Applied Air IOMDFCDFM-1 Operation Manual

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MAINTENANCE MANUAL FOR DFC & DFM

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. 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.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.

IOMDFCDFM-1

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Page 1 IOMDFCDFM-1 INSTALLATION, OPERATION AND MAINTENANCE MANUAL FOR DFC & DFM 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* Applied Air assumes no responsibility for loss or Concealed Damage In Transit damage in transit; therefore, you should protect Sometimes transit damage is not noticed until the yourself by following these instructions: goods are unpacked.
Page 3: Section Ii: General Information
SECTION II - GENERAL INFORMATION A. Purpose unit will keep insects, dust and condensation out The purpose of this manual is to present a guide for of the unit and critical components. Rotate the proper installation, maintenance, and operation of the fan(s) monthly.
Page 4: Section Iii: Installation
SECTION III - INSTALLATION FOR CANADIAN INSTALLATIONS ONLY blower does not rub against blower housing, and that 1. All installations must conform with local building bearing set screws are tight. If units are not set imme- diately, cover all openings that might be exposed to the codes, or, in the absence of local codes, with weather.
Page 5 B. Locating the Unit Use extreme caution in handling the curb. Proper han- Prior to locating the unit, authorities having jurisdic- dling and positioning will assure a water-tight curb unit tion should be consulted before installations are made. 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 secure in that position before wiring unit. All gas piping must be in accordance with the require- Failure to do so may result in personal injury or ments outlined in the National Fuel Gas Code - ANSI death from electrical shock.
Page 7 The appliance must be isolated from the gas supply pip- Refrigerant Piping ing system by closing it’s individual manual shutoff valve during any pressure testing of the gas supply piping Evaporator Coil – Blow Through system at test pressure equal to or less than 1/2 PSIG. The cooling coil section is located in the unit so that Correctly sized piping must be run to the unit.
Page 8 SUGGESTED P-TRAP DESIGN FOR CONDENSATE DRAIN PANS UNDER A POSITIVE PRESSURE 90° LONG RADIUS PVC ELBOW NIPPLE 90° LONG RADIUS PVC ELBOW DRAIN PAN DRAIN PVC ADAPTER FITTING FPT x SLIP PVC PIPE NOTE: NIPPLE 'G' TO BE A MINIMUM OF PVC PIPE 1/2"...
Page 9 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 (blower, discharge, heater, ets). (See Fig. 1.) of the standing roof seam (Fig.4). Place roof cap (Fig.
Page 10: Section Iv: Pre-Start Up
SECTION IV - PRE START-UP 10. Check thermostat(s) for normal operation. Do not attempt start-up without completely reading and understanding this manual, along with the 11. Check to ensure all manual reset safety devices Digital Control Sysem user manual. have been reset and limits are in the normal operating position.
Page 11 This equipment has been electrically and ﬁ re tested BEFORE ATTEMPTING TO START THE HEATER, READ THE TYPICAL SEQUENCE OF OPERATION prior to shipment. However, during transit control setpoints can change, and wiring can come loose. Do AS SHOWN BELOW: not assume controls are defective until all associated setpoints and wiring are checked.
Page 12: Section V: Unit Start Up
SECTION V - UNIT START-UP GENERAL Before attempting to start the heater read and To disable the fans go to “Unit Modes” and enter understand the the sequence of operations and [OFF]. electrical schematic, and the Digital Control System user manual. NOTE: A BACview or PC is required to change Unit Modes.
Page 13 Honeywell Flame Safeguard Control NOTE: 3 OR 4 TRIALS MAY BE NEEDED TO A keyboard display module (Honeywell #S7800A1142) PURGE AIR FROM PILOT LINE. IF BURNER HAS is recommended to read the ﬂ ame signal, and is a MAIN FLAME ROD OR SCANNER, YOU WILL NEED good troubleshooting device.
Page 14: Section Vi: Unit Shut Down
Safety Controls Check All Cooling is Enabled By The Following: A. Flame Safeguard – Close last manual gas valve before main burner. Operate unit in Heat mode. After MDT And MRT Standard: pilot ﬂ ame has been established, close manual pilot To enable the cooling, rotate the “Temperature gas valve.
Page 15: Section Vii: Troubleshooting Guide
SECTION VII - TROUBLE SHOOTING 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 16 SECTION VII - TROUBLE SHOOTING continued Causes for hold conditions in the INITIATE sequence: 2. Main Flame Establishing Period (MFEP): 1. AC line dropout detection. a. After PFEP, and with the presence of ﬂ ame, 2. AC line noise that can prevent a sufﬁ cient reading the main fuel valve, terminal 9, is powered.
Page 17 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 18 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 19 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 20 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 21 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 22 SECTION VII - TROUBLESHOOTING continued Fan and Heat Mode Symptom Cause Remedy A. Blower does not operate. 1. Check power source. 1. Low or no voltage. 2. Circuit breaker open. 2. Check and replace. 3. Customer interlock not closed or 3.
Page 23 SECTION VII - TROUBLESHOOTING continued Heat Mode continued Symptom Cause Remedy D. Pilot does not light after 1. Manual pilot shut-off valve closed. 1. Slowly open valve. prepurge has timed 2. Inlet gas pressure lower than 2. Increase gas pressure. required gas pressure out (10 seconds) and voltage is present on...
Page 24 SECTION VII - TROUBLESHOOTING continued Heat Mode continued Symptom Cause Remedy G. No heat with pilot ok and no 1. Flame safeguard relay Run/ 1. Place in Run position (see voltage is present at ﬂ ame Test switch in Test position or technical cut sheet on ﬂ...
Page 25 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. Power/Status LED Span Override Switch - When terminals 3 &...
Page 26: Troubleshooting Guide
TROUBLESHOOTING GUIDE Modulating Discharge Temperature (MDT or MDT 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 27 TROUBLESHOOTING GUIDE Modulating Discharge Temperature (MDT or MDT 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 28 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 29 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 30 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 31 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 32 TROUBLESHOOTING GUIDE Checking The Burner Velocity Pressure Some adjustments can be made by repositioning the burner proﬁ le plates. If the velocity will allow the High Velocity Switch to open, you can open the proﬁ le PS-10 & PS-11 air switches are factory calibrated. plates.
Page 33 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 34: 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 35 B. Lubrication Instructions 2. Pillow Block Bearings – Pillow block bearings are used on supply blower(s). Bearings have been pre-lubricated Item Manufacturer Bearing Type with high-quality lithium-complex base grease with All 3 phase US., Baldor Single row ball an EP additive. The grease is a lithium-complex base fan motors or equal bearings...
Page 36 Browning Bearing Set Screw Torque Values 8. Slide the new shaft through the ﬁ rst blower wheel hub. Model# Shaft Size Torque (in-lbs) 9. Once the shaft is completely through the ﬁ rst blower wheel, slide a bearing onto this end of the Set Screw shaft by pushing on the inner ring.
Page 37 24. Place a drop of “BLUE” Loctite on the blower the same type and size. In addition, the factory not setscrews and tighten all of the setscrews. only suggests, but insists, that air ﬁ lters be checked 25. Align the blower and motor sheaves using a laser every 30 days (daily in icy or snowy weather) and or straight edge and tighten the blower sheave to replaced with new ﬁ...
Page 38 B Section a. Shut the system down totally, disconnecting or small Pounds locking out power supply so there can be no pulley Pounds Force for accidental start-up during inspection. diameter Belt Force for times b. Inspect the burner carefully, including upstream range in Manufacturer Normal...
Page 39: Section Ix: Mestek Burner
SECTION IX - MESTEK LINE BURNERS Inspection and Maintenance of Gas Ports Use of an electric drill motor is not suggested unless Conduct initial inspection within the ﬁ rst month after both Pin Vise and Drill can be chucked up in a vari- commissioning.
Page 40: Section X: Manifold And Valve Adjustments
SECTION X - MANIFOLD AND VALVE ADJUSTMENTS The I/O Zone 583 Controller HIGH AND LOW FIRE MANIFOLD ADJUSTMENT FOR MAXITROL VALVES WITH DDC (UC-01) must be calling for the burner to be enabled. The DO-2 light will be on and Burner Enable Relay (RE-28) needs to be energized.
Page 41: 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 42: 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.
Page 43 – 43 –...
Page 44 4830 Transport Drive, Dallas, TX 75247 Phone: 214-638-6010 Fax: 214-905-0806 www.appliedair.com...

Applied Air IOMDFCDFM-1 Operation Manual

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