LJ Wing WDF Operation Manual

Direct gas-fired heaters with ddc controls

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MAINTENANCE MANUAL FOR WDF MODEL

DIRECT GAS-FIRED HEATERS 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 flammable vapors and liquids in open

containers 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.

INSTALLATION, OPERATION AND

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.ljwing.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.

IOMWDF-4

Table of Contents

Troubleshooting

Summary of Contents for LJ Wing WDF

Page 1 IOMWDF-4 INSTALLATION, OPERATION AND MAINTENANCE MANUAL FOR WDF MODEL DIRECT GAS-FIRED HEATERS 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 all emergency shutoff devices. *IMPORTANCE NOTICE* LJ Wing assumes no responsibility for loss or damage Concealed Damage In Transit in transit; therefore, you should protect yourself by Sometimes transit damage is not noticed until the following these instructions: goods are unpacked.
Page 3: Section Ii: General Information
SECTION II - GENERAL INFORMATION A. Purpose The purpose of this manual is to present a guide for Shipments are made F.O.B. Dallas, Texas by ﬂ at- proper installation, maintenance, and operation of the bed truck. The unit is securely strapped, tied, and Direct Gas-Fired System, and supplement, but not to blocked to prevent shipping damage.
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 and nuts may have become loosened, particularly in the pillow block ball bearing assemblies in the fan codes, or, in the absence of local codes, with section.
Page 5 Use extreme caution in handling the curb. Proper B. Locating the Unit Prior to locating the unit, authorities having jurisdic- handling and positioning will assure a water-tight curb tion should be consulted before installations are made. unit installation. Approval permits should be checked against the unit received.
Page 6 E. Electrical Connections F. Field Piping WARNING: Open all disconnect switches and Gas Piping All gas piping must be in accordance with the require- secure in that position before wiring unit. ments outlined in the National Fuel Gas Code - ANSI Failure to do so may result in personal injury or Z223.1.
Page 7 disconnect switch. 2. Field wiring is typically indicated on the wiring The appliance must be isolated from the gas supply diagram as dashed lines. When running any ﬁ eld piping system by closing it’s individual manual wiring for control circuit be sure wire is sized for shutoff valve during any pressure testing of the gas a maximum 10% voltage drop.
Page 8: Section Iv: Pre-Start Up
SECTION IV - PRE START-UP 9. Check thermostat(s) for normal operation. Do not attempt start-up without completely reading 10. Check that system duct work is installed and free and understanding this manual, along with the from obstructions. Digital Control Sysem user manual. 11.
Page 9: Section V: Unit Start Up
SECTION V - UNIT START-UP GENERAL To disable the fans go to “Unit Modes” and enter Before attempting to start the heater read and understand the the sequence of operations [OFF]. electrical schematic, ignition module, control components, gas train, burner and the Digital NOTE: A BACview or PC is required to change Unit Control System user manual.
Page 10 Open ﬁ rst main gas shut-off valve slowly. Reset high- Install manometer at test port on the last tee of the low gas pressure switches (if applicable). Check main burner manifold, or MR valve test port. gas line for leaks using soap solution. Slowly open last manual gas shut-off valve.
Page 11: Section Vi: Unit Shut Down
Safety Controls Check All Suggested Control Settings A. Ignition Control (RE-02) – Close last manual gas (Refer to Digital Control System user manual for default settings) valve before main burner. Operate unit in Heat mode. The ignition control must lock out within approximately TS-02 Space Temperature Sensor ..
Page 12: Section Vii: Troubleshooting Guide
SECTION VII - TROUBLE SHOOTING This equpipment has been electrically and ﬁ re tested Check Safety Shutdown Performace prior to shipment. However, during transit control setpoints can change, and wiring can come loose. Do WARNING: Fire or explosion hazard. Can not assume controls are defective until all associated cause property damage, severe injury or death.
Page 13 SECTION VII - TROUBLESHOOTING continued Fan and Heat Mode Symptom Cause Remedy A. If blower does not 1. Check power source. 1. Low or no voltage. operate. 2. Check and replace. 2. Fuse(s) blown. 3. Customer interlock not closed or 3.
Page 14 SECTION VII - TROUBLESHOOTING continued Heat Mode continued Symptom Cause Remedy 1. Manual shut-off valve closed. D. If burner does not light 1. Slowly open valve. after prepurge has 2. Inlet gas pressure lower than 2. Increase gas pressure. timed out (5 seconds) required gas pressure and voltage is present 3.
Page 15 TROUBLESHOOTING GUIDE FOR AMPLIFIER (RE-26) The SC-1 signal conditioner provides signal conversion for a high impedance 2-10VDC signal source to drive a 24VDC solenoid. The control should be powered by an isolated 24VAC transformer to drive up to a .5A dc solenoid. Span Override Switch - When terminals 3 &...
Page 16: Troubleshooting Guide
TROUBLESHOOTING GUIDE Modulating Discharge Temperature (MDT or VDT EXPERT) Controls Portions reproduced with permission from Maxitrol ® Company Symptom Possible Cause Field Test Remedy A. No Gas Flow 1. Modulating valve 1. Arrow on side of valve should 1. Install properly. with DO-2 improperly installed.
Page 17 TROUBLESHOOTING GUIDE Modulating Discharge Temperature (MDT or VDT EXPERT) Controls continued ® Portions reproduced with permission from Maxitrol Company Symptom Possible Cause Field Test Remedy G. Incorrect 1. Inlet pressure too low. 1. Read pressure at inlet to 1. Increase inlet pressure if Maximum Fire.
Page 18 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE Modulating Room Temperature (MRT, MRT-PRO or MRT-EXPERT) Controls Portions reproduced with permission from Maxitrol ® Company Symptom Possible Cause Field Test Remedy A. No Gas Flow with 1. Valve improperly 1. Arrow on side of valve 1.
Page 19 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE Modulating Room Temperature (MRT, MRT-PRO or MRT-EXPERT) Controls continued Portions reproduced with permission from Maxitrol ® Company Symptom Possible Cause Field Test Remedy G. Continuous High 1. Foreign material 1. Remove bottom plate and 1. Clean, replace valve and/or Fire (Electronics holding valve open.
Page 20 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE 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. Check auxiliary circuit wiring and the fan is enabled.
Page 21 TROUBLESHOOTING GUIDE To Calibrate the Building Pressure Transducer To calibrate the Flow Station Pressure Transducer (PT-13) (PT-15) 1. Remove the tubes at the Low and High pressure 1. Remove the tubes at the Low and High pressure ﬁ ttings. ﬁ ttings. 2.
Page 22 TROUBLESHOOTING GUIDE Checking The Burner Velocity Pressure Some adjustments can be made by repositioning the burner proﬁ le plates. If the high switch is open, you can open the proﬁ le plates. If the low switch is open PS-10 & PS-11 air switches are factory calibrated. you can close the proﬁ...
Page 23 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 24: Section Viii: Maintenance Schedule And Lubrication Requirements
SECTION VIII - MAINTENANCE SCHEDULE AND LUBRICATION REQUIREMENTS WARNING: Failure to comply with the general 5. Quarterly safety information may result in extensive a. Complete the monthly maintenance schedule. property damage, severe personal injury or b. Inspect all drives for proper belt tension and wear. death.
Page 25 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 26 7. Remove the shaft from the unit by sliding the Browning Bearing Set Screw Torque Values 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 27 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 tension weekly during the ﬁ rst 60 days, after which not require greasing.
Page 28 If any mixing plates are loose or missing CAUTION: Solutions used to clean coils must fasteners, tighten/replace as necessary. Always not be corrosive to metals or materials used in use zinc plated or stainless fasteners. The the manufacturer of this equipment. If cleaning solutions are applied through means of high mixing plates on the burner may display “hairline”...
Page 29: Section Ix: Mestek Burner
SECTION IX - MESTEK LINE BURNERS Use of an electric drill motor is not suggested unless Inspection and Maintenance of Gas Ports Conduct initial inspection within the ﬁ rst month after both Pin Vise and Drill can be chucked up in a vari- commissioning.
Page 30: Section X: Manifold And Valve Adjustments
SECTION X - MANIFOLD AND VALVE ADJUSTMENTS The I/O Zone 583 Controller HIGH AND LOW FIRE MANIFOLD ADJUSTMENT (UC-01) must be calling for the FOR MAXITROL VALVES WITH DDC burner to be enabled. The DO-2 light will be on and Burner Enable Relay (RE-28) needs to be energized.
Page 31: Section Xi: Thermistor Curves
CIRCUIT ANALYSIS – MAXITROL GAS VALVES Connect a DC volt meter (capable of reading 0-24V DC) on the Modulator (M611) or Modulator-Regulator (MR212) Valve terminals. The operation of the Valve with regard to voltage is as follows: from 0 volts to approximately 5 volts, the modulat- ing valve should be on bypass ﬂ...
Page 32: Section Xii: Replacement Parts
SECTION XII - REPLACEMENT PARTS Replacement parts may be ordered from the factory. When parts are ordered, MODEL NUMBER, SERIAL All warranty parts will be shipped freight allowed from NUMBER, FACTORY ORDER (F.O.) and PART NUM- factory for normal ground service. Warranty parts must be BERS are required.