﬂ ame is established, shut the burner down and repeat steps. You may have to the required reading.
Page 23 Modulating Operation C000723 Set high ﬁ re by adjusting main gas regulator and by the high ﬁ re adjusting screw on the butterﬂ y valve. Observe ﬂ ame as burner modulates when thermostats are adjusted. NOTE: Flame should modulate slowly and evenly throughout the entire travel, although ﬂ...
Page 24 TYPICAL SEQUENCE FOR MODULATING THERMOSTAT WITH 135 OHM CONTROLS – 24 –...
Page 25 TYPICAL SEQUENCE FOR MODULATING THERMOSTAT WITH 4-20 mA CONTROLS – 25 –...
Page 26: Section V: Unit Start Up With Ddc Controls
SECTION V – UNIT START-UP WITH DDC CONTROLS Before attempting to start the heater read and To disable the fans, go to “Unit Modes” and enter understand the sequence of operations, electrical [OFF]. schematic, ﬂ ame safeguard control, control com- ponents, gas train, burner and the Digital Control NOTE: A BACview or PC is required to change Unit System user manual.
Page 27 Heat is Enabled By The Following: Honeywell Flame Safeguard Control (RE-02): A keyboard display module (Honeywell #S7800A1142) MDT And MRT Standard: is recommended to read the ﬂ ame signal, and is a good To enable the heat, rotate the “Temperature Setpoint” troubleshooting device.
Page 28 Setting the Main Flame After the burner lights; adjust gas pressure regulator, using a manometer, and combustion air damper to IMPORTANT: When the Flame Safeguard relay module match the normal manifold pressure shown on unit is switched to the TEST mode, it stops and holds at nameplate.
Page 29 FINAL CHECKS AND ADJUSTMENTS Detectable Carbon Monoxide (CO) After the burner has been in operation for at least 10 minutes, this allows the combustion chamber and heat exchanger to reach an equilibrium temperature; • Fuel input too high • Not enough burner air a ﬂ...
Page 30: Section Vi: Unit Shut Down
Cooling is Enabled By The Following MRT or MDT Expert With a (KP-01) BACview: To enable the cooling for MRT Expert, scroll through MDT & MRT Standard: the “SETPOINTS” menu in the BACview and enter To enable the cooling, rotate the remote “Temperature the desired room Cooling Occupied and Unoccupied Setpoint”...
Page 31: Section Vii: Troubleshooting
SECTION VII - TROUBLE SHOOTING Check Safety Shutdown Performance This equipment has been electrically and ﬁ re tested prior to shipment. However, during transit control setpoints can WARNING: Fire or explosion hazard. Can cause change, and wiring can come loose. Do not assume con- property damage, severe injury or death.
Page 32 SECTION VII - TROUBLE SHOOTING continued HONEYWELL RM7897A1002, RM7897C1000 7800 SERIES RELAY MODULES PRINCIPAL TECHNICAL FEATURES 5. MAIN FLAME ESTABLISHING PERIOD (MFEP) The RM7897 provides all customary ﬂ ame safeguard (RM7897A, teminal 21) functions as well as signiﬁ cant advancements in safety, a.
Page 33 SECTION VII - TROUBLE SHOOTING continued Causes for hold conditions in the INITIATE sequence: a. After PFEP, and with the presence of ﬂ ame, the 1. AC line dropout detection. main fuel valve, terminal 9, is powered. If a ﬂ ame- 2.
Page 34 SECTION VII - TROUBLE SHOOTING continued SETTINGS AND ADJUSTMENTS Figure 6 - Selectable Site-Conﬁ gurable Jumpers Selectable Site-Conﬁ gurable Jumpers The relay module has three site-conﬁ gurable jumper SELECTABLE CONFIGURATION JUMPERS options, see Fig. 6 and Table 7. If necessary, clip the RUN/TEST SWITCH (EC7895C;...
Page 35 SECTION VII - TROUBLE SHOOTING continued Figure 2 - Wiring Subbase and Sequence Chart for RM7897A Q7800 FOR DIRECT SPARK IGNITION (OIL OR GAS) IGNITION TRANSFORMER LINE VOLTAGE ALARM MAIN VALVE BURNER MOTOR (BLOWER) (L1) BURNER CONTROLLER/LIMITS RUNNING INTERLOCK (INCLUDING AIRFLOW SWITCH) INTERMITTENT PILOT/IGNITION...
Page 36 SECTION VII - TROUBLE SHOOTING continued The POWER LED provides fault identiﬁ cation when the Relay Module locks out on an alarm. Fault identiﬁ cation is a series of fast- and slow-blinking LED lights. The fast blinks identify the tens portion of the fault code (three fast blinks is 30), while the slow blinks identify the units portion of the fault code (two slow blinks is 2).
Page 37 Blinking Fault Codes and Recommended Troubleshooting Fault Code System Failure Recommended Troubleshooting Code 3-2 Lockout Interlock Check wiring to make sure that the Lockout Interlocks are connected properly powered at improper *Running/ between terminals 6 and 7. Correct any errors. Interlock On point in sequence or On Reset and sequence the relay module.
Page 38 Blinking Fault Codes and Recommended Troubleshooting Fault Code System Failure Recommended Troubleshooting Code 5-3 Man-Open Switch, Start Check wiring and correct any errors. *Man-Open Switch or Control On in Make sure that the Manual Open Valve Switch, Start Switch and Control are Sw.;...
Page 39 SECTION VII - TROUBLESHOOTING continued Symptom Cause Remedy A. Supply fan(s) do not 1. Check power source. 1. Low or no voltage. operate. 2. Replace fuse(s). 2. Fuse(s) blown. 3. Close or connect customer 3. Customer’s interlock not interlock. closed or connected. 4.
Page 40 SECTION VII - TROUBLESHOOTING continued Symptom Cause Remedy B. No voltage at ﬂ ame 1. Place switch in "on" 1. Fan and Heat "off-on" safeguard relay input switch in "off" position. position. terminals (RE-02). 2. Check modulating motor for 2. SW-11/SW-13 in MT-11/MTR-4 (if applicable) not closed.
Page 41 SECTION VII - TROUBLESHOOTING continued Symptom Cause Remedy 1. Flame safeguard relay 1. Place switch in run position, see E. If pilot does not light run/test switch in test technical cut sheet on ﬂ ame safe after 90 second pre- position or is defective.
Page 42 SECTION VII - TROUBLESHOOTING WITH DDC CONTROLS Symptom Cause Remedy A. Supply fan(s) do not 1. Check power source. 1. Low or no voltage. operate. 2. Replace fuse(s). 2. Fuse(s) blown. 3. Close or connect customer 3. Customer’s interlock not interlock.
Page 43 SECTION VII - TROUBLESHOOTING WITH DDC CONTROLS continued Symptom Cause Remedy B. No voltage at ﬂ ame 1. Enable the heating mode. 1. Heat Mode is disabled. safeguard relay input 2. Incorrect setpoint. 2. Check for proper setting. terminals (RE-02). 3.
Page 44 SECTION VII - TROUBLESHOOTING WITH DDC CONTROLS continued Symptom Cause Remedy 1. Flame safeguard relay 1. Place switch in run position, see E. If pilot does not light run/test switch in test technical cut sheet on ﬂ ame safe after 90 second pre- position or is defective.
Page 45 SECTION VII - TROUBLESHOOTING WITH DDC CONTROLS continued Modulating Discharge Temperature (MDT or MDT EXPERT) Controls Symptom Possible Cause Field Test Remedy A. No Gas Flow 1. Gas valves improperly 1. Arrow on side or bottom of 1. Install properly. with DO-2 installed.
Page 46 SECTION VII - TROUBLESHOOTING WITH DDC CONTROLS continued Modulating Room Temperature (MRT, MRT-PRO or MRT-EXPERT) Controls Symptom Possible Cause Field Test Remedy A. No Gas Flow with 1. Gas valves improperly 1. Arrow on side or bottom 1. Install properly. DO-2 on UC-01 installed.
Page 47 SECTION VII - TROUBLESHOOTING WITH DDC CONTROLS continued Modulating Room Temperature (MRT, MRT-PRO or MRT-EXPERT) Controls continued Symptom Possible Cause Field Test Remedy 1. Readjust linkage on valve or G. Continuous High 1. Foreign object holding 1. Inspect linkage valve. Fire (Electronics butterﬂ...
Page 48 SECTION VII - TROUBLESHOOTING WITH DDC CONTROLS continued Cooling Mode Symptom Cause Remedy A. There is no voltage at cooling relays 1. Cooling mode is disabled 1. Enable the cooling mode. (RE-34) (RE-35) and/or (RE-33) and 2. Auxiliary switch on starter (ST-01) 2.
Page 49 SECTION VII - TROUBLESHOOTING WITH DDC CONTROLS continued To Calibrate the Building Pressure Transducer (PT-13) 1. Remove the tubes at the Low and High pressure ﬁ t- tings. 2. The voltage at –COM and OUT should be 2.5 VDC. If not adjust Z (do not adjust S). 3.
Page 50 MULTIPLEXED VOLTAGE CHART RESISTOR SWITCH OHMS IN VALUE RESISTOR ID CLOSED CIRCUIT VOLTS DC 1000 RS1,2,3,4 2000 RS2,3,4 1000 0.30 4020 RS1,3,4 2000 0.55 8060 RS3,4 3000 0.76 RS1,2,4 4020 0.95 RS2,4 5020 1.10 RS1,4 6020 1.24 7020 1.36 RS1,2,3 8060 1.47 RS2,3...
Page 51 CHECKOUT PROCEDURE FOR INTERFACE MODULE (IM-02) Q7230 Adjustments The Q7230A provides adjustable range (zero and 5. Set the controller to output the signal required to span) for two-wire current or voltage control. Separate drive the motor to the closed position. Wait for the potentiometers are provided on the circuit module for motor to stop driving closed.
Page 52: Section Viii: Servicing The Burner
SECTION VIII - SERVICING THE BURNER This section is intended as a guide in making some repairs and adjustments to the power burner. Many of the repairs will require the service of a skilled heating service technician. For more information refer to the burner I.O.M.
Page 53 The arc from the electrode tip should jump from tip to the body of the pilot housing and should be lined with the hole in the backside of pilot housing, so that the blower air passing throught this hole will cause the arc to "FLAG" (or move around).
Page 54 Gas, Oil or Gas/Oil Burner Diffuser Adjustment DIFFUSER POSITION ADJUSTMENT Gas/Air Premix Adjustment Knob Blast Tube Diffuser Position Adjustment Moving the blast tube diffuser assembly fore or aft on gas or oil ﬁ ring will move the ﬂ ame front (point of re- tention) in order to attain the best (quietest/smoothest) combustion for speciﬁ...
Page 55 MAXON MODEL ( 400 ) OVENPAK Burners 1) GAS-ELECTRIC IGNITION The gas-electric pilots used on MAXON burners are either ﬂ ame rod or scanner design. 2) POOR FLAME SIGNAL Try adjusting needle valve or pilot pressure regulator. Should this not be successful, check the primary pilot air. If neither of these methods improve the reading, inspect the ﬂ...
Page 56 FLUE GAS ANALYSIS This curve correlates the relative values of O and CO Again following the 4% O vertical axis fo fuel line E (#2 for the fuels listed, as well as the percentage of excess Fuel Oil ) and to the left to the CO column shows that air at given O and CO...
Page 57: Section Ix: Maintenance Schedule And Lubrication Requirements
SECTION IX - MAINTENANCE SCHEDULE AND LUBRICATION REQUIREMENTS WARNING: Failure to comply with the general e. Check the voltage and amps on all motors. safety information may result in extensive f. Check the operation of all safety limits and con- property damage, severe personal injury or trols.
Page 58 B. Lubrication Instructions CAUTION: An excess of grease will overheat the bearings. Item Manufacturer Bearing Type All 3 phase US., Baldor Single row ball NOTE: On totally enclosed fan cooled (TEFC) fan motors or equal bearings motors, the rear end fan housing must be removed (1 HP to to expose the grease plugs.
Page 59 Browning Bearing Set Screw Torque Values 7. Remove the shaft from the unit by sliding the bearings and blower wheels along the shaft as Model# Shaft Size Torque (in-lbs) the shaft is extracted. Unless a blower wheel is damaged, it should be unnecessary to remove the Set Screw blower wheel from the blower housing.
Page 60 24. Monitor for excessive heat or vibration during It is necessary, therefore, to tighten all belts during the operation. ﬁ rst few months of operation, and to check for proper 25. All bearings are pre-lubricated and should not tension weekly during the ﬁ rst 60 days, after which require greasing.
Page 61 CAUTION: Solutions used to clean coils must not be corrosive to metals or materials used in the manufacture of this equipment. When using any type of coil cleaner, always read the manufacturer's warnings and directions to properly use their product. If cleaning solutions are applied through means of high pressure spray, care must be taken to avoid damaging coil ﬁ...
Page 62: Section X: Thermistor Output Curve For Units With Ddc Controls
SECTION X - THERMISTOR OUTPUT CURVE FOR UNITS WITH DDC CONTROLS Typical 10,000 Ohm Thermistor Output Curve 30000 25000 20000 15000 10000 5000 Temperature in Degrees F – 62 –...
Page 63: Section Xi: Replacement Parts
SECTION XI - REPLACEMENT PARTS Replacement parts may be ordered from the factory. NUMBER, FACTORY ORDER (F.O.) AND PART NUM- All warranty parts will be shipped freight allowed from BERS are required. Belts, ﬁ lters and fuses are not cov- the factory via standard ground service.
Page 64 4830 Transport Drive, Dallas, TX 75247 Phone: 214-638-6010 Fax: 214-905-0806 www.appliedair.com...