Sterling Plumbing SDRIOM 2 User Manual

SDRIOM-2  
PN# 94.2000.03  
P
HVAC PRODUCTS  
4830 TRANSPORT DRIVE, DALLAS,TX 75247  
PHONE: 214-638-6010 FAX: 214-905-0806 www.sterlinghvac.com  
INSTALLATION, OPERATION AND MAINTENANCE MANUAL FOR  
SDR MODEL DIRECT GAS-FIRED HEATERS  
ATTENTION: READTHIS MANUAL AND ALL LABELS ATTACHEDTOTHE UNIT CAREFULLY  
BEFORE ATTEMPTINGTO INSTALL, OPERATE OR SERVICETHIS UNIT! CHECK UNIT RATING  
PLATE FORTYPE OF GAS AND ELECTRICAL SPECIFICATIONS AND MAKE CERTAINTHATTHESE  
AGREE WITHTHOSE AT POINT OF INSTALLATION. RETAIN FOR FUTURE REFERENCE.  
FORYOUR SAFETY  
The use and storage of gasoline or other flammable vapors and liquids in open containers  
in the vicinity of this appliance is hazardous.  
FORYOUR SAFETY  
If you smell gas:  
1. Open Windows  
2. Don’t touch electrical switches.  
c
3. Extinguish any open flame.  
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.  
WARNING: Install, operate and maintain unit in accordance with manufacturer’s  
instructions to avoid exposure to fuel substances or substances for 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.  
lINSTALLER’S RESPONSIBILITY  
Installer Please Note: This equipment has been test fired 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.  
POST AND MAINTAINTHESE INSTRUCTIONS IN LEGIBLE CONDITION  
SECTION III - INSTALLATION  
This equipment must be installed and wired in accordance  
Recirculation of room air is not permitted. All air must be  
ducted from the outdoors.  
with regulations of the National Board of Fire Under-  
writers, National Electrical Code, and local governing bodies.  
The following recommendations are not intended to  
supplant any requirements of federal, state, or local codes  
having jurisdiction. Authorities having jurisdiction should be  
consulted before installations are made. Local codes may  
require additional safety controls and/or interlocks.  
If in doubt regarding the application of this appliance,  
consult the factory.  
Locate the unit exactly level. Special attention should be  
given to the duct, electrical, and fuel connection points.  
Install duct work with adequate flexible connections to  
isolate vibrations from the duct work. All duct work should  
have taped or caulked seams. Duct work should be  
properly sized so as not to inhibit airflow. This information  
should be cross-checked with the position of support  
beams and stand pipes to insure that clearance dimensions  
coincide with those of the unit. The minimum clearance to  
combustible material must be maintained as listed inTable 1.  
All installations in airplane hangers must be in accordance  
with current ANSI/NFPA No. 409. All installations in public  
garages must be in accordance with the current Standard  
for Parking Garages, NFPA No. 88A, or the Standard for  
Repair Garages, NFPA No. 88B, and with CAN/CGA B149  
Installation Codes.  
CAUTION: Do not install heating system in  
corrosive or flammable atmospheres! Premature  
failure of, or severe damage to the unit will result!  
Table 1  
Minimum clearance to combustible material and access  
clearance (consult local codes and regulations)  
CAUTION: Heating system must not be installed  
in locations where air for combustion would contain  
chlorinated, halogenated or acidic vapors. If located  
in such an environment, premature failure of the  
unit will occur!  
Clearances to Combustible Material  
Vertical Units  
36 inches  
6 inches  
6 inches  
6 inches  
12 inches  
Zero  
Horizontal Units  
36 inches  
6 inches  
Front*  
Rear  
Right  
Left  
Top  
Floor  
6 inches  
6 inches  
12 inches  
6 inches  
A. Handling the Equipment  
The Direct Gas-Fired unit has been designed for rigging  
and handling through the use of special lifting lugs installed  
on the ends of each unit. As explained previously, the basic  
unit is designed for shipping in one piece where shipping  
limitations allow. Some optional accessories may require  
field mounting.  
* Consider control side as front of unit.  
On outdoor curb mounted installations, flash and seal roof  
curb to prevent leakage. The cross section of factory  
provided curb is formed to accept wood nailing strip and  
insulation provided by others.  
When unloading and setting the unit, use the lifting lugs  
provided or move the equipment on rollers. Hooks, jacks  
or chains must not be used around the casing, main control  
panel or exterior mounted controls.  
C. Location of Accessories  
Where applicable, standard or optional accessories will  
be placed inside the fan section of the unit for shipment,  
and must be removed and installed by the mechanical or  
electrical contractor.  
During transit, unloading and setting of the unit, bolts and  
nuts may have become loosened, particularly in the pillow  
block ball bearing assemblies in the fan section. It is  
recommended that all nuts and set screws be tightened.  
Turn fan shaft by hand to make certain that blower does  
not rub against blower housing, and that bearing set screws  
are tight.  
Field provided discharge or inlet dampers must be  
equipped with an end switch and interlocked to insure  
maximum design opening before starting and running  
circuits may be energized.  
Open the cover on the electrical control box located on  
the unit. Inspect all wire terminals and wiring terminations  
to ensure that all connections are tight.  
Field constructed intake accessories should be properly  
designed to minimize the entry of rain and snow.  
If this unit is not installed immediately, cover all openings  
that might be exposed to the weather. Rotate fan monthly.  
Adequate building relief must be provided, so as to not  
over-pressurize the building, when the heater is operating at  
its rated capacity. This can be accomplished by taking into  
account, through standard engineering methods, the struc-  
ture’s designed infiltration rate, by providing properly sized  
relief openings, by interlocking a powered exhaust system,  
or by a combination of these methods.  
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.  
3
D. Electrical Connections  
DANGER: Never use an open flame to detect  
gas leaks. Explosive conditions may exist which  
would result in personal injury or death.  
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.  
WARNING: To avoid equipment damage or  
possible personal injury, do not connect gas piping  
to this unit until a supply line pressure/leak test  
has been completed. Connecting the unit before  
completing the pressure/leak test may damage  
the unit gas valve and result in a fire hazard.  
WARNING: Controls must be protected from  
water. Do not allow water to drip on the  
ignition system.  
NOTE: Before installing any wiring, check the unit  
rating plate for supply power rating.  
The gas line should be supported so that no strain is  
placed on the unit. Pipe compounds, which are not  
soluble to liquid petroleum gases, should be used on  
threaded joints.  
All electrical connections and wiring must conform to the  
current edition of:ANSI/NFPA No. 70 National Electrical  
Code and applicable state and local codes.  
The appliance and its individual shutoff valve must be  
disconnected from the gas supply piping system during  
any pressure testing of that system at test pressures in  
excess of 1/2 PSIG.  
Entry location for all field-installed and control wiring is  
located beside the control panel.  
If optional disconnect is not furnished with heater, the  
field provided disconnect must be of the proper size and  
voltage. Refer to unit nameplate for minimum circuit  
ampacity and voltage. The disconnect must be installed  
in accordance with Article 430 of the current edition of  
ANSI/NFPA No. 70 National Electrical Code.  
The appliance must be isolated from the gas supply piping  
system by closing its 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. Please note  
that gas line pressure must be as shown on rating plate  
when unit is operating at full input.  
Check the supply voltage before energizing the unit. The  
maximum voltage variation unbalance must not exceed 2%.  
F. Field Wiring and Remote Control Installation  
1. Connect the power lines to the line side of the main  
disconnect switch.  
NOTE: Should any original wire supplied with the  
heater have to be replaced, it must be replaced  
with wiring material having a temperature rating of  
at least 105° C.  
2. Mount and wire remote control panel, thermostats,  
temperature sensors, and any other field installed  
controls as indicated on the unit control wiring diagram.  
3. Connect the wires to the appropriate field wiring  
terminals as indicated on the unit control wiring diagram.  
4. If the optional low-temperature limit was not an integral  
part of the heater, the factory recommends that a low-  
temperature limit control be installed in areas where  
freeze protection is needed in the event of burner shut-  
down.  
E. Field 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. A drip leg and/or filter should  
be provided upstream of the unit’s inlet gas connection. A  
shut-off must be located external of the unit’s enclosure.  
The location of this valve must comply with all local codes.  
A 1/8 inch N.P.T. test gauge connection must be installed  
immediately upstream of the gas supply connection to the  
unit.  
G. LocatingTemperature Controls  
The room or outdoor thermostats should be mounted  
where they will not be subjected to direct impact of  
the heated air or radiant heat from the sun. It is also  
recommended that thermostats, especially those with  
mercury bulb contacts, be mounted on a vibration free  
surface. Interior walls or the side of building columns away  
from the heater are usually the location best suited for  
mounting thermostats.  
Refer to the heaters rating plate for determining the  
minimum gas supply pressure for obtaining the maximum  
gas capacity for which this heater is specified.  
Controls with outdoor bulbs require that the outdoor bulb  
be shielded from direct radiation from the sun. Unit mounted  
sensors are factory located and mounted.  
4
SECTION IV - PRE START-UP  
A. Pre Start-Up  
6. Check set screws on all bearings, pulleys and fans for  
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.  
All information in this service manual is typical. All products  
are semi-custom and changes may occur.  
tightness.  
7. Check voltage supplied to disconnect switch. The  
maximum voltage variation should not exceed 10%.  
Phase voltage unbalance must not exceed 2%.  
8. Check thermostat(s) for normal operation.  
9. Check that system duct work is installed and free from  
obstructions.  
SuggestedTools and Instruments  
Volt/Ohm Meter  
Tachometer  
Manometer (0-10" W.C.)  
Standard Hand Tools  
Gas Pressure Gauge (0-35 lbs.)  
Thermometer  
Ammeter  
Microammeter  
D.CVolt Meter  
10.Check that fans turn free in housing.  
11.Check burner for proper location and alignment.  
12.Check that filters and accessories are installed correctly.  
13.Check that vent lines have been run to atmosphere on  
indoor units. Note that some units will use vent  
limiters and vent lines are not required.  
NOTE: All servicing and adjustments of the Direct  
Gas-Fired unit should be performed by a qualified  
service engineer.  
14.Check that all manual gas shut-off valves are closed.  
15. When failure or malfunction of this heater creates a  
hazard to other fuel burning equipment, (e.g. when the  
heater provides make-up air to a boiler room), the  
heater is to be interlocked to open inlet air dampers  
or other such devices.  
16. If inlet duct is attached to the heater, a purge  
timer must be provided and set to purge 4 times  
the inlet duct volume.  
1. The owner’s representative or equipment operator  
should be present during start-up to receive instructions  
on care and adjustments of the equipment.  
2. Remove all shipping blocks, brackets and bolts from  
supply fan base with optional isolation base.  
3. Check all wiring for loose connections and tighten if  
necessary.  
Purge time in seconds = 4 x L x W x H x 60  
SCFM  
CAUTION: Line side of disconnect may be  
energized.  
L = duct length in feet,W = duct width in feet,  
H = duct height in feet, SCFM = rating plate air  
throughput.  
4. Inspect all fan and motor bearings and lubricate if  
necessary.Tighten setscrews on pulleys, bearings, and fans.  
Refer to the electrical schematic for the proper  
circuit placement. Purge timer P/N 65.0711.00.  
CAUTION: Do not rupture grease seals.  
5. Inspect pulleys and belts for tightness, tension and  
alignment. Do not over tighten belts.  
5
SECTIONV - UNIT START-UP  
Close or replace all doors and service panels.  
Unit will run for 5 seconds before ignition trial.  
Turn main disconnect switch off. Verify the incoming line  
voltage matches the unit nameplate rating. If the voltage is  
over 10% of nameplate rating or phase voltage unbalance  
is over 2%, notify the contractor or power company.  
NOTE: 3 OR 4TRIALS MAY BE NEEDEDTO  
PURGE AIR FROM GAS LINE.  
UnitedTechnologies Electronic Controls Spark Ignitor  
Watch microammeter carefully. The reading should be at  
least 5.0 microamps. If the reading is too low, slowly turn  
the low-fire adjustment on the modulating valve in or out  
until satisfactory readings are obtained. When adjusting  
low fire, there should be a continuous flame along the  
entire burner length without any blowout spots.  
Turn Heat OFF/ON switch to the OFF position. Turn main  
disconnect switch on. Turn Fan OFF/ON switch to the  
ON position. Damper opens. Blower fan turns on.  
Turn Fan OFF/ON switch to OFF position and check sup-  
ply blower for proper rotation.  
Refer to MaxitrolValve Adjustment instructions  
in Section IX for setting high and low fire gas  
pressure settings.  
NOTE: To change rotation of the blower, simply  
interchange any two (2) of the line leads of the  
motor starter for three (3) phase motors. Refer to  
motor nameplate for reversing single (1) phase  
motors.  
When the flame is adjusted, shut the unit off by turning the  
Fan and Heat switches to OFF.  
Turn Fan OFF/ON switch to the ON position. Check for  
proper blower rpm. Check that all motor amp draws do  
not exceed nameplate ratings, and the overload relay is set  
to the motor nameplate amperage.  
Setting Main Flame  
Install manometer at test port on the last tee of the burner  
manifold or modulating valve.  
Slowly open all manual gas shut-off valves.  
Check dampers for proper operation. Be sure they operate  
freely, and the linkage does not bind.  
Restart unit. After main gas valves open and burner lights  
check gas lines for leaks.  
Make sure all manual gas shut-off valves are in the closed  
position.  
Adjust high gas pressure reading (from manometer) to  
match firing rate shown on unit nameplate.  
Turn Heat OFF/ON switch to the ON position. Blower  
fan will run.  
Adjust the high and low fire setting according to the  
MaxitrolValve Adjustment instructions in Section IX. The  
high fire setting must not exceed the pressure stated on  
the rating plate.  
Turn Fan and Heat OFF/ON switches to OFF position.  
Setting Burner  
When adjusting low fire, there should be a continuous flame  
along the entire burner length without any blow out spots.  
NOTE: To adjust gas pressure on supply lines where  
a regulator has been installed (to reduce the inlet  
pressure to 1/2 PSIG or less), remove dust cap of main  
gas regulator and turn adjusting screw clockwise to  
increase pressure, or counter-clockwise to decrease  
pressure.  
Main flame is now set. Recheck the microamp signal on the  
ignition control throughout the full burner input range. Re-  
check low fire setting. Cycle unit 2 or 3 times to insure  
good ignition.  
Set all thermostats to call for heat. Set inlet ductstat (if  
applicable) above outside air temperature.  
Safety Controls Check  
A. High Temperature Limit and Firestats – These limit  
controls are not adjustable and are checked by the  
factory. Reset the red button(s) to be sure they are  
ready for operation. Contact the factory if these switch-  
es fail to reset.  
Connect a DC microammeter between the SENSE terminal  
and the flame rod sensing wire.  
Turn Fan and Heat OFF/ON switches to ON position.  
B. Ignition Control - Operate unit in Heat mode. After  
flame has been established, close last manual gas valve  
before main burner.The ignition control must trip out  
within 15 seconds. Reset the ignition control by turning  
the HEAT switch to the OFF position.  
Open inlet manual gas shut-off valve slowly. Reset high and  
(if applicable) low gas pressure switches. Check main gas  
line for leaks using soap solution.  
6
C. Gas Pressure Switches - Operate unit in Heat mode.  
The low pressure switch will trip out and must be reset  
before resuming operation when the inlet gas valve is  
turned off during operation.The high pressure switch  
may be checked out by reducing the setting of its trip  
point below unit operating pressure. It should then trip  
out and shut off the burner. Return the adjustment to  
its original setting and reset to resume operation.  
When checking operation of air pressure switches on  
systems without pilot the heat switch will have to be  
turned off approximately five seconds to reset the igni-  
tion control.  
E. Temperature Controls – These controls are checked by  
adjusting control settings to a lower temperature setting  
while the unit is operating on high fire and observing  
cutoff. The controls should be reset to settings shown  
below:  
When checking operation of gas pressure switches on  
systems without pilot the heat switch will have to be  
turned off for approximately five seconds to reset the  
ignition control.  
Suggested Control Settings  
TC-01 Room Thermostat ................... Customer Discretion  
TC-03 On-Off Inlet Ductstat ............................................65°F  
TC-08 Freeze Thermostat ..................................3 min.,...45°F  
PS-04 Low Gas Pressure Switch ................................1.0”w.c  
PS-07 High Gas Pressure Switch............125% of firing rate  
TC-09 Night Set Back Room .................Customer Discretion  
TC-52 RemoteTemperature Selector .... Customer Discretion  
FL-02 High Temperature Limit (manual) ........ Not adjustable  
RE-26 High Limit Discharge Ductstat ................................95°F  
RE-26 Low Limit Discharge Ductstat ................................55°F  
PS-12 Clogged Filter Switch ....... Adjust to Field Conditions  
PS-13 Building Pressure Switch ..Adjust to Field Conditions  
D. Air Pressure Switches - The high air pressure switch is  
checked by removing the sensing tube from the enter-  
ing air side of the burner. Switch operation will shut  
off the burner. Recycle is automatic when the sensing  
tube is replaced.The low air pressure switch is checked  
by removing the sensing tube from the leaving air side  
of the burner. Switch operation will shut off the burner.  
Recycle is automatic when the sensing tube is replaced.  
SECTIONVI - UNIT SHUTDOWN  
A. Extended Shutdown -  
1. Set the Heat OFF/ON switch to the OFF, then turn the  
Fan switch to the OFF position.  
B. Emergency Shutdown ONLY -  
1. Open the main electrical disconnect switch.  
2. Close all manual gas valves.  
2. Close all manual gas valves.  
3. Open the main electrical disconnect switch.  
7
SECTIONVII TROUBLESHOOTING  
System without Pilot  
Symptom  
Cause  
Remedy  
A. If blower does not operate.  
1. Low or no voltage.  
2. Fuse(s) blown.  
1. Check power source.  
2. Check and replace.  
3. Customer interlock not closed  
or connected.  
3. Close or connect customer  
interlock.  
4. Fan Off-On switch in Off position.  
5. Time clock, night setback thermo-  
stat or field installed controls  
open.  
4. Switch to On position.  
5. Check time clock, night setback  
thermostat and field installed  
controls for proper settings.  
6. Reset freeze stat by interrupting  
power. Check for proper setting  
and burner operation.  
6. Freeze protection tripped.  
7. Damper motor not operating, or  
its end switch not making.  
7. Check for power at damper motor  
and that end switch has been wired  
correctly to the N.O. (normally  
open) contact. Check that the  
linkage is clear and not binding.  
8. Push reset button on starter and  
check amps.  
8. Overload protection on motor  
starter tripped.  
9. Belts loose or broken  
10. Bearings seized.  
9. Turn power off and check belts.  
10. Check and replace.  
11. Motor may be burned or incor-  
rectly wired.  
11. Turn power off and check motor  
and wiring.  
12. Motor overheating.  
12. Check burner firing rate.  
B. If there is no voltage at ignition  
control.  
1. Heat Off-On switch in Off  
position.  
1. Switch to On position.  
2. Burner enable relay open  
(if applicable).  
2. Check for power and replace if  
necessary.  
3. Outside air temperature higher  
than On-Off inlet ductstat  
(if applicable).  
3. Lower On-Off inlet ductstat  
setting.  
4. Field purge timer open  
(if applicable).  
4. Check for power and replace if  
necessary.  
C. Burner does not light after 5 sec-  
onds pre purge of flame safeguard  
relay and there is voltage at igni-  
tion control.  
1. Manual gas shut-off valve closed.  
2. Inlet gas pressure lower than  
required gas pressure.  
3. Type of gas (Natural, LP) supplied  
different from factory required  
type.  
1. Slowly open valve.  
2. Increase gas pressure.  
3. Replace with factory required  
type of gas.  
4. Auxiliary switch on starter not  
closed.  
4. Check for power and replace if  
necessary.  
5. Air flow switches not closing.  
5. Adjust the air flow and external  
static pressure to match rating  
plate.  
6. High temperature limit switch  
open.  
7. High or low gas pressure switches  
open (if applicable).  
6. Correct problem. Reset by pushing  
down the reset button.  
7. Correct problem. Reset both  
switches.  
8. Main gas valve relay open.  
8. Check for power and replace if  
necessary.  
8
SECTIONVII TROUBLESHOOTING  
System without Pilot continued  
Symptom  
Cause  
Remedy  
C. continued  
9. Defective gas valve or actuator.  
9. Check power to gas valves. If gas  
pressure matches unit rating plate  
and valve does not open, replace  
gas valve or actuator.  
10. Defective spark rod or out of  
position. (see spark rod diagram  
#P-001004)  
10. Make sure spark rod is producing  
a sufficient spark to light off  
burner, make sure porcelain is  
not cracked. Check wiring or  
replace if necessary.  
11. Flame rod not sensing flame. (see 11. Make sure flame rod is in flame.  
spark rod diagram #P-001003)  
Make sure porcelain is not  
cracked. Check wiring or replace  
if necessary.  
12. Defective regulator.  
13. Blocked vent lines or vent  
limiters.  
12. Clean or replace regulator.  
13. Check vent lines or replace vent  
limiters.  
14. Low fire set too low or too high. 14. Adjust setting on modulating valve  
or gas valve.  
D. Burner will not respond to tem-  
perature.  
1. For Maxitrol system.  
2. For Honeywell system.  
1. See following troubleshooting  
guide for Maxitrol series 14 & 44.  
2. See following troubleshooting  
guide for Honeywell series.  
9
SECTIONVII TROUBLESHOOTING  
P-001004  
P-001003  
10  
UnitedTechnologies Electronics Controls  
Operation of the Series 1016-400 Direct Spark  
Ignition Control  
On a call for heat a five second pre-purge is initiated.  
Upon completion of the pre-purge, the gas valve and 60  
Hz spark are energized. When flame is detected, the con-  
trol enters the steady state heating condition. Steady state  
heating will continue until the call for heat is satisfied.  
all outputs and enters lockout. Reset is accomplished by  
cycling the power off for a minimum of 5 seconds.  
If flame is lost once it has been established, the control will  
shut off the gas valve within 0.8 seconds and locks out.  
If flame is sensed during a purge period when no flame  
should be present, the control will remain in purge with  
the gas valve off until the false flame disappears.  
If the gas valve is found to be powered when it should be  
off, or not powered when it should be on, the control will  
enter lockout with all outputs off. Reset is accomplished  
by cycling the power off for a minimum of 5 seconds.  
If ignition is not achieved within 15 seconds, the control  
shuts off the gas and locks out. If the trial for ignition has  
been accomplished without ignition, the control shuts off  
TROUBLESHOOTING GUIDE  
Series 14 DischargeTemperature Control  
Reproduced with permission from Maxitrol® Company  
FieldTest  
Remedy  
1. Install properly.  
Symptom  
Possible Cause  
A. No Gas Flow  
1. Modulating valve  
improperly installed (or  
see Symptom “L”).  
1. Arrow on side of valve  
should point in direction  
of gas flow.  
1. Prove the power source.  
B. Continuous Low  
Fire (Electronics  
Problem)  
1. Short circuit or no  
voltage to the amplifier.  
2. Open circuit in TD114  
Remote Temperature  
1. Check for 24V AC at  
amplifier terminals 7 & 8.  
2. Inspect for loose or  
broken wires between  
amplifier terminals 1 & 2  
and TD114 terminals 1 & 3.  
3. Connect test resistor as  
described in Preliminary  
Circuit Analysis in Section  
IX. Follow procedures  
outlined.  
2. Tighten connections or  
replace wiring.  
Selector circuit or wiring.  
3. If modulating voltages are  
obtained, check TS114  
circuit for shorts. Replace  
TS114 if necessary.  
3. Short circuit in TS114  
Discharge Air Sensor  
circuit of wiring.  
4. If items B1-3 check out, and  
modulating voltages are still  
not obtained, amplifier may  
be assumed faulty. Replace.  
4. Faulty amplifier.  
4. Check items B1-3.  
1. Replace modulator head if  
not approximately 45-55  
ohms for M611Valve and  
60-80 ohms for MR212Valve.  
2. Clean or replace plunger if  
necessary.  
C. Continuous Low  
Fire (Electronics  
OK).  
1. Short circuit or open  
circuit in Modulator  
Coil.  
1. Measure resistance across  
modulator terminals with  
connecting wires detached.  
2. Plunger missing, jammed, 2. Inspect. Plunger should be  
or improperly installed.  
installed to operate freely in  
solenoid sleeve.  
1. Adjust to proper minimum  
fire.  
D. Incorrect Minimum  
Fire Erratic or  
1. Incorrect by-pass  
metering valve  
1. See valve adjustments in  
Section IX.  
Pulsating Flame  
adjustment.  
2. Excessive negative  
burner pressure.  
2. If reading is greater than 1.5”  
negative pressure, check for  
clogged filters or other inlet  
air restrictions. Consult  
2. Close main gas supply and  
measure manifold pressure  
with blower operating.  
Reading should be less than  
1.5” W.C. negative pressure.  
factory for other solutions.  
11  
TROUBLESHOOTING GUIDE  
Series 14 DischargeTemperature Control continued  
Reproduced with permission from Maxitrol® Company  
FieldTest  
Remedy  
Symptom  
Possible Cause  
E. Continuous High  
Fire (Electronics  
Problem).  
1. Short circuit in TD114  
Remote Temperature  
1. Inspect for shorts at or  
between Amplifier terminals  
1 & 2 or TD114 terminals  
1 & 3.  
1. Correct wiring if shorts exist.  
Selector circuit or wiring.  
2. Open circuit in  
TS114/TS1007  
2. Check TS114/TS1007 for  
open internal circuit.  
Connect test resistor as  
described in Preliminary  
Circuit Analysis. Follow  
procedure outlined.  
3. Inspect.  
2. If modulating voltages are  
obtained, check TS114/  
TS1007 for open circuits.  
Replace TS114/TS1007.  
Discharge or Inlet Air  
Sensor circuit or wiring.  
3. Jumper not connected  
across amplifier  
3. Correct the wiring.  
terminals 2 & 3.  
F. Continuous High  
Fire (Electronics  
OK).  
1. Foreign object 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 seat. Clean valve  
or replace if necessary.  
2. Clean or, if necessary,  
replace plunger  
G. Incorrect  
1. Inlet pressure too low.  
1. Read pressure at inlet to  
modulating valve using a  
manometer with unit  
1. Increase inlet pressure if  
possible.  
Maximum Fire.  
operating at full fire.  
Pressure should be equal  
to the sum of outlet pres-  
sure setting plus pressure  
drop of the valve.  
2. Incorrect outlet pressure 2. Read manifold pressure  
2. See valve adjustments in  
Section IX.  
adjustment of Pressure  
Regulator.  
using manometer and  
compare with the pressure  
stated on the specification  
plate.  
H. Erratic or Pulsating  
Flame  
1. Hunting  
1. Adjust sensitivity control  
counter-clockwise.  
1. If flame stabilizes, adjust  
sensitivity control to  
maintain an even flame.  
2. If the flame is steady  
throughout the entire  
modulating range, the  
TS114 must be moved.  
2. Erratic air patterns or  
improper TS114 location.  
2. Connect test resistor  
as described in Preliminary  
Circuit Analysis.Turn  
TD114 selector dial so  
heater goes through its  
entire modulating range.  
3. Temporarily wire each  
TD114,TS114 and MR212  
externally and observe  
heater/equipment  
3. Wiring is run next to  
high voltage switching  
circuits causing induced  
voltages.  
3. If smooth operation  
results, isolate affected  
wiring from source of  
induced voltage.  
operation.  
12  
TROUBLESHOOTING GUIDE  
Series 14 DischargeTemperature Control continued  
Reproduced with permission from Maxitrol® Company  
FieldTest  
Remedy  
Symptom  
H. continued  
Possible Cause  
4. Faulty Amplifier or  
erratic voltage supply.  
4. With test resistor  
connected (per item H2)  
and TD114 locally  
4. If erratic or unstable D.C.  
voltages are obtained  
throughout the modulating  
range, the amplifier may be  
assumed faulty. Replace. If  
erratic operation is noted  
only over a small range of  
2 or 3 volts, the voltage  
sources may contain surges.  
Consult factory for other  
solutions.  
connected (per item H3)  
turn TD114 selector dial  
through entire modulating  
range. Observe D.C.  
voltage across modulator  
terminals.  
I. Incorrect Discharge  
Air Temperature  
1. Inlet Air sensor is used.  
2. Incorrect wiring.  
1. Inlet Air Sensor changes  
1° or each 3.5°, 5° or 8°  
outside temperature change  
from 60° (predetermined -  
turndown varies with  
model used).  
1. Sensed temperature will  
vary from TD114 dial  
settings. This is intentional.  
2. Check wiring diagram for  
heater.  
2. Correct wiring.  
3. System out of  
calibration.  
3. Sensed temperature  
(thermometer next to  
TS114) does not correspond  
toTD114 setting.  
3. See calibration procedure.  
4. Improper TS114  
location.  
4. Sensed temperature (thermo- 4. Move TS114 to location  
meter next toTS114) does  
not represent average  
where average representative  
temperature can be sensed.  
discharge air temperature.  
5. Remove Override  
5. Room Override  
Thermostat circuit  
closed.  
5. TD114 dial setting, then check  
thermostat setting and/or  
check wiring for shorts.  
Thermostat lead from  
terminal 2 of TD114.  
J. Burned out  
Transformer.  
1. Short circuit in  
modulator coil.  
1. Measure resistance across  
modulator terminals with  
red lead wires disconnected.  
2. Inspect wiring.  
1. Replace modulator head if  
less than 40 ohms.  
2. Short circuit  
2. Correct wiring if short  
is found.  
between amplifier  
and modulator valve.  
K. Discharge Air  
Temperature too  
low when TS115  
is operative.  
1. Override Temperature  
setting is too low.  
1. Check “Override Tempera- 1. Reset to correct temperature.  
ture Selector” of TD114.  
2. Burner capacity may be  
insufficient.  
2. Check for high fire (Maxitrol 2. If on high fire, control can  
manifold pressure specified  
for heater).  
do no more. Heater unable  
to furnish additional heat to  
raise temperature.  
L. Automatic Control  
Valve will not open  
despite full range of  
modulating voltage  
at terminals 3 & 4.  
1. Faulty automatic  
control valve.  
1. Read voltage across auto  
valve terminals. If 24V AC,  
valve is faulty.  
1. Replace automatic control  
valve.  
2. Open wire to automatic 2. Read voltage across  
valve. terminals 5 & 6. If 24V AC,  
2. Correct wiring.  
check for open circuit to  
automatic valve.  
13  
TROUBLESHOOTING GUIDE  
Series 44 RoomTemperature Control  
Reproduced with permission from Maxitrol® Company  
FieldTest  
Remedy  
1. Install properly.  
Symptom  
Possible Cause  
A. No Gas Flow.  
1. Valve improperly  
installed.  
1. Arrow on side of valve  
should point in direction  
of gas flow.  
B. Continuous Low  
Fire (Electronics  
OK).  
1. Open circuit in  
modulator coil.  
1. Remove wires connected  
to amplifier terminals 6 &7  
and measure resistance.  
MR212 (60-80 ohms), M611  
(45-55 ohms).  
1. If proper resistance values  
are not observed, replace  
modulator head or repair  
wiring.  
2. Plunger missing, jammed 2. Inspect. Plunger should be  
2. Clean or replace plunger is  
necessary.  
or improperly installed.  
installed to operate freely in  
solenoid sleeve.  
3. Ruptured main or  
balancing diaphragm.  
3. Disassemble valve for  
inspection of internal parts.  
3. Replace diaphragm if  
ruptured.  
C. Continuous Low  
Fire (Electronics  
Problem).  
1. No voltage to the  
amplifier.  
2. Short in modulator coil  
circuit.  
1. Check for 24V AC at  
amplifier terminals 8 & 9.  
2. Measure resistance per  
item 2.  
1. Provide 24V AC to amplifier.  
Refer to item K1.  
2. If proper resistance values are  
not observed, replace the mod-  
ulator head or repair wiring.  
3. Short in TS144 circuit.  
4. Faulty amplifier.  
3. Remove wires connected to 3. If readings are incorrect, replace  
amplifier terminals 1, 2 & 3.  
Measure resistance across  
wires 1 & 3. Meter should  
read greater than 2500 ohms.  
the TS144 or repair wiring.  
4. Follow procedures outlined 4. If power source and  
in “Preliminary Circuit  
Analysis” in Section IX.  
modulator coil check out  
(items 5 & 6) but proper  
modulating voltages cannot  
be obtained, then amplifier  
may be assumed at fault.  
Install replacement amplifier.  
D. Incorrect Low Fire. 1. Incorrect by-pass metering 1. SeeValve Adjustments -  
1. Adjust to proper low fire.  
2. If greater than 1.5”  
valve adjustment.  
2. Excessive negative  
burner pressure.  
Section IX.  
2. Close main gas supply and  
measure manifold pressure  
with blower operating.  
Should be less than 1.5”  
W.C. negative pressure.  
negative pressure, check  
equipment for clogged  
filters and other inlet air  
restrictions. For other  
solutions, consult factory.  
E. Continuous  
1. Faulty amplifier.  
1. Follow procedures outlined 1. If amplifier is proven at fault,  
Minimum Discharge  
Air Temperature.  
in “Preliminary Circuit  
Analysis” in Section IX.  
2. Remove wires connected  
to amplifier terminals 4 & 5.  
Set T244 or TD244 to max-  
imum setting. Measure  
install replacement amplifier.  
2. Short in T244 or  
2. If reading is incorrect, replace  
The T244,TS244/TD244 or  
repair wiring.  
TS244/TD244 circuit.  
resistance across wires.  
Meter should read 6000  
ohms 1000 (T244). If  
TS244/TD244 are used,  
meter should read 4500  
ohms 1000 (TS244) and  
2100 ohms 150 (TD244).  
Control circuits external to Series 44 can cause burner malfunction. Always check manual valve to be  
certain gas is on, and check limit controls for normal operation.  
14  
TROUBLESHOOTING GUIDE  
Series 44 RoomTemperature Control continued  
Reproduced with permission from Maxitrol® Company  
FieldTest  
Remedy  
Symptom  
E. continued  
Possible Cause  
3. Incorrect space  
3. Follow procedures outlined 3. If proper action is obtained,  
temperature calibration.  
in “Preliminary Circuit  
Analysis” in Section IX.  
first check item E2.  
Recalibrate if necessary.  
F. Incorrect  
Maximum or  
1. Improper TS144  
location.  
1. Compare sensed  
1. Move TS144 to location  
where average temperature  
can be sensed.  
temperature reading at  
TS144 with average  
Minimum  
Discharge Air  
Temperature.  
discharge air temperature.  
2. Follow procedures outlined 2. If proper temperatures are  
2. Incorrect discharge  
air temperature  
calibrations.  
in “Preliminary Circuit  
Analysis” in Section IX.  
not observed, refer to  
Discharge Air Temperature  
calibration procedures.  
G. Continuous High  
Fire (Electronics  
OK).  
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. Clean, or if necessary,  
replace plunger  
H. Continuous High  
Fire (Electronics  
Problem).  
1. Open circuit in TS144.  
1. Inlet pressure too low.  
1. Measure resistance per  
item C3.  
1. If readings are incorrect,  
replace the TS144 or repair  
wiring.  
I. Incorrect High Fire  
1. Read inlet pressure at valve 1. Increase inlet pressure if  
using manometer with  
heater operating at full fire.  
Pressure should be at least  
equal to the sum of: outlet  
pressure setting and  
possible or change to larger  
valve. Consult factory  
about possibility of using  
special spring to reduce  
pressure drop on selected  
installations.  
pressure drop of the valve  
plus 1.0” W.C.  
2. Incorrect outlet  
2. Read outlet pressure using  
manometer and compare  
with the pressure stated  
on the specification plate.  
2. SeeValve Adjustments in  
Section IX.  
pressure adjustment.  
J. Continuous  
1. Faulty amplifier.  
1. Follow procedures outlined 1. If amplifier is proven at  
Maximum Discharge  
Air Temperature.  
in “Preliminary Circuit  
Analysis” in Section IX.  
2. Measure resistance per  
item E2.  
fault, install replacement  
amplifier.  
2. If reading is incorrect,  
replace T244,  
2. Open circuit in T244  
or TS244/TD244.  
TS244/TD244 or repair  
wiring.  
3. Incorrect space  
3. Follow procedures outlined 3. If proper action is obtained,  
temperature calibration.  
in “Preliminary Circuit  
Analysis” in Section IX.  
first check item J2.  
Recalibrate if necessary.  
K. Burned out  
1. Short in modulator coil 1. Measure resistance per  
circuit. item B1.  
1. If proper resistances are  
not observed, replace  
modulator head or repair  
wiring.  
Transformer. No  
Voltage to Amplifier.  
Control circuits external to Series 44 can cause burner malfunction. Always check manual valve to be  
certain gas is on, and check limit controls for normal operation.  
15  
TROUBLESHOOTING GUIDE  
Series 44 RoomTemperature Control continued  
Reproduced with permission from Maxitrol® Company  
L. Incorrect Space  
Temperature  
1. Incorrect maximum  
discharge air  
1. Check to see if heater is  
delivering air at maximum  
discharge air setting.  
1. If desired temperature is  
not reached, increase  
temperature setting  
(A1044).  
maximum discharge air  
temperature setting.  
2. Incorrect minimum  
discharge air  
2. Check to see if heater is  
delivering air at minimum  
discharge air setting.  
2. If desired space temperature  
is not reached, decrease  
minimum discharge air  
temperature  
setting (A1044).  
3. Insufficient burner  
capacity.  
temperature setting.  
3. Check to see if heater is  
operating at high fire.  
3. If desired space temperature  
is not reached with heater at  
high fire, it may be undersized.  
4. Consult factory. If tempera-  
ture reading is incorrect,  
check items L1, L2 & L3, then  
recalibrate if necessary.  
4. Incorrect space  
temperature  
4. Place thermometer next  
to T244 or TS244. Compare  
space temperature reading  
with T244 or TD244 dial  
setting.  
calibration.  
Control circuits external to Series 44 can cause burner malfunction. Always check manual valve to be  
certain gas is on, and check limit controls for normal operation.  
8. With main burner operating, check the gas control flow  
rate as before (using the meter clocking method or  
check pressure using a manometer connected to the  
outlet pressure tap on the control).  
9. If necessary, adjust the low pressure regulator to match  
the appliance rating.  
HoneywellTwo StageValve  
Two-stage models require that you check and adjust both  
high and low pressure regulator settings.Two-stage appli-  
ance operating sequences vary. Consult the appliance man-  
ufacturer instructions for the specific operating sequence  
and regulator adjustment procedure for the appliance in  
which the control is installed.  
a. Remove the pressure regulator adjustment cap.  
b. Using a screwdriver, turn the inner adjustment screw  
1. Set appliance to operate on high.  
for LO pressure clockwise  
counterclockwise  
sure to the burner.  
to increase or  
to decrease the gas pres-  
2. Carefully check the main burner lightoff. Make sure that  
the main burner lights smoothly and that all ports  
remain lit.  
10.Once high and low pressure have been checked and  
adjusted, replace pressure regulator adjustment cap. If  
the desired outlet pressure or flow rate can not be  
achieved by adjusting the gas control, check the  
control inlet pressure using a manometer at the inlet  
pressure tap of the control. Take the necessary steps to  
provide proper gas pressure to the control.  
3. Check the full rate (high) manifold pressure listed on  
the appliance nameplate for high pressure.The gas con-  
trol full rate outlet pressure should match this rating.  
4. With main burner operating, check the gas control flow  
rate using the meter clocking method or check pres-  
sure using a manometer connected to the outlet pres-  
sure tap on the gas control.  
5. If necessary, adjust the high pressure regulator to match  
the appliance rating.  
Check Safety Shutdown Performance  
a. Remove the pressure regulator adjustment cap.  
b. Using a screwdriver, turn the inner adjustment screw  
WARNING: Fire or explosion hazard. Can cause  
property damage, severe injury or death. Perform  
the safety shutdown test any time work is done  
on a gas system.  
for HI pressure clockwise  
counterclockwise  
to increase or  
to decrease the gas pres-  
sure to the burner.  
6. After high pressure has been checked, check low pres-  
sure regulation.Two-stage appliance operating  
sequences vary. Consult the appliance manufacturers  
instructions for the specific operating sequence and reg-  
ulator adjustment procedure for the appliance in which  
the control is installed and for instructions on how to  
prevent the control from moving to high stage while  
checking the low pressure regulator setting.  
NOTE: Read steps 1 through 7 before starting, and  
compare to the safety shutdown or safety lockout  
tests recommended for the intermittent pilot (IP)  
ignition module.Where diffferent, use the proce-  
dure recommended for the module.  
7. Check the low rate manifold pressure listed on the  
appliance nameplate. Gas control low rate outlet pres-  
sure should match this rating.  
16  
1. Turn off gas supply.  
2. Set thermostat or controller above room temperature  
to call for heat.  
3. Watch for ignition spark or for glow at hot surface  
igniter either immediately or following prepurge. See IP  
module specifications.  
4. Time the length of the spark operation. See the IP  
module specifications.  
5. After the module locks out, open the manual gas cock  
and make sure no gas is flowing to the pilot or main  
burner. With modules that continue to spark until the pilot  
lights or the system shuts down manually, the pilot should  
light when the manual gas control knob is opened.  
6. Set the thermostat below room temperature and wait  
one minute.  
7. Operate system through one cmplete cycle to make  
sure all controls operate properly  
SECTIONVIII - MAINTENANCE SCHEDULE AND LUBRICATION REQUIREMENTS  
Periodic maintenance is essential to the efficient operation  
and extended service life of this equipment. Failure to pro-  
vide maintenance as recommended may void the equip-  
ment warranty.  
f. Check the pilot assembly (if applicable). Clean and  
adjust if necessary.  
g. Inspect the burner carefully. Clean and adjust if  
necessary.  
h. Check voltages and amp draw on main fan motor.  
i. Check the operation of all safety controls  
individually.  
A. Maintenance Schedule  
1. Weekly  
a. Check that fan belts are tight and sheaves are  
aligned.The fan belts can be checked every  
30 days after the first 60 days of new belt run-in.  
j. Check the operation of the automatic gas shut off  
valves and check them for leakage at the pressure  
test ports provided.  
4. Off Season orYearly  
CAUTION: Do not overtighten belts.  
a. Complete the monthly and quarterly maintenance  
schedule.  
2. Monthly  
b. Inspect all fan wheels and housings. Clean if  
necessary.  
c. Check that all fan wheels and sheaves are securely  
set on the shaft.  
d. Inspect all bearings and alignment.Adjust if  
necessary.  
e. Inspect allV-belts. Replace if necessary.  
f. Inspect all electrical components, connections and  
terminals. Clean and tighten where necessary.  
g. Test ignition spark.Adjust gap if necessary.  
h. Clean ignition electrodes and check for cracks.  
i. Test flame safeguard relay and replace components  
if necessary.  
j. Inspect all regulators, relief valves, motorized  
valves, solenoid valves, vent valves, manual shut off  
valves and safety shut off valves. Check their oper-  
ation and clean as necessary.  
a. Check all valves, piping and connections for leaks.  
b. Check the flame signal.  
c. Check the fuel pressure in the fuel supply line to  
each heater.  
d. Check the burner manifold pressure at full fire and  
that low fire has a continous flame all across burner.  
e. Clean the flame sensor(s).  
f. Inspect filters. Clean or replace as necessary.  
g. Inspect the main fan bearings.  
h. Check all dampers, damper actuators and linkages.  
Adjust and tighten if necessary.  
i. Ensure that there are no obstruction blocking the  
air supply to the heater or the air discharge from  
the heater.  
j. Inspect the area and make sure that no com-  
bustible or hazardous material has been stored  
within the clearances as shown on the unit name-  
plate.  
k. Ensure all vents to the atmosphere are clean and  
free from obstruction.  
3. Quarterly  
l. Inspect and clean all drip legs in the fuel line.  
m. Lubricate fan motor as directed by motor manu-  
facturer.  
n. Inspect fan motor wiring for loose connections.  
o. Lightly oil all door latches.  
a. Complete the monthly maintenance schedule.  
b. Check the belt tension for the main fan(s) and  
adjust if necessary.  
c. Check the alignment of the sheaves and adjust if  
necessary.  
p. Check that cabinet is weathertight, replace door  
gaskets and recaulk as necessary.  
d. Inspect all bearings set screws for tightness and  
lubricate bearings if necessary.  
e. Check the pilot electrical system (if applicable).  
Adjust if necessary.  
NOTE: Keep screened air intakes clear of obstruc-  
tions at all times.  
17  
B. Lubrication Instructions  
A slight showing of grease at the seals with accompanying  
normal bearing temperature indicates proper lubrication.  
Normal temperature can range from “cool” to “hot to  
the touch” depending on size, speed and surrounding  
conditions. Excessive bearing temperature indicates faulty  
lubrication. An insufficient amount of grease is suggested  
by a bearing showing no grease at the seals, and a higher  
than normal temperature and noise level. Excessive  
leakage of grease at the seals, and a high operating  
temperature suggest too much grease.  
Item  
Manufacturer  
U.S., Baldor or  
BearingType  
All 3 phase fan  
Single row ball  
bearings  
motors (1 HP to equal  
20 HP) ODP,TEFC  
Recommendation: See following note.  
All 1 phase motors Century, G.E. or Bronze sleeve  
(Fractional HP)  
ODP,TEFC or  
TEAO  
equal  
bearings  
Frequency of Lubrication - Frequency of lubrication  
depends upon operating conditions. The bearing  
operating temperature is the best index for determining  
a relubrication schedule. The following chart gives the  
frequency of relubrication based upon continuous  
operation for various operating temperatures and can  
be used as a satisfactory guide for determining when  
all ball bearings should be relubricated.  
Recommendation: See following note.  
Fractional HP Century, G.E. or Bronze sleeve  
single phase, ODP equal  
or TEFC  
bearings  
Recommendation: See following note.  
Fan shaft bearings Fafnir or equal Self-aligning single  
row ball bearings,  
resilient mounted  
Recommendation: See following note.  
Speed  
Temperature Cleanliness Interval  
500 RPM  
Up to 150°F  
Up to 210°F  
Over 150°F  
Up to 150°F  
Clean  
Clean  
Clean  
Dirty  
2 months  
2 weeks  
weekly  
1 week to  
1 month  
daily to  
weekly  
daily to  
weekly  
daily to  
weekly  
Dampers  
Arrow or equal Sleeve  
Recommendation: See following note.  
1000 RPM  
1500 RPM  
Any Speed  
1. Blower Motors - Some motors require lubrication  
while others do not. Those that require lubrication can  
be identified by the presence of grease plugs in the motor  
casing at each end. Motors that do not have grease plugs  
cannot be greased and are lubricated for the life of the  
motor bearing.  
Any Speed  
Any Speed  
Any Speed  
Over 150°F  
Any Temp.  
Any Temp  
Dirty  
Very Dirty  
Extreme  
Conditions  
Lubrication of motors should be done while the motor is  
warm and at a standstill. Remove and clean all grease plugs  
and insert a grease fitting in the upper hole in the motor  
casing at each end. (Viewed as if motor were sitting  
horizontally on its base.) There may be one or two plugs  
in each end casing of the motor. Add a small amount of  
a clean, good grade ball bearing grease, such as Exxon  
Polyrex EM or equal, with a low pressure grease gun. Run  
the motor five minutes before removing the grease fittings  
and replacing the plugs.  
3. Dampers - Dampers should be inspected monthly for  
securely fastened linkages and smooth operation. If  
dampers are binding or excessively noisy, lubrication may  
be required. Place one drop of #20 wt. machine oil on  
each blade bearing and linkage ball joint. Do not over  
lubricate. Wipe away any excess from the area. Be sure  
to note that dampers over 49 inches long have intermedi-  
ate bearings which require lubrication.  
C. Air Filters  
CAUTION: An excess of grease will overheat the  
bearings.  
All filter banks should be equipped with a manometer or  
differential pressure switch to indicate when the filters are  
dirty. Filters should be replaced when the differential  
pressure across them reaches the manufacturer’s  
recommended final value. Dirty filter elements should  
be replaced with a clean element of the same type and  
size. In addition, the manufacturer strongly recommends,  
that air filters be checked every 30 days and replaced  
with new filters (throw-away type) or cleaned (washable  
type) as required. Cleanable filters should be given new  
application of filter coating after washing to maintain  
optimum filter performance.  
NOTE: On totally enclosed fan cooled (TEFC)  
motors, the rear end fan housing must be removed  
to expose the grease plugs.  
2. Pillow Block Bearings - Pillow block bearings are used  
on supply blower(s) as required. Bearings have been pre-  
lubricated with a number 2 lithium base grease.  
Relubrication should be done with a similar grease using  
a low pressure grease gun. Wipe all grease fittings clean  
before adding grease. Grease should be added slowly, in  
small amounts at frequent intervals while the shaft is being  
manually rotated.  
The frequency of cleaning and replacing air filters applies  
twelve months of the year where blowers are used for  
ventilation and heating.  
18  
D. BeltTension and Adjustment  
B Section Belt  
Pounds  
Pounds  
Belt tension is adjusted during the initial run-in and test  
periods at the factory. However, the belts are run as slack  
as possible to prevent excessive damage to the bearings,  
yet tight enough to prevent slippage.  
small  
pulley  
diameter  
range in  
inches  
Manufacturer & Force for Force for  
Type Belt  
Normal  
Tension  
11/2 times  
Normal  
Tension  
It is necessary, therefore, to check belt tension during the  
first few months of operation, and to check for proper  
tension weekly during the first 60 days, after which  
30-day check intervals are sufficient.  
3.4-4.2  
Gates Hi-Power  
4.4  
6.6  
4.4-4.6  
5.8-8.6  
Gates Hi-Power  
Gates Hi-Power  
4.9  
5.8  
7.4  
8.7  
Note: For recommendation of other types of belts, consult  
respective manufacturers.  
CAUTION: Turn off all power to the equipment  
before checking belt tensions.  
F. Gaskets  
CAUTION: Do not over tighten belts.  
Gaskets are used on doors, inspection covers, some filter  
racks, and some outdoor air dampers. Inspect gaskets  
periodically and repair or replace as required.  
CAUTION: Do not attempt to tighten any belt or  
belts by changing the pitch of an adjustable pulley.  
This will change the air flow and fan speed.  
Consult the factory if the fan speed must be  
changed.  
G. Heater  
1. At least a yearly inspection is recommended for  
heating installations and more frequently for process  
applications in year-round operation. Your own  
experience is the best guide in determining frequency  
of inspection, but as a minimum, the following  
procedure should be followed:  
Suggested BeltTension Method  
1. Check tension frequently during the first 24-48  
hours of run-in operation. Ideal tension is the lowest  
tension at which the belt will not slip under peak load  
conditions. Over tensioning shortens belt and bearing  
life.  
a. Shut the system down totally, disconnecting or  
locking out power supply so there can be no  
accidental start-up during inspection.  
2. To properly tension a conventionalV-belt drive,use the  
following procedure:  
b. Inspect the burner carefully, including upstream and  
downstream sides of mixing plates as well as burner  
body face. Note that complete burner assembly  
may have to be removed for proper inspection and  
cleaning. Any accumulation of scale or foreign  
material on either side of the mixing plates should  
be removed with a wire brush. Check visually that  
no holes in the mixing plates are blocked. If any  
burner ports are plugged, even partially, clear them  
with a piece of wire. Consult the factory for  
alternate procedures.  
a. Measure the span length.  
b. At the center of the span, apply a force perpendicular  
to the span to deflect the belt 1/64 inch for every  
inch of span length. For example, for a 40 inch  
span, apply a force that will deflect the belt 40/64  
or 5/8 of an inch.  
c. Compare the force you have applied with the  
values given in the table below. If the force is  
between the values for normal tension and 1 1/2  
times normal tension, the belt tension should be  
satisfactory. If the belt tension is not within this  
range, it can be adjusted by loosening the motor  
mounting bolts and adjusting the position of the  
motor along its base.  
WARNING: Do not enlarge burner ports or  
performance may be drastically affected.  
If any mixing plates are loose or missing fasteners,  
tighten or replace as necessary. Always use zinc  
plated or stainless fasteners.  
NOTE: A new drive can be tightened to two times  
the minimum value shown to allow for normal  
drop in tension during the run-in period.  
The mixing plates on the burner may display  
“hairline” cracks. These cracks are normal and  
caused by thermal stresses occurring during com-  
bustion. The presence of these “hairline” cracks in  
no significant way affects the combustion efficiency  
or performance of the heater. Should a large  
opening develop, it may cause difficulties in cross  
ignition of flame across the face of the burner. If  
this does occur, the specific mixing plate or plates  
involved must be replaced.  
19  
c. Put system back into operation and view burner  
while cycling through full firing range. This will give  
a visual check for blocked burner ports. Clean  
burner ports as necessary using a #47 drill. Burner  
plates should be cleaned with a wire brush at least  
once a year.  
3. Replace all access panels, which have been removed,  
and operate the unit for a test period. Check for  
normal response and function of all controls.  
4. Check all gas piping for possible leaks using a soap  
bubble solution.  
2. Inspect the flame rod and ignition electrode for dirt  
and moisture. Wipe off if necessary. Examine for any  
evidence of premature arcing. If in doubt, check con-  
tinuity of flame rod to be sure it is not grounding out.  
Replace if required.  
5. Inspect the support means to be sure that everything  
is firmly anchored in place.  
The porcelain on the ignition electrode must be intact,  
not cracked.  
SECTION IX - MAXON NP-I AIRLO® 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 PinVise with  
drill bit to remove.  
Annual inspections are normally adequate once the initial  
piping debris is removed.The operating conditions of the  
burner will determine how frequently maintenance is actu-  
ally required.  
Use of an electric drill motor is not suggested unless both  
PinVise and Drill (as shown) can be chucked up in a vari-  
speed drill unit. Use caution, because it is easy to snap the  
bits off in a port when using a drill motor. Removal of bro-  
ken bits from the gas ports is difficult.  
Alternate drill sizes which may be used are 5/64” (for #47)  
and 1/16” (for #50).  
Contact your Maxon representative to answer questions  
or address any problems.  
20  
SECTION X - MAXITROLVALVE ADJUSTMENTS  
AND PRELIMINARY CIRCUIT ANALYSIS  
M411, 511, 611Valve  
MR212Valve  
High Fire Manifold Adjustments  
High Fire Manifold Adjustments  
1. Disconnect wires from amplifier terminal #4 (Series  
14), or #2 and #4 (Series 44). This causes the valve  
to call for continuous high fire.  
1. Disconnect wires from amplifier terminal #4 (Series  
14), or #2 and #4 (Series 44). This causes the valve to  
call for continuous high fire.  
2. Adjust the pressure regulator to obtain the rating  
plate manifold pressure.  
3. Reconnect the wires to amplifier terminal #4 (Series  
14) or #2 and #4 (Series 44).  
2. Remove seal cap (A) and turn regulator pressure  
adjusting screw to obtain desired manifold pressure.  
(Clockwise rotation increases pressure.)  
3. Reconnect the wires to amplifier terminal #4 (Series  
14), or #2 and #4 (Series 44).  
Low Fire or Bypass Adjustments  
1. Disconnect wire from amplifier terminal #8. This  
causes the valve to call for continuous low fire.  
2. Remove cap (A) and turn adjusting screw (B) to  
desired low fire adjustment. (Clockwise rotation  
reduces minimum flow rate.)  
NOTE: If low bypass is on maximum, the desired  
high fire outlet pressure may not be achieved.  
Low Fire or Bypass Adjustments  
1. Disconnect wire from amplifier terminal #8. This  
causes valve to call for continuous low fire.  
2. Remove cap (B) and loosen lock screw (C). Turn (D)  
to desired low fire adjustment. (Clockwise rotation  
reduces minimum flow rate.)  
3. Replace cap (A) and reconnect wire to amplifier  
terminal #8.  
3. Tighten screw (C), replace cap (B) and reconnect wire  
to amplifier to terminal #8.  
21  
PRELIMINARY CIRCUIT ANALYSIS - SYSTEM 14  
For ease in troubleshooting, it is advisable to wire the  
system as follows (this differs from the normal connection).  
The Discharge Air Sensor is disconnected and replaced  
with a 10,000 ohm,1/2 watt test resistor (terminals 3 and  
4). If inlet air sensor is being used, disconnect and replace  
with a jumper. On units where the Remote Temperature  
Selector is located a considerable distance from the heater,  
it may be advantageous to connect the selector at the  
heater location.  
PRELIMINARY CIRCUIT ANALYSIS - SYSTEM 44  
This Preliminary Circuit Analysis will provide identification  
of faulty components, improper wiring or calibration, and  
other difficulties when used with the tabulated  
Troubleshooting Guide.  
NOTE: All voltages and resistance readings are  
approximate.  
Section 1  
1. Wire the system per Figure 1.  
Connect a DC volt meter (capable of reading 0-24V DC)  
on the Modulator or Modulator-RegulatorValve terminals.  
Set the temperature to the minimum dial setting. The DC  
voltage should read 0 volts. The DC voltage should  
gradually increase to at least 20 volts as you slowly rotate  
the dial to the maximum dial setting. If these voltages are  
obtained, the valve function can now be checked out.  
2. Connect a DC voltmeter to amplifier terminals #6  
and #7.  
3. Turn the Test-Potentiometer to minimum resistance  
(2,000 ohms). The DC voltage should read 0 volts.  
4. Turn the Test-Potentiometer slowly to maximum  
resistance (12,000 ohms). The DC voltage should  
gradually increase to at least 18 volts.  
The operation of the valve with regard to voltage is as  
follows: from 0 volts to approximately 5 volts, the  
If proper voltages are observed, continue on with  
Section 2.  
modulating valve should be on bypass flow with the heater  
operating on low or minimum fire. From approximately  
5 volts to 15 volts DC, the valve should be performing its  
modulating function and the heater should be firing at a  
modulated flow rate between low and high fire, depending  
on the voltage. Above approximately 15 volts DC, the  
valve should be delivering full flow to the heater and the  
unit should be on full fire. If the DC voltage is obtained  
on the valve terminals, but the heater does not respond as  
described, the problem can be isolated to the valve itself  
or to the gas control manifold of the heater.  
If proper voltages are not observed, the problem is  
identified with the Amplifier, the 24-volt AC power  
supply, or the circuit connected to terminals #6 and #7.  
Section 2  
1. Turn power OFF. Wire system per Figure 2. Turn  
power ON.  
2. Turn Test-Potentiometer to minimum resistance.  
Voltage should be 0 volts.  
3. Turn Test-Potentiometer slowly to maximum resistance.  
The DC voltage should gradually increase to at least  
18 volts.  
In the event proper voltages are obtained and the valve  
responds correctly to these DC voltages, the problem  
could well be in the wiring leading to the Discharge Air  
Sensor itself. This should also be reviewed in the check  
list.  
If proper voltages are observed in both Section 1 and  
2, the amplifier is satisfactory.  
If proper voltages are not observed, continue testing  
to identify the difficulty. Faults may be identified with  
the amplifier, the 24V power supply, or the circuit  
connected to terminals #6 and #7.  
If the proper voltages are not obtained when wired as  
instructed, the problem can be isolated to the electronics  
and this may once again be reviewed in the check list.  
After test, remove the test resistor and reconnect the  
Discharge Air Sensor to terminals 3 and 4. If Remote  
Temperature Selector has been moved, return it to its  
original position.  
Section 3  
1. Observe burner flames and/or burner pressure as  
Test- Potentiometer is turned through full range.  
NOTE: From 0-5 volts, heater should be at bypass  
or low; 5-15 volts, heater should respond with vari-  
ous input rates; beyond 15 volts, heater is at maxi-  
mum input.  
If proper operation is observed, continue procedure to  
check operation of sensing and selecting components.  
If proper operation is not observed, see Trouble-shoot-  
ing Guide to test M and MR valves and connecting  
wiring.  
22  
Section 4  
Figure 1  
1. With proper voltages observed thus far and modulator  
responding correctly, wire the system (see Figure 1),  
except have TS144 connected in place of jumper. Set  
A1044 MIN temperature selector at least 10°F above  
outdoor temperature. Set A1044 MAX temperature  
selector at mid-range. Heater is now under control  
by TS144 Discharge Air Monitor.  
2. Turn Test-Potentiometer to maximum resistance.  
Delivered air temperature should be per A1044 MAX  
temperature setting. Turn Test-Potentiometer to  
minimum resistance. Delivered air temperature  
should be per A1044 MIN temperature setting. If  
proper delivered air temperatures are observed, the  
problem is identified with the space temperature  
sensing and/or temperature selecting components and  
circuits. See Troubleshooting Guide. If proper  
delivered air temperatures are not observed, check  
calibration. See Troubleshooting Guide.  
Figure 2  
MIN  
MAX  
Section 5  
1. After test, remove all test equipment and reconnect all  
components.  
SECTION XI - REPLACEMENT PARTS  
Replacement parts may be ordered from the factory. All  
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.  
warranty parts will be shipped freight allowed from the  
factory via standard ground service. Warranty parts must  
be returned prepaid within 30 days. Credit will be issued  
if part is complete, defective and returned on time.  
Dealer/Contractor Name:  
City:  
Address:  
State:  
Zip:  
Ph:  
23  
FOR CANADIAN INSTALLATIONS ONLY  
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.  
1.  
2.  
All electrical connections must be in  
accordance with Canadian Electrical Code,  
Part 1, CSA Standard C22.1.  
All electrical connections must conform to the current edition of the Canadian Electrical Code, Part 1 CSA Standard  
C22.1 and applicable local codes.  
SECTION XII - RECIRCULATION  
WARNING: On heaters, which recirculate room  
air, outside ventilation air must be provided in  
accodance with the information shown on the  
heater nameplate.  
If gas fork trucks or other fossil fuel powered equipment  
are utilized in the conditioned area, additional ventilation  
requirements for the facility must be addressed separately.  
The heater inlet shall be located in accordance with appli-  
cable building code provisions for ventilation air.  
Recirculation of room air may be hazardous in the pres-  
ence of:  
• flammable solids, liquids and gases  
• explosive materials such as grain dust, coal dust,  
gunpowder, etc.  
Field constructed intake accessories should be properly  
designed to minimize the entry of snow and rain.  
All ventilation air to the heater shall be ducted directly  
from the outdoors.  
• substances such as refrigerants or aerosols which may  
become toxic when exposed to heat or flame.  
If in doubt regarding the application, consult the heater  
manufacturer.  
Recirculation is not recommended in uninsulated buildings  
where outside temperatures fall below 32°F (0°C).  
ETL labeled heaters must be equipped with a control sys-  
tem and an air measuring station provided by the heater  
manufacturer and installed on the return air damper or  
duct.  
Excessive recirculation or insufficient ventilation air, which  
results in inadequate dilution of combustion products gen-  
erated by the heater, may create hazardous concentrations  
of carbon monoxide, nitrogen dioxide, and other combus-  
tion products in the heated space.  
24  

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