Energy Tech Laboratories Modular Direct Fired Heaters manual

April 2006 Rev. 9 FOR YOUR SAFETY The use and storage of gasoline or other flammabl e vapors and liquids in open containers in the vicinity of this appliance is hazardous . Standard and Modular Direct Fired Heaters Installation, Operation, and Maintenance Manual Modular Direct Fired Heater Standard Direct Fired Heater Direct Fired Module Save these[...]

TABLE OF CONTENTS WARRANTY ....................................................................................................................... ........................... 3 INSTALLA TION ................................................................................................................... .......................... 4 Mechanical ...[...]

3 WARRANTY This equipment is warranted to be free from defe cts in materials and workmanship, unde r normal use and service, for a period of 12 months from date of shipm ent. This warranty shall not apply if: 1. The equipment is not installed by a qualifi ed instal ler per the MANUFA CTURER’S installation instructions shipped with the product, 2.[...]

4 INSTALLATION It is imperative that this unit is in stalled and ope rated 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 1-866-784-6 900 for warranty and technical support issues. Mechanical WARNING: DO NOT RAISE VENTILATOR BY T[...]

5 Recom men ded S uppl y Du ctwor k S izes Bl ower Si ze Duct Size St rai ght Duct Lengt h 10 14 x 14 48 i n. 12 16 x 16 54 i n. 15 20 x 20 72 i n. 18 24 x 24 86 i n. 20 26 x 26 108 i n. 25 32 x 32 168 i n. through vertical portion of the ventilator base assembly flange using a minimum of eight (8) lug screws, an chor bolt s, or ot her suita ble fa[...]

6 Direct Fired Module Installation Indoor (INLINE) Installation Heat Module Add-On Installation Modular heat units shippe d to add heat onto existin g blower only application s require field mechanical and wiring installation. 1. Remove existing filter intake and lifting lugs from blower section in take side. 2. Attach heat module to blower intake [...]

7 Gas Pressure Table Gas Pressure Type Gas Pressure Size 1-3 Inlet Pressure 7 in. w.c. – 14 in. w.c. Size 4-5 Inlet Pressure 7 in. w.c. – 5 psi. Max. Manifold Pressure - Natural Gas 5 in. w.c. maximum Max. Manifold Pressure - Propane 2.5 in. w.c. maximum Gas Connection Sizes Unit Size Gas Pipe Size (NPT) Size 1 ¾” Size 2 1” Size 3 1” Siz[...]

8 Copper Wire Ampacity Wire Size AWG Maximum Amps 14 20 12 25 10 30 8 40 6 55 4 70 Electrical Before connecting powe r to the heater, read and understand this entire section of this docume n t. As-built wiring diagrams are furnished with each fan b y the factory, and are atta ched to the door of the unit. Electrical wiring and connections should be[...]

9 Remote Control Panel On units shipped with the optional remote control panel , an ele ctrical drop containing th e panel wiring is provided with the heate r. There is a terminal strip in side the remote panel th at matches the terminals in the heater unit. The remote panel shoul d be wired as shown below. BL YW RD BK PK RD WH OR BR GY BK RD YW PK[...]

10 Pilot Assembly OPERATION Prior to starting up or operating the heater, che ck al l fasteners for tightness. In particular, che ck the set screw in the wheel hu b, bearings and t he fan sheav es (pulleys). With p ower and gas to the heater OFF or prior to connecting ventilator to po wer, turn the fan whee l by ha nd to be sure it is not st riking[...]

11 Maxitrol M511 and M611 Low Fire Bypass Screw Mod Valve Voltage Summary Volts DC Firing Mode 0 to 5 VDC Low Fire 5 to 15 VDC Modulation 15 to 20 VDC High Fire Maxitrol MR212 Lo w Fire Bypass Scre w Average Man ifold Pressure vs. Firing Rate/Ft. of Bu rn er -1.0 0 0.00 1.00 2.00 3.00 4.00 5.00 6.00 0 100000 2000 00 300000 400000 50000 0 600000 Fi [...]

12 Adju st pilot fla me. Lock u ni t in to hig h f i re. Ad j us t incomi ng gas pressur e. Doe s h igh fi r e pr oduce at least a 70°F temp rise an d produce the correct m anifold pressu re? A djust h igh fire No Lock unit in to low fire. Yes Does thin flame fill ent i re b urne r le ng t h? Adju s t low fire. Sett in g i n comi n g p ressu re: P[...]

13 Maximum RPM and HP Chart Blower Size Maximum RPM Maximum HP 10” 1800 2 12” 1500 3 15” 1400 5 18” 1200 5 20” 1000 10 25” 900 20 Pulley Adjustment Illustration Setscrew Torque Thread Size Torque (IN/Lb) No. 10 33 1/4” 80 5/16” 156 3/8” 275 7/17” 384 1/2” 600 Final Start Up Procedure 1. With the air and burner systems in full [...]

14 Pulley Combination Chart Motor RPM 1725 1/3 to 1-1/2 H P MOTOR PULL EY Dd1 Dd2 Pd1 Pd2 AX BELTS 1VL34 1.9 2.9 2 3 Open Closed BLOWER PULLEY DATUM DIAMETER PITCH DI A METER 5 4 1/2 4 3 1/2 3 2 1/2 2 1 1/2 1 1/2 0 AK114 11 11.2 308 323 339 354 370 385 400 416 431 447 462 1/3 to 2 HP MOTOR PULL EY Dd1 Dd2 Pd1 Pd2 AX BELTS 1VL40 2.4 3.4 2.6 3.6 Open[...]

15 Flame Safety Controller Air Flow Switch DC Flame Signal DC Voltage Flame Status 0 to 5 VDC No Flame 6 to 11 VDC Weak Flame 12 to 18 VDC Strong Flame Sequence of Operation The direct-fired heater is most easily understood wh en broken down into smaller individual system s. There are two main systems, a make -up air fan and a heater. T he make-up [...]

16 Maxitrol 14 Amplifier High Temperature Limit airflow switch to close. The high airflo w switch prot ects against profile plate fail ures that cause excessive airflow through the burne r. In the ev ent that the pressure drop across th e burner is not in the range of the airflow switch, gas flow to the burne r is stopped by the Flame Safety Contro[...]

17 9 Begins Pilot Trial For Ignition and turns on PTFI LED 9 The pilot g as solenoid valve is opene d, the sp ark igniter begins spar king, and the flamerod sensor watches for flame initiation 9 When flame is establishe d, the FLAME LED is illuminated and m a in valve opens and the FSC powers the Maxitrol system and gas flow begin s modulating 9 Th[...]

18 Components The following image and list outlines the typical di rect fired heater components and their fun ctions. 1. Gas Inlet – Main gas supply conn ection 2. Motor Starter – Contactor with overload protec tion to start and prot ect motor. 3. Freeze-Stat Thermosta t (Optional) – De-energizes blo wer motor if the discharge air temperature[...]

19 Remote Panel Option The Remote Panel is a device used to control the ope r ation of the heater from a remote location. This unit is available in both a “2 Position” or “3 Position ” configuration and with or with out a cooling output. It also will accommodate both the Maxitrol discharge te mperature dial and the Maxitrol space sensing Se[...]

20 Troubleshooting The following tables list cause s and corrective actions for possibl e problems wit h direct fired heater units. Review these lists prior to consulting manufacture r. Airflow Troubleshooting Chart Problem Potential Cause Corrective Action Blown fuse or open circuit breaker Replace fuse or reset circuit breaker and check amps Disc[...]

21 Burner Troubleshooting Chart Problem Potential Cause Corrective Action 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 pressur e Pilot valve is off Turn pilot valve on Pilot orifice fitting leak Tighten pilot orifice Excessiv[...]

22 Remote Panel Troubleshooting Chart Light Indication Condition Possible Cause Bad voltage to unit Main disconnect i n “OFF” Position Circuit breaker tripped No Lights Power not available to Remote Panel Bad main transformer Proper unit Off Operation No problem Manual/Off/Auto Switch in “Off” Position (3 Position Remo te Panels Only) Impro[...]

23 Is Freeze-Stat open? Adjust or Replace Is end switch on Moto ri ze d Damp er closed? Adjust or Replace actuator YES YES NO Nothing Happe ns Is Overload tripped on starter? Reset & m easure FLA of m otor. Is it higher than rating? Adjust or change Pull ey NO NO YES Blower runs but there is no heat Is the air fl ow LED on Flame Saftey ill umin[...]

24 Flame Safety Service Guide (Airflow LED may or may not be illuminated)[...]

25 Flame Safety Service Guide (continued) (Airflow LED may or may not be illuminated)[...]

26 MAINTENANCE To guarantee trouble fre e operation of this heater, th e man ufacturer sugge sts following these guid elines. Most problems associated with f an failures are directly related to poor servi ce and maintenance. Please record any mainte nance or service performe d on this fan in the docum ent ation section located at the end of this ma[...]

27 Burner Orifice Drill Size Orifice Drill Size Gas Port 31 Air Port 43 2 weeks after startup 1. Belt tension should be checked after the first 2 weeks of fan ope ration. Belts tend to stretch and settle into pulleys after an in itial start-up sequence. Do not tension bel ts by changing the setting of the motor pulley , this will change the fan spe[...]

28 April 2006 Rev. 9 Start-Up and Maintenance Documentation START-UP AND MEASUREMENTS SHOULD BE PERFORMED AFTER THE SYSTEM HAS BEEN AIR BALANCED AND WITH TH E HEAT ON (Warranty will be void without completion of this form) Job Information Job Name Service Company Address Address City City State State Zip Zip Phone Number Phone Number Fax Number Fax[...]