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. RETAIN FOR FUTURE REFERENCE.
SECTION I - FOREWARD Table of Contents Section I: Foreword, Table of Contents, and Important Notice .................................. 2 Section II: General Information .................................... 3 Section III: Installation.................................................. 4 Section IV: Pre-Start Up ............................................ 10 Section V: Unit Start Up ............................................. 12 Section VI: Unit Shut Down........................................
SECTION II - GENERAL INFORMATION A. Purpose The purpose of this manual is to present a guide for proper installation, maintenance, and operation of the Direct Gas-Fired System, and supplement, but not to replace, the services of qualified field service personnel to supervise the initial start-up and adjustment of the unit.
SECTION III - INSTALLATION blower does not rub against blower housing, and that bearing set screws are tight. If units are not set immediately, cover all openings that might be exposed to the weather. FOR CANADIAN INSTALLATIONS ONLY 1. All installations must conform with local building codes, or, in the absence of local codes, with current CAN/CGA-B149-Installation Codes For Gas Burning Appliances and Equipment. Open the cover on the electrical control box located on the unit.
B. Locating the Unit Prior to locating the unit, authorities having jurisdiction should be consulted before installations are made. Approval permits should be checked against the unit received. On Direct Gas-Fired units, which recirculate room air, outside ventilation air must be provided in accordance with the information shown on the heater nameplate. All ventilation air to the heater must be ducted directly from the outside. See Section XIII. Use extreme caution in handling the curb.
E. Electrical Connections F. Field Piping WARNING: Open all disconnect switches and secure in that position before wiring unit. Failure to do so may result in personal injury or death from electrical shock. Gas Piping All gas piping must be in accordance with the requirements outlined in the National Fuel Gas Code - ANSI Z223.1. It is required that a ground union be installed adjacent to the manifold for easy servicing.
The appliance must be isolated from the gas supply piping system by closing it’s individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressure equal to or less than 1/2 PSIG. Correctly sized piping must be run to the unit. Regulator Venting NOTE: Regulators and devices that have vent limiting orifices installed do not require a vent line. a.
SUGGESTED P-TRAP DESIGN FOR CONDENSATE DRAIN PANS UNDER A POSITIVE PRESSURE 90° LONG RADIUS PVC ELBOW NIPPLE 90° LONG RADIUS PVC ELBOW J TO DRAIN DRAIN PAN PVC ADAPTER FITTING FPT x SLIP PVC PIPE NIPPLE PVC PIPE NIPPLE NOTE: 'G' TO BE A MINIMUM OF 1/2" PLUS THE TOTAL SYSTEM STATIC PRESSURE ("W.C.). G 'J' TO EXCEED THE POSITIVE STATIC PRESSURE IN "W.C. OF THE SECTION OF THE UNIT WHERE THE DRAIN IS INSTALLED.
DIRECTIONS FOR FIELD ASSEMBLING AND WEATHERPFOOFING SECTIONS 1. Apply gasket material to the end of the first section (blower, discharge, heater, ets). (See Fig. 1.) NOTE: One roof cap is attached to a standing seam on each section for shipping purposes only. It will be necessary to remove this PRIOR TO SLIDING SECTIONS TOGETHER. Failure to do so may damage seams, preventing proper seal. 2. Slide adjoining section against the tacky taped first section.
SECTION IV - PRE START-UP Do not attempt start-up without completely reading and understanding this manual, along with the Digital Control Sysem user manual. Pre Start-Up The owners representative or equipment operator should be present during start-up to receive instructions on care and adjustments of the equipment. All equipment has been factory tested, adjusted, metered and inspected to meet conditions set at the time the order was placed. Only minimal adjustments should be required.
This equipment has been electrically and fire tested prior to shipment. However, during transit control setpoints can change, and wiring can come loose. Do not assume controls are defective until all associated setpoints and wiring are checked. If you do not have the optional BACview 6 (KP-01) keypad display it will be difficult to troubleshoot any alarm that may occur on the unit.
SECTION V - UNIT START-UP GENERAL To disable the fans go to “Unit Modes” and enter [OFF]. Before attempting to start the heater read and understand the the sequence of operations and electrical schematic, and the Digital Control System user manual. NOTE: A BACview or PC is required to change Unit Modes. For a more detailed control sequence see the Digital Control System User Manual.
Honeywell Flame Safeguard Control A keyboard display module (Honeywell #S7800A1142) is recommended to read the flame signal, and is a good troubleshooting device. A V.O.M. can also be used on the DC voltage test jacks marked “+” and “-” on flame amplifier. Open pilot and first main gas shut-off valves slowly. Last main gas shut-off valve before burner must remain closed at this time. Reset high-low gas pressure switches (if applicable). Check pilot and main gas lines for leaks using soap solution.
Safety Controls Check All A. Flame Safeguard – Close last manual gas valve before main burner. Operate unit in Heat mode. After pilot flame has been established, close manual pilot gas valve. The flame safeguard must trip out within 15 seconds. (See Safety Shutdown Performance on page 10. Cooling is Enabled By The Following: B. Firestats – These limit controls are not adjustable and are checked at the factory. Reset the red button(s) to be sure they are ready for operation.
SECTION VII - TROUBLE SHOOTING HONEYWELL RM7897A1002, RM7897C1000 7800 SERIES RELAY MODULES PRINCIPAL TECHNICAL FEATURES The RM7897 provides all customary flame safeguard functions as well as significant advancements in safety, annunciation, and system diagnostics. Safety Shutdown (Lockout) Occurs if: 1. INITIATE PERIOD a. Purge card is not installed or removed. b. Purge card is bad. c. Configuration jumpers have been changed (after 200 hours) - Fault Code 110. d.
SECTION VII - TROUBLE SHOOTING continued Causes for hold conditions in the INITIATE sequence: 1. AC line dropout detection. 2. AC line noise that can prevent a sufficient reading of the line voltage inputs. 3. Low line voltage brownouts. The INITIATE sequence also delays the burner motor starter from being energized and de-energized from an intermittent AC line input or control input.
SECTION VII - TROUBLE SHOOTING continued SETTINGS AND ADJUSTMENTS Selectable Site-Configurable Jumpers The relay module has three site-configurable jumper options, see Fig. 6 and Table 7. If necessary, clip the site-configurable jumpers with side cutters and remove the resistors from the relay module.
SECTION VII - TROUBLE SHOOTING continued Figure 2 - Wiring Subbase and Sequence Chart for RM7897A Q7800 FOR DIRECT SPARK IGNITION (OIL OR GAS) G 12 L2 13 10 IGNITION TRANSFORMER LINE VOLTAGE ALARM 3 14 8 MAIN VALVE BURNER MOTOR (BLOWER) 4 15 5 (L1) 16 BURNER CONTROLLER/LIMITS 6 17 RUNNING INTERLOCK (INCLUDING AIRFLOW SWITCH) 7 18 INTERMITTENT PILOT/IGNITION 8 19 MAIN FUEL VALVE(S) 9 20 10 21 F 22 2 IGNITION FLAME DETECTOR PREIGNITION INTERLOCK 10-SECOND INTERRUPTED PILOT
SECTION VII - TROUBLE SHOOTING continued The POWER LED provides fault identification when the Relay Module locks out on an alarm. Fault identification 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). Three fast blinks followed by two slow blinks would be fault code 32. This identifies a running interlock on during STANDBY.
Blinking Fault Codes and Recommended Troubleshooting Fault Code Code 3-2 *Running/ Interlock On During Standby* System Failure Lockout Interlock powered at improper point in sequence or On in Standby. Recommended Troubleshooting 1. 2. 3. 4. 5. Code 3-3 *VPS in Improper State* VPS (Valve Proving Switch) in wrong state during VPS Test. 1. 2. 3. 4. 5.
Blinking Fault Codes and Recommended Troubleshooting Fault Code System Failure Recommended Troubleshooting Code 5-3 *Man-Open Sw.; Start Sw. or Control On* Man-Open Switch, Start Switch or Control On in the wrong operational state. 1. 2. Code 6-1 *Internal Faults* Relay Module self-test failure. 1. 2. 3. 4. 5. 3. Code 6-2 *Internal Faults* Relay Module Self-Test failure. 1. 2. 3. 4. Code 6-3 *Device Specific* Fault with special OEM input circuits. 1. 2. 3. 4. 5.
SECTION VII - TROUBLESHOOTING continued Fan and Heat Mode Symptom A. Blower does not operate. B. No voltage at flame safeguard relay (RE-02) input terminal and the fan is enabled. Cause Remedy 1. Check power source. 2. Check and replace. 3. Close or connect customer interlock. 4. Enable the fan. 5. Check time clock, night setback thermostat and field installed controls for proper settings. 6. Reset freeze stat by interrupting power. Check for proper setpoint and burner operation. 7.
SECTION VII - TROUBLESHOOTING continued Heat Mode continued Symptom D. Pilot does not light after prepurge has timed out (10 seconds) and voltage is present on flame safeguard output terminals. Cause 1. Manual pilot shut-off valve closed. 2. Inlet gas pressure lower than required gas pressure 3. No gas through pilot regulator with inlet gas pressure ok. 4. No gas through pilot solenoid. 5. Type of gas (natural - LP) supplied different from factory required type. Note: components may change. 6.
SECTION VII - TROUBLESHOOTING continued Heat Mode continued Symptom Cause Remedy G. No heat with pilot ok and no voltage is present at flame safeguard relay output terminals. 1. Flame safeguard relay Run/ Test switch in Test position or fucntioning problem. 1. Place in Run position (see technical cut sheet on flame safeguard relay). H. Burner will not respond to temperature. 1. For DDC System. 1. See Digital Control System User manual. 2. Refer to following troubleshooting guide for RTC controls.
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 & 4 are shorted together the span setting is ignored forcing the ratio to 100%. Start Up Delay - The unit will pause for 10 seconds after power is applied to begin driving the output.
TROUBLESHOOTING GUIDE Modulating Discharge Temperature (MDT or MDT EXPERT) Controls Portions reproduced with permission from Maxitrol® Company Symptom Possible Cause A. No Gas Flow with DO-2 on UC-01 energized. 1. Modulating valve improperly installed. 1. Arrow on side of valve should point in direction of gas flow. 1. Install properly. B. Continuous Low Fire (Electronics Problem). 1. Short circuit or no voltage to the amplifier (RE-26). 2. Faulty amplifier (RE-26). 1.
TROUBLESHOOTING GUIDE Modulating Discharge Temperature (MDT or MDT EXPERT) Controls continued Symptom G. Incorrect Maximum Fire. Possible Cause 1. Inlet pressure too low. 2. Incorrect outlet pressure adjustment of Pressure Regulator. H. Incorrect Discharge Air Temperature 1. Unit Enable Potentiometer (MP-15) not set correctly. 2. Discharge Air Temperature Sensor (TS-03) not reading correctly. 3. The Heating Discharge Air Setpoint on MDT-EXPERT Control System is not set correctly. I.
TROUBLESHOOTING GUIDE Modulating Room Temperature (MRT, MRT-PRO or MRT-EXPERT) Controls Symptom Possible Cause Portions reproduced with permission from Maxitrol® Company Field Test Remedy A. No Gas Flow with DO-2 on UC-01 energized. 1. Valve improperly installed. 1. Arrow on side of valve should point in direction of gas flow. 1. Install properly. B. Continuous Low Fire (Electronics OK). 1. Open circuit in modulator coil. 1.
TROUBLESHOOTING GUIDE Modulating Room Temperature (MRT, MRT-PRO or MRT-EXPERT) Controls continued Symptom Possible Cause Portions reproduced with permission from Maxitrol® Company Field Test Remedy G. Continuous High Fire (Electronics Problem). 1. Foreign material holding valve open. 2. Plunger jammed. 1. Remove bottom plate and inspect valve and seat. 2. Inspect - plunger should be smooth and clean and operate freely in solenoid sleeve. 1. Clean, replace valve and/or seat if necessary. 2.
TROUBLESHOOTING GUIDE Cooling Mode Symptom Cause Remedy A. There is no voltage at cooling relays (RE-34) (RE-35) and/or (RE-33) and the fan is enabled. 1. Cooling mode is disabled 2. Auxiliary switch on starter (ST-01) is not closed. 3. Air flow switches open. 1. Enable the cooling mode. 2. Check auxiliary circuit wiring and contact. 3. Adjust the air flow and external static pressure to match the unit rating plate. DO NOT ADJUST SWITCHES. 4. Change to correct setpoints.
TROUBLESHOOTING GUIDE To Calibrate the Building Pressure Transducer (PT-13) 1. Remove the tubes at the Low and High pressure fittings. 2. The voltage at –COM and OUT should be 2.5 VDC. If not adjust Z (do not adjust S). 3. Make sure the Low and High fittings are clean and clear (do not insert any sharp objects into the pressure fittings). Make sure the tubing is also clean, clear of any debris and then reinstall the tubes on the transducer.
TROUBLESHOOTING GUIDE Checking The Burner Velocity Pressure PS-10 & PS-11 air switches are factory calibrated. Do not adjust. The permissible pressure range should be marked on the switches. If it’s close to the high or low trip points of the airflow switches, you could have nuisance burner shutdowns. High Velocity Switch open means too much velocity and Low Velocity Switch open means not enough velocity across the burner profile plates.
MULTIPLEXED VOLTAGE CHART RESISTOR VALUE RESISTOR ID 1000 2000 4020 8060 RS1 RS2 RS3 RS4 MULTIPLEXED VOLTAGE VALUES SWITCH CLOSED OHMS IN CIRCUIT VOLTS DC RS1,2,3,4 RS2,3,4 RS1,3,4 RS3,4 RS1,2,4 RS2,4 RS1,4 RS4 RS1,2,3 RS2,3 RS1,3 RS3 RS1,2 RS2 RS1 NONE UNPLUGGED 0 1000 2000 3000 4020 5020 6020 7020 8060 9060 10060 11060 12080 13080 14080 15080 NA 0 0.30 0.55 0.76 0.95 1.10 1.24 1.36 1.47 1.57 1.65 1.73 1.80 1.87 1.92 1.98 3.
SECTION VIII - MAINTENANCE SCHEDULE AND LUBRICATION REQUIREMENTS WARNING: Failure to comply with the general safety information may result in extensive property damage, severe personal injury or death. Periodic maintenance is essential to the efficient operation and extended service life of this equipment. Failure to provide maintenance as recommended may void the equipment warranty. A. Maintenance Schedule 1. Daily a. Check gauges, monitors, instruments and equipment settings. 2.
B. Lubrication Instructions 2. Pillow Block Bearings – Pillow block bearings are used on supply blower(s). Bearings have been pre-lubricated with high-quality lithium-complex base grease with an EP additive. The grease is a lithium-complex base mineral oil, NLGI Grade 2 consistency, with a base oil viscosity of ISO VG220. Re-lubrication should be done with lithium-complex thickened grease with a comparable NLGI consistency and base oil type and viscosity.
Browning Bearing Set Screw Torque Values Model# Shaft Size Torque (in-lbs) Set Screw VPS-212 VPS-214 VPS-116 VF2S-116 VPS-219 VF4S-219 VPS-220 VPS-223 VPS-323 VF4S-227 VPS-327 VPS-231 VF4S-231 VPS-331 VPS-235 VF4S-235 VPS-236 VPS-239 VF4S-243 VPS-343 VPS-347 3/4 7/8 1 1 1 3/16 1 3/16 1 1/4 1 7/16 1 7/16 1 11/16 1 11/16 1 15/16 1 15/16 1 15/16 2 3/16 2 3/16 2 1/4 2 7/16 2 11/16 2 11/16 2 15/16 66 - 85 66 - 85 66 - 85 66 - 85 66 - 85 66 - 85 126 - 164 126 - 164 126 - 164 126 - 164 228 - 296 228 - 296 228
24. Place a drop of “BLUE” Loctite on the blower setscrews and tighten all of the setscrews. 25. Align the blower and motor sheaves using a laser or straight edge and tighten the blower sheave to the shaft. 26. Replace the belts and tighten the motor base adjustment for the proper belt tension. Over tightening the belt tension will severely reduce belt and bearing life. Belt deflection should be approximately 1/64 inch for every inch of span length. 27.
B Section small Pounds pulley Pounds Force for diameter Belt Force for 11/2 times range in Manufacturer Normal Normal Inches & Type Belt Tension Tension 3.4-4.2 Gates Hi-Power 4.4 6.6 4.4-4.6 Gates Hi-Power 4.9 7.4 5.8-8.6 Gates Hi-Power 5.8 8.7 Note: For recommendation of other types of belts, consult respective manufacturers. a. Shut the system down totally, disconnecting or locking out power supply so there can be no accidental start-up during inspection. b.
SECTION IX - MESTEK LINE BURNERS Inspection and Maintenance of Gas Ports Conduct initial inspection within the first month after commissioning. Visually check the gas ports of new burner assemblies for any piping scale or debris. Use Pin Vise with drill bit to remove. Use of an electric drill motor is not suggested unless both Pin Vise and Drill can be chucked up in a varispeed drill unit. Use caution, because it is easy to snap the bits off in a port when using a drill motor.
SECTION X - MANIFOLD AND VALVE ADJUSTMENTS The I/O Zone 583 Controller (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. This will put power to the Burner Relay (RE-02). If the outside air temperature is above the Heating Economizer 65°F Setpoint the burner will be disabled.
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 modulating valve should be on bypass flow with the heater operating on low or minimum fire.
SECTION XII - REPLACEMENT PARTS Replacement parts may be ordered from the factory. All warranty parts will be shipped freight allowed from factory for normal ground service. Warranty parts must be returned prepaid within 30 days. Credit will be issued if part is complete, defective and returned on time. When parts are ordered, MODEL NUMBER, SERIAL NUMBER, FACTORY ORDER (F.O.) and PART NUMBERS are required. Belts, filters, and fuses are not covered under warranty.
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