I.C.E. BMA-136 HBR User Manual
BMA SERIES
DIRECT GAS-FIRED MAKE-UP AIR
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
READ MANUAL CAREFULY BEFORE INSTALLING
OR OPERATING THE FURNACE
FOR YOUR SAFETY FOR YOUR SAFETY
If you smell gas follow these instructions, The use and storage of gasoline or other flammable
1) Open windows. vapors and liquids in open containers in the
2) Do not touch electrical switches. vicinity of this appliance is hazardous.
3) Extinguish any open flame.
4) Call the gas supplier immediately.
MODEL: SERIAL NUMBER:
JOB: DATE OF INSTALLATION:
WARNING
IMPROPER INSTALLATION, ADJUSTMENT, SERVICE OR MAINTENANCE CAN
CAUSE PROPERTY DAMAGE, INJURY OR DEATH. PLEASE READ THE
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTION
THOROUGHLY.
*THIS UNIT IS TO BE SERVICED BY QUALIFIED PERSONNEL*
**DO NOT TAMPER WITH THE UNIT OR CONTROLS**
INSTALLER’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.
THIS EQUIPMENT SHALL BE INSTALLED AND WIRED IN ACCORDANCE WITH THE REGULATIONS OF
THE NATIONAL BOARD OF FIRE UNDERWRITERS, CANADIAN ELECTRIC CODE AND LOCAL
GOVERNING BODIES. THE INSTALLAION CODE FOR “GAS BURNING, APPLIANCES AND EQIPMENT,
CAN 1-B149”, AND APPLICALBLE PROVINCIAL REGULATIONS FOR THE CLASS, WHICH SHOULD BE
FOLLOWED CAREFULLY IN ALL CASES.
INSTALLER/SERVICE CONTRACTOR
NAME:
ADDRESS:
TELEPHONE:
CONTACT:
GENERAL INFORMATION
GENERAL NOTES
This Direct Fired BMA Series is used to provide make-up air to satisfy an exhaust system within a building. Normal discharge
temperature is in the 65°F – 75°F range except for the paint booth unit which can discharge at up to 140°F in the cure mode
(booth unoccupied and booth lights off). The sequence of operation and wiring diagram are located in the weatherhousing on
outdoor units and control compartment on indoor units.
WARNING
Fire or Explosion hazard can cause property damage, severe injury or death. Ensure that all air taken into the unit is
free from the presence of:
a) Flammable solids, liquids and gases.
b) Explosive materials. Example: grain dust, coal dust, gun powder etc.
c) Substance which may be come toxic when exposed to heat or passing through a gas flame.
INSTALLATION AND SERVICE INSTRUCTIONS
The information provided is a guide to the proper installation, operation and troubleshooting of the unit. Retain the manual as
a reference for operation and maintenance personnel. Should contact with the factory be necessary, provide the unit model
number and serial number. Install and wire the equipment in accordance to the applicable national and local governing bodies
codes. Authorities having jurisdiction should be consulted before making the installation. Local codes may require additional
safety controls and/or interlocks.
UNIT LOCATION
Prior to locating the unit check with the authorities having jurisdiction. The unit should be located with clearance to open
access doors and remove filters. Ensure that the unit is installed level. Provide adequate clearance on either side of the unit to
service blower, bearings, motors, drives and filters. Ensure that the position of the heater relative to support beams is correct
so as to provide adequate support for the equipment. For roof mounted units, check the spacing of the roof structure beams to
avoid interference with air ducts.
LOCATION OF ACCESSORIES
The remote panel will be shipped as a separate package. Mount the panel and have an electrical contractor install wiring.
FACTORY TESTING & START UP CHECKLIST
All BMA series units are factory fired and tested prior to shipping. Each unit is shipped with the tester’s report and a start-up
checklist. Complete the start-up checklist and return one copy to the factory.
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INSPECTION OF EQUIPMENT
All shipments are made F.O.B. the factory. The unit is securely strapped or blocked to prevent shipping damage and each
shipment inspected prior to leaving the plant. All parts, where feasible, are strapped to or included in the unit. Upon receipt of
goods, check the shipment against the bill of lading to ensure all items have been received. Carefully check the unit for
physical damage in the presence of the carrier’s representative. Should parts be missing or damage noted, file a claim
immediately with the carrier. ICE does not assume responsibility for the handling of the goods in transit and is not
responsible for the initiation of freight claims.
INSTALLATION AND SERVICE INSTRUCTIONS
Direct Gas Fired Make-Up Air Heaters
LOCATION OF UNIT AND DISTRIBUTION
Inlet
All air handled by this unit must be brought directly from outdoors. The intake shall be designed and located to prevent snow,
rain, flammable gas, toxic gases and other deleterious materials from entering the unit. (Less than 500 F.P.M. is an accepted
velocity.)
INSTALLATION
Smaller models are shipped as one total unit. All other models are shipped in sections which are easily erected on the job site.
The main sections consist of a burner damper section which contains the motor and a blower section. The secondary sections
are the filter, louver, mixing box etc., which are added in sections as required.
1. All sections are pre-drilled and are bolted together in the field (as per figure 1).
2. Belts must be installed on the motor and limit and discharge controls may have to be mounted and/or
wired.
3. When clearance is not a factor, ensure that the unit is adequately protected from obstruction.
NOTE: On roof top units the joint will have to be caulked to prevent rain from entering the unit.
Indoor Suspension
On indoor models holes at the base of the units are provided for 5/8” suspension rods (see drawing No. BMA-HD). Unit must
be lifted and handled from the lifting holes provided at each end of the channel iron, when suspending from the ceiling. If
units are to be lifted from the bottom for mounting on a platform (as with a fork lift), unit must be supported.
NOTE: DO NOT LIFT CABINET WITHOUT THIS SUPPORT.
Rooftop Installation
Support rails (minimum of 4” high) must be provided underneath the unit. In some cases, more height may be required when
installing the supply duct through the roof (see figure 1) or if a unit is a bottom discharge (see figure 2).
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CLEARANCE
Minimum clearance from the unit, to combustible construction, is clearly marked on the rating plate attached to the unit.
No source of flammable vapors, gases or dust shall be with in 20’ horizontally of any unit unless that source is separated from
the unit by an enclosure of fire and vapor resistive materials.
On indoor suspended units, when necessary to provide working clearance beneath the unit, the installation shall be made at a
suitable height above the floor.
CONNECT DUCTWORK
1. On indoor units, install fresh air duct to inlet of unit. Install intake hood or louvers with screen.
a) Make required opening in wall and line with angle frame inside. Should be completed before outside is
started to avoid crumbling.
b) Insert insulated fresh air “collar” through opening with flanges turned out to provide rigidity.
c) Anchor intake hood with birdscreen to wall.
d) Caulk perimeter of opening to make rain tight.
2. Connect discharge air duct or discharge grille to unit outlet. If unit is installed on a roof, be sure that the duct going
through the roof is adequately flashed and sealed to prevent leakage. (see figure 1).
3. Where a ductwork system or other enclosure is directly connected to the inlet or outlet of the heater is such a way as to
cause a possible gas trap and accumulation of a flammable mixture, a pre-purge cycle shall be incorporated to provide not
less than 4 complete air changes of the duct work or enclosure by volume prior to an ignition
4. Where additional automatically operated inlet or discharge air louvers are used, they shall be electric interlocked to ensure
the maximum designed opening before either starting or running circuits may be energized.
FIRE DAMPER
Fire dampers installed in inlet or outlet duct systems shall be interlocked to shut down the unit in case of fire in the duct work
and should be arranged so that the unit will only be electrically energized when in the wide open position.
HAZARDOUS CONDITIONS
In the event that the make-up air heater failure creates a hazard to other fuel burning equipment in the building the unit shall be
interlocked to open balancing inlet air dampers. These dampers can be of the motorized type, (see wiring diagram).
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EXHAUST INTERLOCK
a) This unit shall be electrically interlocked so that it will operate only when the associated exhaust system(s) is
functioning. An exhaust air flow proving switch shall be used (Refer to sheet exhaust interlock) for typical application,
and (wiring diagram) for electric hookup.
b) The total air discharge capacity of the unit cannot exceed by more than 10% the total discharge capacity of the exhaust
systems in conjunction with which it is used. Where the tempered air is discharged directly into a booth, the total air
discharge capacity of the booth.
c) The exhaust air proving switches should be set as to open when the volume of exhaust drops by more than 10% (dirty
exhaust filters, etc.).
CONNECT GAS SUPPLY
a) Run correctly sized gas line to the unit. Install manual shut off valve plug-cock type approved for the application.
NOTE: Gas line pressure must be a least 7” W.C” when unit is operating at full input (Burner manifold pressure at full input
is from 4” to 4 ½” W.C.) Check rating plate on unit for maximum gas input.
b) Bleed and vent lines shall be installed in accordance with the applicable requirements.
COMPLETE WIRING
1. Install remote supervisor panel or if summer-off-winter switch (is used) in the desired location.
2. Complete wiring to supervisor panel or summer-off-winter switch is shown on wiring diagram.
3. Install fused disconnect switch (to be furnished by installer) and connect 3 phase power supply to disconnect switch
mounted on unit. Voltage must correspond to voltage marked on rating plate.
4. Complete all wiring to accessories (interlocks) as per wiring diagram provided on the unit.
NOTE: It is recommended that filters be removed during winter operation, if up stream from burner.
WARNING
FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE, SEVERE INJURY, OR DEATH.
Check for gas leaks with rich soap and water solution any time work is done on a gas control.
START-UP PROCEDURE
1. Remove shipping blocks from:
a) Blower if rubber or spring isolated.
b) Check to be sure that damper opens, if tied down, remove wire.
c) Check modulating discharge controller, on units, to ensure that it is in the blower air stream. On some units this control
may be mounted external from the unit. If so, check to see that the sensor is installed in the discharge air stream of
the make-up air heater and that the controller is wired to the modulating motor, regulating gas supply to burner.
2. Make sure that the main firing valve is closed, but that gas is available in the service line.
3. Check to ensure exhaust fans are wired into the control panel and that there is power to the exhaust starter relays. Check
to ensure exhaust fans interlock switches are installed and wired to the control panel.
4. Familiarize yourself with the sequence of operation and wiring diagrams. This will give you information as to how the
unit operates.
5. Check voltage to ensure it matches the voltage stamped on the unit rating plate, and all wires are connected between unit
and remote panel.
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The timers TD-1 - TD-5 are factory set but you should check them to ensure they have not moved during transit to job
6.
site.
6A. Normal setting of high limits are -165°F.
7. Operate unit through paint mode by pushing in the system “on” push button. The unit should operate as per sequence of
operation.
7A. Pilot
The Protectorelay monitors the pilot flame through the flame rod. A minute current is sent from the relay through the
flame rod, and trough the pilot flame to “ground”. The relay detects the current flow and acts to open the safety valve as
required. When no flame exists, current cannot flow and the relay acts to close the valve. Current flow depends only on
flame contact on the rod: temperature of the rod is of no importance.
Since the flame rod is a current-carrying conductor, it must be free of any contact with conductive parts of the pilot
burner. Insulator must be clean, dry and free from cracks. While the flame rod is made of a heat resistant alloy it may,
after long service, deteriorate to the point of flame contact. Check for serious corrosion or loss of metal. It must be
tight enough in the insulator to maintain its position. Do not use too much force or the insulator may crack.
Proper operation of the flame rod can be checked by measuring the flame rod current; refer to flame safeguard
instruction sheet with unit. Lacking a micrometer, a check can be made with an operating burner through all its normal
phases. Relay response should be prompt with no chattering or drop out.
The spark rod (Midco Burner see figure 5 for gap setting, Maxon Burner spark ignitor No. 18075) produces a high
tension arc at the correct location for lighting the pilot. Ignition transformer must be rated for 6000 Volts, 20
Miliampers secondary, minimum.
The spark rod or spark ignitor, must be free of contact with conductive parts of the pilot burner. Insulator must be clean,
dry and free of cracks. Check the spark rod for serious corrosion or loss of metal. It must be held tightly enough in the
insulator to maintain its position.
Gap must be 1/16” to 3/32” ( see figure 5). Setting can also be checked by cycling the pilot. Ignition must be prompt
and positive. Do not allow careless positioning to cause arc of flame rod; serious relay damage would result.
If the spark ignitor on Maxon burners shows deterioration of ignitor points the complete spark ignitor should be
replaced (part No. 18075).
8. If pilot tries for ignition, but locks out, the air proving switches (high and low) that are mounted across the profile plate,
should be checked to make sure that the proper amount of air is flowing through the unit. Check to make sure blowers
are running in the proper direction. This can be checked by placing a differential gauge across the profile plate of the
burner section. If the pressure drop is between .30” W.C., and .95” W.C., these switches should be made, then check
pilot to ensure proper flame. Check instruction sheet for flame safeguard system.
Pilot adjustment screw is in the Thermax shut-off valve. When setting, adjust for the best reading, then open pilot set
screw slightly.
8A. Main flame supervision: With units that have more than three feet of burner from point or supervision, a second flame
rod will be on the main burner. This switching is done with a time delay relay (see wiring diagram). This can be
disconnected for testing for pilot, or you have to ensure main flame by opening up the firing valve within 15 seconds
after pilot solenoid is powered. As supervision will switch from pilot to main flame in that time. Check to ensure that
unit will lock-out in the event of main flame failure on low-fire by closing main firing valve.
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Gradually open firing valve to start main flame. Check for flame over entire burner length. Adjust the pressure
9.
regulator to 4” or 4 ½ ” W.C. pressure or the amount of gas marked on the rating plate.
10. On all units that have Maxitrol modulation. Read over the Maxitrol literature for the high fix and low fire setting. By
removing the wire from #2 on the amplifier the unit will stay on low fire and allow you to set the by pass or low fire
setting to ensure that the flame is completely across burner and is between 1” and 1 ½ ” long.
11. To set up high fire you will require to remove wire from #4 on amplifiers. A resistor should be placed across #3 and #4
of the amplifier remove when test complete) to check out discharge sensor. The resistors are attached to the Maxitrol
literature.
11A. Check gas pressure switch setting.
High pressure gas switch …………………………………..…… 6” W.C.
Low pressure gas switch ………………………………….……. 2” W.C.
NOTE: The high and low gas pressure switches may be the manual reset type on some units.
FLAME SUPERVISION CHECK
a) The flame supervision should be checked periodically to insure that the controls are operational. With the unit on full
operation and firing, close the main manual firing valve and pilot manual firing valve. This should lock out the unit.
b) The units with more than 3 feet of burner from the point of supervision have dual flame rod and a delay timer for main
flame supervision. Closing the main firing valve should lock out the safety relay and the unit should shut-down.
c) The main safety valve should be checked for gas tightness by placing a manometer in the manifold between the safety
valve and the manual firing valve (a 1/8” plug is provided for this). If there is a build up of pressure with the unit
locked out and the manual valve closed, the safety valve should be replaced.
d) The complete gas line and manifold should be checked for gas tightness.
C.F.M.
a) This unit depends upon an adequate supply of air for good combustion and operation. Care should be taken to ensure
that properly sized inlet hood and ductwork are installed and that the unit is discharging the right amount of C.F.M.
TROUBLE SHOOTING GUIDE
On start up, the unit will not operate properly. It may be an electrical mix up in the wire from the unit to the control panel
(see wiring drawing).
The wire connector shown 12 are in the remote panel.
The wire connector shown E12 are on the unit.
It is recommended you have a volt meter AC/DC, and a differential pressure gauge 0” - 2”
(magnehelic) and a gas pressure gauge 0” - 12”.
1. If inlet damper fails to open when system switch is pushed in.
a) Check to see if power is on #4. If no power supply starter overloads (1 OLS-1), may be open R1-1 normally
closed contacts may be open. Main flame safe guard relay needs to be reset.
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