Installation and Maintenance Manual IM-685-1
Group: Applied Systems
Part Number: IM685
Date: January 2004
SuperMod
TM
Forced Draft Gas Fired Furnace
on McQuay Applied Rooftop Systems
HT***A* with RM7895A Flame Safeguard
© 2004 McQuay International
IM 685-1 1
When writing to McQuay for service or replacement parts, refer to the model number of the unit as stamped on the serial plate,
attached to the unit. If there is an in-warranty failure, state the date of installation of the unit and the date of failure along with an
explanation of the malfunctions and the description of the replacement parts required. Parts are warranted for ninety (90) days
unless covered by original uni t w a rranty .
General
Warranty Exclusion.......................................................... 3
Ventilation and Flue Pipe Requirements.......................... 3
Factory Mounting............................................................. 3
Factory Checkout .............................................................3
Installation
General ............................................................................. 3
Flue Box........................................................................... 3
Wind Deflector........ ....................................... .................. 4
Electrical........................................................................... 4
Gas Pressure Requirements.............................................. 4
Gas Piping........................................................................ 4
Valve and Regulator Venting........................................ .... 5
Normally Open Vent Valve .............................................. 6
Gas Piping Routing into Unit........................................... 6
On-the-Roof Piping (Models 020-140) ........................6
Through-the-Curb Piping (Models 020-140)................ 6
Typical Piping Connections................... ....................... 6
Gas Piping (Models 150-200)....................................... 7
Gas Piping Within the Vestibule...................................7
Field Gas Piping Required............................................ 7
Condensate Drain................................ .......................... 7
Vestibule (Models 150-200) ......................................... 7
Start-up & Operating Proce dures
Start-up Responsibility..................................................... 8
Start-up Procedure ............................................................ 8
Before Start-up................................................................. 8
About This Burner............................................................ 8
Prepurge is Low-High-Low................................. ......... 8
Low Fire Start................................................ ............... 8
"Pilot" is Main Flame Modulated Down
to Pilot Rate ................................................................ 8
Set Control System to Enable Heating............................. 8
Start-up Preliminary......................................................... 8
Preliminary "Dry" Run..................................................... 9
Flame Start-up......................................................... ......... 9
Modulate Firing Rate ............................. ... ....................... 9
Combustion Tests........................................................... 10
Cycle the Unit................................................................. 10
Record Data....................................................................10
References
Typical Electrical Schematic.......................................... 10
Typical Sequence of Operation ...................... ... ............. 10
Typical Piping Schematic................................................11
Typical Burner Control Box........................................... 12
Flame Safeguard
Keyboard Display Module..............................................12
Operation.........................................................................12
Normal Start-up...............................................................12
LED Display ...................................................................12
Service
General............................................................................13
Gun Assembly.................................................................13
Gun Assembly Removal and Installation .......................13
Flame Rod Adjustment ................................................. ..13
Flame Rod Installation.................................................. ..13
Ignition Electrode Adjustment........................................13
Air & Gas Adjustments...................................................14
Gas Supply Pressure .......................................................14
High Pressure Regulator .................................................14
Gas Adjustment...............................................................14
Air Adjustment................................................................14
Air and gas Control Linkage...........................................14
Actuator Crankarm..........................................................15
Switch Adjustments........................................................15
Altitude Considerations ..................................................15
Gas Valve Pressure Regulator Adjustment .....................16
Adjustment Procedure for Parallel Valves ......................16
Check Manifold Pressure at Minimum rate....................16
Combustion Testing ........................................................17
Verify Input Rate.............................................................17
Check CO
, CO and Stack Temperature.........................17
2
Cleaning Heat Exchanger (Models 032-200) .................17
Cleaning Heat Exchanger (Models 020-025) .................18
Leakage Symptoms.........................................................18
Checking for Leaks.........................................................18
Causes of Failures...........................................................18
Replacing a Heat Exchanger...........................................19
Furnace Condensation ....................................................19
Rear Cleanout Port..........................................................20
Furnace Condensate Drain Kit........................................20
Considerations.............................................................20
Install .875 Copper Drain Line....................................20
Install the Cover Over Drain Pipe...............................20
Combination Fan and Limit Control...............................20
Maintenance
Monthly, Twice Yearly, Yearly........................................ 21
Troubleshooting Chart ....................................................22
Typical Parts List - 60 Hz ...............................................24
Capacities & Adjustments Table..........................25
Performance & Service History............................26
SERVICED BY:
TELEPHONE NO: INSTALLATION DATE:
Installer: Leave this manual with owner. It is to be posted and maintained in legible condition.
2 IM 685-1
General
This forced draft gas burner is specifically designed for use
with the furnace on McQuay applied rooftop heating and air
conditioning units which are for outdoor installation only.
Each model size has unique burner head components to tailor the shape of the flame to each particular stainless steel
combustion chamber, to match the capacity requirement, and
to offer a desirable turndown potential when arranged for
modulation. This is a forced draft burner with a high pressure combustion air fan and will operate against pressure.
This eliminates the need for draft inducers, chimneys, draft
hoods, barometric dampers, and Breidert caps.
Warranty Exclusion
Do not operate the furnace if chlorinated vapors are present,
the airflow through the furnace is not in accordance with rating plate, or if wiring or controls were mo dified or tampered
with. Damage caused or contributed to by such conditions is
not covered by the warranty.
WARNING
Do not operate gas heating units in an atmosphere contaminated with corrosive chemicals such as halogenated hydrocarbons, chlorine, cleaning solvents,
refrigerants, swimming pool exhaust, etc. Exposure to
these compounds can cause severe damage to the gas
furnace and personal injury or death.
Ventilation & Flue Pipe Requirements
The McQuay applied rooftop unit is equipped with an outdoor air louver to supply adequate combustion air. The unit
also has a flue outlet assembly and requires no additional
chimney , flue pipe, Breidert cap, draft inducer, etc.
Factory Mounting
This burner and gas train has been installed and wired at the
factory. See "Gas Piping." Also note that models 150
through 200 have the burner removed for shipment; see
“Vestibule (Models 150 thru 200)” on page 7.
Factory Checkout
This complete heating plant was fired and tested at the factory. It was adjusted to the required capacity and efficiency.
Modulating air and gas linkages, pressure regulators, and
stops were adjusted for proper operation at all firing levels.
The unit was fired through several complete sequences of
start-up through shutoff to check operation. A check was
made of the air switch, gas pressure switch, high limit opera-
tion, and combustion characteristics including CO2 and CO
(at several firing rates on modulating burners).
If the burner was specified for operation at higher altitudes,
combustion air adjustments were compensated to result in
proper settings at the higher altitude. This checkout normally eliminates on-the-job start-up problems; however, the
equipment is subject to variable job c onditi ons an d shippi ng
shocks can change adjustments, cause damage, and loosen
connections and fasteners. Therefore, it is necessary to go
through the complete start-up procedure even though the
unit may appear to be operating properly.
Installation
General
The installation of this equipment must be in accordance
with the regulations of authorities having jurisdiction and all
applicable codes. It is the responsibility of the installer to
determine and follow the applicable codes. Sheet metal
parts, self-tapping screws, clips, and such items inherently
have sharp edges, and it is necessary that the installer exercise caution. This equipment must be installed by an ex perienced professional installation company that employs fully
trained technicians.
Flue Box
The flue box is not installed at the factory because it would
increase the width of the unit beyond the allowable shipping
width. All holes are prepunched, the fasteners are furnished
and everything is shipped inside a box in the burner section
of the unit. On Models 150 through 200, it is shipped in the
same crate as the vestibule. Remove and discard the shipping cover installed over the furnace tube outlets before
installing the flue box. See “Figure 1. Flue Box” on page 4.
1. Remove the screws (2) in the casing of the unit that line
up with the bottom lip holes of the flue box tube sheet
(3). These screws will later be replaced, at which time
they will also attach the bottom of the flue box to the
unit.
2. .Install flue box wrapper sheet (4) by sliding it up from
below. Attach with side screws (5). At this time reinstall
bottom screws (2)
.
McQuay Model Designation
Furnace
Model
Output
Capacity
(MBH)
IM 685-1 3
20 25 32 40 50 64 65 79 80 100 110 140 150 200
200 250 320 400 500 640 650 790 800 1000 1100 1400 1500 2000
(
)
Figure 1. Flue Box
4
Factory
Caulk
Factory
Welded
Seams
Electrical
The McQuay burner receives its electrical power from the
5
3
main unit control panel. No additional power wiring must be
routed to the burner. The sequencing of the burner is also
controlled through this panel and therefore is factory wired.
No additional wiring will be required. Note that models 150
through 200 furnaces require reassembly of some electrical
connections as the burner is removed for shipment.
WARNING
Improper installation, adjustment, alteration, service or
maintenance can cause property damage, severe personal injury or death. Read the installation, operating
and maintenance instructions thoroughly before installing or servicing this equipment.
If you smell gas:
1. Open Windows and ventilate area thoroughly.
2. Don’t touch electrical switches.
3. Eliminate open flames, pilot lights, arcing or sparking
equipment, or other sources of ignition.
4. Evacuate the area.
Threaded Drain
both corners
2
Wind Deflector
The wind deflector is not installed at the factory because it
would increase the width of the unit beyond the allowable
shipping width. The deflector is shipped in the burner vestibule of the unit. Install the wind deflector over the combu stion air intake opening of the burner compartment before
operating the burner. Use inner hinge screws on top hinged
door (see Figure 2). Side hinged doors have holes for mounting (see Figure 5). Models 020 and 025 have a different style
wind deflector. It mounts on the door and has a top opening
flush with the roof of the unit (see Figure 14).
Figure 2. Wind Deflector (Models 032 thru 140)
Tube Ends
3
Flue Box
Tube Sheet
4
Flue Box
Wrap
5. Immediately call your gas supplier from a different
area.
Do not use and store gasoline or other flammable
vapors or liquids in open containers near this appliance
or in areas sharing ventilation with it.
Gas Pressure Requirements
The pressure furnished to the combination gas control(s)
must not exceed 13.9 in. W.C. When the supply pressure is
above 13.9 in. W.C., a high pressure regulator must precede
the combination gas control(s). The inlet gas pressure must
not exceed the maximum pressure rating of the high pressure
regulator, and the outlet pressure must furnish gas to the
appliance pressure regulator within the pressure range mentioned above, preferably at 7.0 in. W.C. when firing at maximum rate.
Gas Piping
The connection size at the burner is shown in Table 5 under
columns 13 thru 15. Gas piping m ust be siz ed to pro vide the
minimum required pressure at the burner when the burner is
operating at maximum input. Consult the appropriate local
utility on any questions on gas pressure available, allowable
piping pressure drops, and local piping requirements.
Install all piping in accordance with the National Fuel Gas
Code (ANSI Z223.1), (NFPA 54-1999) and any applicable
local codes.
The proper size piping must be run from the meter to the gas
Wind Defle cto r
burner without reductions. Undersized piping will result in
inadequate pressure at the burner. The pressure will be at its
Hinge Inner
Screw
Burner
Access
Door
4 IM 685-1
lowest when it is needed the most, at times of maximum
demand. Therefore, it can cause intermittent hard-to-find
problems because the problem may have left before the service technician has arrived. Avoid the use of bushings wherever possible.
Remove all burrs and obstructions from pipe. Do not bend
pipe; use elbows or other pipe fittings to properly locate
pipe. A drip leg must be installed in the vertical line before
each burner such that it will not freeze. Install unions so gas
train components can be removed for service. All pipe
threads must have a pipe dope which is resistant to the
action of LP gas. After installation, pressurize th e piping as
required and test all joints for tightness with a rich soap
solution. Any bubbling is considered a leak and must be
eliminated. Do not use a match or flame to locate leaks.
Table 1. Capacity of pipe natural gas (CFH)
WITH PRESSURE DROP OF .3" W.C. & SPECIFIC GRAVITY OF 0.60
PIPE
LENGTH (FT.)
10 132 278 520 1050 1600 2050 4800 8500 17500
20 92 190 350 730 1100 2100 3300 5900 12000
30 73 152 285 590 890 1650 2700 4700 9700
40 63 130 245 500 760 1450 2300 4100 8300
50 56 115 215 440 670 1270 2000 3600 7400
60 50 105 195 400 610 1150 1850 3250 6800
70 46 96 180 370 560 1050 1700 3000 6200
80 53 90 170 350 530 990 1600 2800 5800
90 40 84 160 320 490 930 1500 2600 5400
100 38 79 150 305 460 870 1400 2500 5100
125 34 72 130 275 410 780 1250 2200 4500
150 31 64 120 250 380 710 1130 2000 4100
175 28 59 110 225 350 650 1050 1850 3800
200 26 55 100 210 320 610 980 1700 3500
½¾11¼1½22½3 4
Valve & Regulator Venting
Valve diaphragm vents, pressure regulator vents, and pressure switch vents are located in the outdoor burner vestibule
and therefore vent tubing is not run to the outside of this vestibule. If local regulations require that this be done, it is a
part of the field gas piping hookup. Remove any plastic protector plugs from regulator and valve vents.
Normally Open Vent Valve
Vent valves such as required by IRI for over 1000 MBH
input units must always be routed to the outdoors. This is
field piping.
PIPE SIZE-INCHES (IPS)
Note: Use multiplier below for other gravities and pressure drops.
Table 2. Specific gravity other than 0.60
SPECIFIC GRAVI TY MULTIPLI ER
0.50 1.100
0.60 1.000
0.70 0.936
0.80 0.867
0.90 0.816
1.00 0.775
Table 3. Pressure drop other than 0.3"
PRESSURE
DROP
0.1 0.577 1.0 1.83
0.2 0.815 2.0 2.58
0.3 1.000 3.0 3.16
0.4 1.16 4.0 3.65
0.6 1.42 6.0 4.47
0.8 1.64 8.0 5.15
MULTIPLIER PRESSURE MULTIPLIER
IM 685-1 5
Gas Piping Routing Into Unit
On-The-Roof Piping (Models 020-140)
1. Remove knockout (1) at corner of burner vestibule door
and saw out corner of door. See Figure 3b. Make saw cuts
(2) tangent to round hole and square with door edges.
2. .Install pipe corner plate (3) on vestibule, locating on prepunched holes. See Figure 3c. This part is shipped inside
the vestibule.
3. .Route gas supply pipe through hole. Carefully plan pipe
route and fitting locations to avoid interference with
swinging of doors, etc.
Through-The-Curb Piping (Models 020-140)
1. Remove bottom access panel (5). See Figure 3c.
2. .Remove knockout (4) and make an opening (6) through
bottom deck directly below knockout hole.
3. .Route gas pipeline through these openings and seal them
off with suitable grommets (7).
See Figure 3a Section A-A.
4. .Replace bottom access panel (5).
Figure 3a.
A
2
1
2
See Figure 3c
Figure 3b.
Typical Piping Connections
Figure 4.
Figure 3c.
4
7
7
A
4
6
3
5
Gas Supply
Section A-A
FSG
A
With Shutoff Cock
Folded Back
C
D
With Shutoff Cock
In Front
C
D
B
A
E
Figure 4b. Figure 4a.
A = Shutoff Cock (ball valve)
B = Union - Furnished.
C = Gas Pipe - Routed in through front
D = Gas Pipe - Routed in through curb
E = Factory Piped Gas Trains
6 IM 685-1
Gas Piping (Models 150 - 200)
The gas piping cannot be routed up to the bu rner from
within the curb on Models 150 through 200 . Gas piping
must be routed across the roof to under the burner vestibule, or a pitch pocket can be provided there. The installer
must cut a hole in the bottom panel of the overhanging
burner vestibule through which to route the gas line up to
the burner gas train. The bottom panel of the vestibule is
at approximately the same elevation as the top of the curb.
Gas Piping within the Vestibule
The gas piping layout within the vestibule will vary
according to the complexity and size of the gas train relative to the available room within the vestibule. As an
example, a gas train with a high pressure regulator and an
extra safety shutoff valve (when required for IRI, etc.) will
require careful use of the available space. The examples
shown in Figure 4 indicate typical piping layouts.
Field Gas Piping Required
The gas train components have all been factory installed
and require only a connection to the supply gas line. The
manual shutoff valve is located within the burner vestibule. If local codes require a manual shutoff valve that is
is accessible from outside the unit, that valve must be relocated
or an additional valve added. In locating such a valve, it is to
be readily accessible and located such that no obstructions
interfere with operation of the handle. See Figure 16a, "Valv e
and Regulator Venting", and "Normally Open Vent Valves".
Condensate Drain
All units are equipped with a 3/4" I.P. condensate drain pipe
projecting from the back side of the furnace section (See See
“Figure 13. Models 032 thru 200 Heat Exchanger” on page 17.
and See “Figure 14. Models 020 thru 025 Heat Exchanger” on
page 18.) If applicable codes or regulations require, this can be
trapped and/or routed to a drain. A trap is not recommended
and heat tape or some other method of freeze prortection is
required.
Vestibule (Models 150 thru 200)
These two furnace sizes exceed the allowable shipping width.
For this reason the burner is disconnected and removed for
shipment. A sheet metal vestibule weather enclosure is also
disassembled for shipment. At installation, the burner must be
re-mounted, the tagged electrical connections re-attached, and
the vestibule re-assembled and mounted as shown in Figure 5.
These items are packed in a crate and shipped as a separate
item.
Figure 5.
#10 Screw
Fasten Wind Deflector
To Door With #10 Screws,
(Door & Wind Defletor
Part of Vestibule Kit)
Side Panel
Cut Gas Line Opening
Door
Top Panel
Hinge
Side Panel,
With Latch
Door
Bottom Panel
IM 685-1 7
Start-up & Operating Procedures
Start-up Responsibility
The start-up organization is responsible for determining that
the furnace, as installed and as applied, will ope rate withi n
the limits specified on the furnace rating plate.
1. .The furnace must not exceed the specified "Maximum
MBH Input." See "Verify Input Rate" on Page 17.
2. .The furnace must not operate at an airflow below the
specified "Minimum Airflow CFM." On variable air volume systems it must be determined that the furnace will
not be operated if or when system cfm is reduced below
the specified minimum airflow cfm.
3. .It must be established that the gas supply is within the
proper pressure range. See "Gas Pressure Requirements"
on Page 4.
Start-up Procedure
Only qualified personnel should perform the start-up and
service of this equipment. It is highly recommended that the
initial start-up and future service be performed by McQuay
certified technicians who are familiar with the hazards of
working on live equipment. A representative of the owner or
the operator of the equipment should be present during startup to receive instructions in the operation, care and adjustment of the unit.
WARNING
Overheating or failure of the gas supply to shut off can
cause equipment damage, severe personal injury or death.
Turn off the manual gas valve to the appliance before
shutting off the electrical supply.
Before Start-up
1. Notify inspectors or representatives who may be
required to be present during start-up of gas fuel
equipment. These could include the gas utility company,
city gas inspectors, heating inspectors, etc.
2. Review the equipment and service literature and become
familiar with the location and purpose of the burner
controls. Determine where the gas and power can be
turned off at the unit, and before the unit.
3. Determine that power is connected to the unit and
available.
4. Determine that the gas piping, meter, and service
regulator have been installed, tested, and meet the
equipment requirements.
5. Determine that proper instruments will be available for
the start-up. A proper start-up requires the following:
voltmeter, manometer or gauges with ranges for both
manifold pressure and inlet gas pressure, keyboard
display module or a 20K ohm/volt meter for flame
safeguard, signal strength measurement, CO
indicator,
2
carbon monoxide indicator, and a stopwatch for timing
the gas meter.
About This Burner
Prepurge is Low-High-Low
The burner air control valve will be at the minimum position
during "off" cycles. Upon a call for heat or any other time
that a prepurge cycle occurs, the air control valve will be
repositioned to the maximum position for the prepurge and
then returned to the minimum position for low fire start.
Low Fire Start
The burner is controlled for proven low fire start. The actuator will position the modulating gas valve and the modulating air valve to the low fire position each time the burner is
to light off. Switch LS1 proves the air and gas valves are at
the low fire position. If LSl is not "made" at light off, the gas
valves cannot open and the flame safeguard will lock out,
requiring manual reset.
"Pilot" is Main Flame Modulated Down to Pilot Rate
The "pilot" is not a separate flame or burner. The "pilot" is
the main flame operating at its minimum rate. That minimum rate is so low that it qualifies as a pilot burner.
Set Control System to Enable Heating
To allow start-up and check-out of the burner, the control
system must be set to call for heating and must be used to
control the amount of heating. Set the control system to call
for heat so MCB-B011 energizes Relay R20. With MCBB011 closed, vary the temperature control set point to
increase, maintain, or reduce the firing rate of the burner as
required for these tests. If MCB-B09 is closed, the firing rate
will decrease. If MCB-B010 is closed the firing rate will
increase. If neither are "made", the firing rate will remain
unchanged.
Start-up Preliminary
1. See “Figure16a.” on page 25. Before energizing the
burner verify that the modulating air and gas valve mechanism moves freely and is not binding, and check the
linkage fasteners for tightness. This can be accomplished
without affecting any adjustments. Remove shoulder
screw (12) that connects the teflon bushing to the actuator
crank arm. The control rod can now be manually moved
back and forth; it should feel smooth with no binding or
scraping. Always remove shoulder screw (12) and test for
binding after reinstalling the gun assembly on Models
HT050-200.
2. .Close the gas line cocks. Install a Keyboard Display
Module, Honeywell Part No. S7800A1001, or connect a
20K ohm/volt meter to the test jack on the flame safeguard. See “Figure 7. RM7895A Flame Safegaurd” on
page 12.
3. .Check the burner fan wheel for binding, rubbing, or
loose set screws.
4. .Check power. Position switch S3 on burner control panel
to AUTO. The LED marked POWER on the flame safe-
8 IM 685-1
guard should come on and after a 10 second "Initiate"
period the burner motor should start. Check for counterclockwise rotation as viewed through the burner fan
housing inlet. If the motor does not start, press the reset
button on the flame safeguard. If the motor still does not
start, consult the appropriate section of the “Troubleshooting Chart” on page 22. Continue on to Item 5 when
burner motor will run 10 seconds after the switch is positioned to AUTO.
5. .Check voltage. With burner switch S3 at AUTO, measure voltage across burner control box terminals 2 and
NB. If it is not between 114 and 126 volts, check the voltage and tapping connections to th e supplying transformer at the unit main control panel.
port ✈✔✉ . The tube must surround the hole and seal
tightly against the burner housing to measure the static
pressure through the hole.
5. .See “Figure 16b.” on page 25. Position the burner switch
S3 to AUTO and with the burner actuator VM1 at the
maximum rate position measure the burner air box pressure at port ✈✔✉ . The actuator will remain at this position for the first 20 seconds of the prepurge period.
Typical static pressure readings are listed in Table 5, Column 6 on page 25. Any appreciable deviation from
these values indicate a burner air problem. Find and fix
the problem before attempting to fire the burner. These
problems could include linkages disturbed during shi pment, etc.
6. .Purge the gas lines. Close the main gas valves and turn the
electrical switches off. Make sure there are no arcing or
sparking switches, motors, or other equipment, pilot lights,
open flames, or other sources of ignition in the areas sharing ventilation. Disconnect the pilot gas tube at the pilot
pressure regulator and bleed the gas line of all air. Close
the pilot cock and reconnect the pilot tubing.
7. .Leak check. Using a rich soap-water mixture and a
brush, check the gas lines for leaks. Correct all leaks
before starting burner. After the burner is operating and
all the downstream valves are open, leak check that portion of the gas train.
8. .Connect a manometer to measure gas manifold pressure
at (1), Figure 16a. There is a 1/8 inch pipe size plugged
tapping in the gas line just before it enters the burner
housing.
Preliminary "Dry" Run
1. Close the gas line cock, Remove the burner front cover
and open the control panel door. Switches LS1 and LS2 in
the lower right hand corner of the control box should be
in view and the modulating actuator VM1 should be at
the minimum rate position. Verify that the right hand
switch LS1 is being held in the 'made' position by the collar on the control rod and that the switch lever is not bottomed out against the plastic switch housing.
2. .Position the burner switch S3 to AUTO. The flame safeguard will go through a 10 second "Initiate" period, after
which the burner motor will start. The modulating gas
valve actuator VM1 will drive the air valve and gas valve
to the maximum rate position. Observe the linkage for
any binding, loose fasteners, or other problems that could
have resulted from shipping.
3. .When the actuator reaches the maximum rate position,
verify that the left hand switch LS2 is held in the 'made'
position by the collar on the control rod and that the
switch lever is not bottomed out against the plastic switch
housing.
4. .See “Figure 16b.” on page 25. Position the burner switch
S3 to OFF. Close the control panel door and reinstall the
burner front cover. Prepare to measure the burner air box
pressure by holding a rubber manometer tube tightly over
Flame Start-up
1. Open the gas line cocks and position switch S3 to AUTO.
The flame safeguard will go through the 10 second "Initiate" period, after which the burner motor will start. The
modulating air and gas valve actuator VM1 will drive the
air valve to the full open position. At full open, the 60
second prepurge period will begin. After 20 seconds at
maximum open, the actuator will begin a 30 second
stroke to reposition the air valve back to the minimum
position. Upon completion of the 60 second prepurge
cycle, gas valve GV1 will open (as indicated when the
LED marked PILOT comes on), the ignition transformer
is powered and the flame should come on at minimum
rate.
2. .Observe the gas manifold pressure manometer during
this sequence. The manifold pressure should be close to
zero (it will indicate a slight heat exchanger pressure
caused by the burner combustion air fan). When gas
valve GV1 opens, it should indicate a manifold pressure
approximate to the values listed in Table 5, Column 10.
Approximately 3 seconds after GV1 is powered, the
flame will come on and the flame signal will read 1.5 to
5.0 volts DC. The LED marked FLAME will come on
when flame is detected and the LED marked MAIN will
come on if flame is being detected at the end of the 10
second trail for ignition period. When the LED marked
MAIN comes on, gas valves GV4-GV8 (whe n included)
will also open and the firing rate will be determined by
the control system. On the initial start-up, if the flame
does not light and the flame safeguard locks out, reset it
and make several attempts to light before assuming there
are problems other than more air in the gas lines. If initial
flame operation is erratic wait until after a period of main
flame operation has further purged the gas lines before
trying to "adjust out" something that may actually be
caused by air in the lines.
Modulate Firing Rates
Set the temperature control system so the burner actuator
VM1 will modulate to increase the firing rate. Observe the
flame signal and the manifold pressure manometer as this is
occurring. The flame signal should remain between 1.5 to
5.0 volts DC through the entire range of the burner, and the
manifold pressure should be between the values indicated by
IM 685-1 9
Combustion Tests
These tests should be run when the furnace is at normal operating temperature (after the furnace has been running 10 to 15
minutes), and should be run at several firing rates incl uding
maximum and minimum.
Cycle the Unit
Cycle the unit through several start-ups with controls calling
for first low fire and finally high fire. Watch for any indications
that the unit is not operating as expected, and for inconsisten
cies that could indicate future problems.
-
a. Check input: See “Verify Input Rate” on page 17.
b. Check C02: See Check CO2, CO & Stack Temperature
c. Check CO: See Check CO2, CO & Stack Temperature
Figure 6a. Typical Electrical Schematic with RM7895A
Record Data
After the gas burner has been successfully started up, checked
out and is operating correctly, readings should be taken and
recorded for future reference (see T able 6). If problems develop
in the future, variations in these readings will indicate what has
changed and where to start looking for problems.
10 IM 685-1
Typical Sequence of Operation
When the rooftop unit is energized, 120 volt power is supplied to the system on/off switch (S1), to burner on/off
switch (S3) and 24 volts to the (BO#11) contacts on the main
control board (MCB).
Note: On field supplied controls, 120V power is supplied
through the system on/off switch (S1) to burner on/off
switch (S3) and to the field supplied gas heat on/off
contacts.
Burner on/off switch (S3) will power the modulating gas valve
actuator (VM1) and terminal #5 (L1) on the flame safeguard
(FSG). Upon a call for heat, the control system will close
(BO#11) on the main control board (MCB), thus energizing
relay (R20). When 120V power is furnished through the system on/off switch (S1), through the burner on/off switch (S3),
through relay (R20) contacts, through the high limit control
(FLC) and through the optional automatic reset low gas pressure switch (LP5) and the optional manual reset high gas pressure switch (HP5), terminal #6 on the flame safeguard (FSG)
is powered. The flame safeguard then energizes its terminal
#4, which powers the burner combustion air blower mot or
(BM). Whenever power is restored to the flame safeguard, the
flame safeguard will go through a 10 second initiation period
before the prepurge period will begin.
The burner air control valve will be at minimum position
during off cycles. Upon a call for heat or any other time that
a prepurge cycle occurs the air control valve will be re-positioned to the maximum position for the prepurge and then
returned to the minimum position for low fire start.
(VM1), through the N/C contacts of (R20) and (R23), positions the burner air and gas control valves to minimum after
run cycle. When (R20) is energized for a new call for heat,
(VM1) through the N/O contacts of (R20) and the N/C contacts of (R21), will re-posit ion the burner air va lve to its
maximum open position for pre-purge. When the air control
valve reaches the full open position, switch (LS2) is 'made',
powering (FSG) terminal #7 through the burner air switch
(AS). This initiates the 60 second prepurge cycle. Concurrently, (LS2) powers timer (TD10) which will energize relay
(R21) after 20 seconds. When (R21) is energized (VM1) will
start the air control valve on its way toward the minimum air
valve position through the N/O contact of (R21) and the N/C
contact of (R23). At the completion of the 60 second
prepurge cycle the valve will be at the minimum open position and the minimum position switch (LS1) will be 'made'.
If (LS1) is not 'made' the combination gas control start
valves (GV1) will not open and the burner will lockout.
After completion of the 60 second prepurge period there will
be a 10 second trial for ignition during which term inal #8
(combination gas valve - GV1) and terminal #10 (ignition
transformer - IT) will be energized. If flame is being
detected through the flame rod (FD) at the completion of the
10 second trial for ignition period, terminal #10 (ignition
transformer - IT) will be de-energized and terminal #9 (relay
R23 coil and main gas valves - GV4 and GV5) will be energized and the control system will be allowed to control the
firing rate. The flame safeguard contains 'LEDS' (lower left
corner) that will glow to indicated operation.
After the flame has lit and been proven, relay (R23) is energized, allowing (VM1), as controlled by (BO#9) and
(BO#10) on the main control board, (MCB), to position the
burner air and gas valves for the required firing rate. When
the main control system closes (BO#10), the gas valve actuator will re-position toward a higher firing rate until (BO#10)
opens or the actuator reaches its maximum position. When
the main control system closes (BO#9), th e actuator will reposition toward a lower firing rate. If neither (BO#9) or
(BO#10) on the main control board (MCB) are closed, the
actuator will remain at its present position. The heating
capacity is monitored by the main control board (MCB)
through (AI #10) via a position feedback potentiometer on
the actuator.
In the event the flame fails to ignite or the flame safeguard
fails to detect its flame within 10 seconds, terminals #4, 8, 9,
and 10 will be de-energized, thus de-energizing the burner
and terminal #3 will become energized. The flame safeguard would then lockout and would require manual resetting. Terminal #3 will energize the heat alarm relay (R24),
which would then energize the remote 'HEAT FAIL' indicator light and send a fail signal to binary input #5 in MicroTech II main control board (MCB).
If an attempt is made to restart the burner by resetting the
flame safeguard, or if an automatic restart is initiated after
flame failure the earlier described prepurge cycle with the
wide open air valve will be repeated.
If the unit overheats, the high limit control (FLC) will cycle
the burner, limiting furnace temperature to the limit control
set point.
Figure 6b. Typical Piping Schematic
ATMOSPHERE
(OPT.)
GV3
SAFETY
VALVE
VENT TO
(OPT.)
N.O. VENT
VALVE
(OPT.)
GV2
SAFETY
VALVE
VENT
LO PRESS.
(OPT.)
LP5
SWITCH
VENT
(OPT.)
HIGH PRESS.
REG.
(REQ'D FOR
OVER .50 PSI)
SHUTOFF
COCK
GV1A
GV4A
(OPT.)
CAPPED LEAK
TEST COCK
VENT
(OPT.)
HP5
COMBINATION GAS CONTROL S
TEST
CONN.
V
v
AIR
SWITCH
HI PRESS.
TEST
SWITCH
COCK
MODULATING
ACTUATOR
BURNER
BLOWER
GV1B
GV4B
GV5B GV5A
GV1 - HT 020 TO 200
GV4 - HT 040 TO 200
GV5 - HT 079 TO 200
GV6 - HT 110 TO 200
GV7 - HT 140 TO 200
GV8 - HT 200 ONLY
IM 685-1 11
Flame Safeguard
See manufacturer's bulletin for more detailed informatio n on
flame safeguard RM7895A.
The Honeywell RM7895A is a microprocessor based integrated burner control that will perform self-diagnostics, troubleshooting, and status indication, as well as the burner
sequencing and flame supervision.
Keyboard Display Module
The Honeywell S7800A1001 module is an optional device
available for use with the RM7895A. It can be a permanent
accessory added to the RM7895A or it can be carried by the
service technician as a tool that is very easy to mount when
servicing the RM7895A. It mounts directly onto the
RM7895A and has a 2 row by 20 column display. The module
will indicate flame signal DC volts, sequence status, sequence
time, hold status, lockout/alarm status, total hours of operation, total cycles of operation, and can provide 127 different
diagnostic messages for troubleshooting the system.
The module will give a fault history. It can be mounted to the
RM7895A and will retrieve information on the six most
recent faults.
Consult the Honeywell bulletin 65-0090-1 "7800 Series,
Keyboard Display Module" and 65-0118-1 "7800 Series,
System Annunciation, Diagnostics and Troubleshooting".
Operation
Initiate Period: When the relay module is powered it goes
through a 10 second "Initiate" period. It will also enter in to
the "Initiate" period if electrical power problems such as low
voltage or momentary interruption occur while the unit is
operating. Operation of the burner fan motor is delayed
throughout the "Initiate" period.
Normal Start-up:
Prepurge: Upon a call for heat the prepurge period will
begin. If the air switch does not detect fan operation in the
first 10 seconds into the prepurge period a recycle to the
beginning of the prepurge will occur.
Ignition Trial: The "start" combination gas control and the
ignition transformer are powered for 10 seconds following
the prepurge. Flame must be proven at the end of that 10 second period or shutdown will occur.
Run: If flame is proven at the end of the 10 second ignition
trial the "start" combination gas control will remain powered
and on multiple valve units, the other parallel piped main
valves will become powered. If a flameout occurs the module will recycle within 3 seconds, and initiate a new prepurge
period. If flame continues to be detected, the module will be
in Run until the power is interrupted to terminal 6 indicating
that the temperature control system no longer requires heat,
or that the high limit or another safety control has opened.
LED Display
There are five labeled LED's located on the front of the
RM7895A which are energized to indicate operation as follows:
POWER The RM7895A is powered.
PILOT The prepurge period is complete and the terminal
for the "start" combination gas control is powered.
FLAME Flame is detected.
MAIN The ignition trial period is complete, flame is
detected, and the terminal for the main gas valve
is powered and a normal recycle is underway.
ALARM The RM7895A is on safety lockout.
Standby: After the initiate period is completed the module
will enter the standby mode and await a call for heat by the
temperature control system.
Figure 6c. Typical Burner Control Box Figure 7. RM7895A Flame Safegaurd
R23
2
5
S
IGNIT.
TRANSF.
TB 11
12
NBNB
11
R21
3
6
C2
N
C
2
N
O
S3
2
3
1
5
6
4
C2
C1
C
N
1
S
L
O
N
C
710
1
4
2
1185
CONTROL
BOX
SWITCH
COMPARTMENT
CONROL BOX
COVER
(SHOWN OPEN)
TD 10
1
1
4
C1
WIRES
FROM
MAIN
BOX
2 4
1
R22
13
2
2
3
45678910
R20
2
3
5
6
C2
AIR
SW.
1
4
C1
L
C
12 IM 685-1
Service
General
Before starting service on this burne r, take the time to read
the sections "About This Burner" and the 'Sequence of Operation" to get an overview.
Gun Assembly
The McQuay gas burner gun assembly is easily removable
and includes the ignition electrode assembly, the flame rod
assembly, and a "Base Air" fitting with orifice. The positioning of this assembly is not considered field adjustable. When
positioned correctly the gun disc will be perpendicular to the
blast tube and back in the cylindrical portion of the blast tube
as shown in Figure 8. The gun pipe will be concentric with
the blast tube.
Figure 8. Gun Assembly
BASIC AIR
ORIFICE
A
B
shoulder screw (12), Figure 16a, and manually slide the control rod back and forth to test for binding after reinstalling
the gun assembly on Models HT050-200. Do not operate the
burner without a tight seal at the grommet.
Flame Rod Adjustment
The gun assembly is removed for flame rod inspection or
service. When correctly adjusted, the flame rod insulator will
be concentric with the hole it passes through, not be shorted
out against the disc, the 0.75 inch long end tip will point
toward the 0.086 inch diameter alignment hole, and the end
tip will clear the disc according to dimension 'C' Figure 9.
Figure 9. Flame Rod and Ignition Electrode
ALIGN FLAME ROD TIP
FLAME ROD
IGNITION
ELECTRODE
.09
C
.086 DIA. HOLE
WITH .086 DIA HOLE
IN BURNER DISC.
ALIGN IGNITION
(REF.)
ELECTRODE TIP
WITH .086 DIA HOLE
IN BURNER DISC.
.086 DIA.
HOLE (REF.)
Model HT*** A B
020 1.98 1.94 .060
025 2.04 1.88 .060
032 2.04 1.88 .067
040 2.17 1.75 .070
050 2.17 1.75 .089
064 217 1.75 .089
065 2.17 1.75 .089
079 2.07 1.85 .102
080 2.07 1.85 .102
100 2.30 1.62 .102
110 2.24 1.68 .098
140 2.30 1 62 .110
150 4.13 1.62 .110
200 4.13 1.62 .110
Base Air
Orifice I.D.
Gun Assembly Removal and Installation
Unplug the ignition lead from the ignition electrode and
unplug the flame rod lead from the flame rod. Disconnect the
3/8 inch copper tube at the brass fitting on the left side of the
gun pipe, open the pipe union and remove the gun assembly.
Models 050-200 include an air tube that must be lifted up
and out of the grommeted hole it is nested into as the gun
assembly is removed. The gun assembly may have to be
manipulated and wiggled as the disc is withdrawn back
through the blast tube. Reassemble in reverse order, being
particularly careful to correctly reinsert the air tube into the
grommeted hole. The tube should slip into the grommet so
there is little leakage, but it should not bear down on it or it
can cause binding on the sliding air valve. Always remove
Model HT*** C
020 .09
025 .09
032 .09
040 .09
050 .40
064 .40
065 .40
079 .40
080 .40
100 .44
110 .35
140 .35
150 .48
200 .75
Flame Rod Installation
The flame rod must be disassembled from its porcelain insulator for removal or installation. Remove the two nuts on the
threaded end of the flame rod, pull the rod out of the insulator, and then remove the insulator by loosening its clamp
screw.
Ignition Electrode Adjustment
The gun assembly is removed for ignition electrode inspection
or service. When correctly adjusted, the ignition electrode
insulator will he concentric with the hole it passes through, the
end of the insulator will be flush with the outside surface of
the gun disc, the electrode tip will point toward the 0.086 inch
diameter alignment hole, and there will be a 0.09 inch spark
gap to the gun disc (see Figure 9). The ignition electrode can
he removed by loosening the clamp screw and sliding the
entire assembly through the disc hole.
IM 685-1 13
Air and Gas Adjustments
The burner has been adjusted and tested at the factory with
accurate instruments. Readjusting the burner after the unit
has been installed should not be necessary.
Verify that the gas supply pressure is correct, the electrical
power is correct, and test the burner thoroughly. Do no make
adjustments unless there is a clear indication that there is a
problem, and proper instruments are available so the adjustments can be made correctly.
Gas Supply Pressure
The maximum pressure rating of the combination gas control(s) used on this burner is 0.50 psi (13.9 in. w.c.), as measured at (2), Figure 16a. If the gas supply pressure is higher
than this an additional regulator must be installed so the
pressure will not exceed 0.50 psi.
Gas burner problems are often due to gas supply pressure
problems. High or low gas pressures can cause nuisance
lockouts of the flame safeguard and combustion problems.
Low gas pressure will reduce the heat output of the furnace
and, if extreme, can cause combustion problems and flame
safeguard lockouts. Every gas supply system has a high pressure regulator somewhere upstream. If it is at the meter and
adjusting the outlet pressure is not an option, the followin g
paragraph "High Pressure Regulator" would still apply.
High Pressure Regulator
If a high pressure regulator is included as part of the burner
gas train or is included elsewhere in the gas supply line, it
should be adjusted so the pressure at the inlet tap to the combination gas valves is 7.0 in. w.c. The inlet tap is (2) on Figure 16a. Check that the pressure is relatively consistent as
the firing rate changes. If any other equipment is served by
that same gas line or pressure regulator, check that the gas
pressure also remains relatively consistent when that equipment is turned on and off. Verify that the regulator closes off
tightly at zero flow by observing that the pressu re does not
creep up when the unit is off. If it does, excessive pressure
will have built up over the off period, possibly exceeding the
pressure rating of the combination gas controls, and causing
other problems at light off.
Gas Adjustments
See the sections on "Gas Valve Pressure Regulator Adjustment", "Gas Supply Pressure", and "High Pressure Regulator". The gas flow rate is determined by the gas pressure and
a characterized element within the modulating gas valve.
The stem of the valve connects to the bracket that positions it
with lock nuts that are adjusted at the factory and determine
the minimum firing rate of the burner. Other than gas pressure adjustments, this is the only adjustable control of the
gas. Adjusting the minimum rate is not intended to be a routine field adjustment. Properly adjusting the minimum rate
requires clocking a gas meter at very low flow rates, or connecting a test flow meter into the gas train.
Air Adjustments
Airflow and the resultant combustion characteristics have
been preset and tested at the factory and no further adjustments should be required. Airflow to the burner is determined by the characterized plate on the air valve outlet (1)
and an adjustable plate (2) on Figure l0a. The adjustable
plate can increase or decrease airflow across the entire stroke
of the valve. If burner airflow is in question, measure the
static pressure at Ports (4) and (5), Figure 16, and compare
those readings with Columns 6 and 8 in Table 5. A significant difference can be a symptom of a problem and the cause
should be investigated.
Air and Gas Control Linkage
An L-shaped control rod is connected to the actuator and
passes through the burner housing and into the control box.
This control rod positions the valves that control the burner
air and gas, and actuates switches in the control box to prove
when it is at the maximum and minimum posit ion . When the
actuator positions the control rod to the minimum rate position, the bracket on the rod that connects to the air valve and
gas valve should be firmly bottomed against the end of the
gas valve which acts as its stop. The linkages to the air and
gas valve should be straight and in alignment. Although the
bracket is to bottom out, the plate connected to it which
slides from right to left to control airflow should slide freely
and not be forced against either the right or left side member
of the air box.
At the minimum rate position, maintain a gap according to
dimension "D", Figure 10a. With that sliding plate in this
minimum rate position, check dimension "E", Figure 10a. To
gauge opening "E", use a drill blank held perpen dicular to
the plate. For Models 050-200, opening "E" can be accessed
through the grommeted opening in the primary air collector.
See (3), Figure 10a. for Models 020-040, the primary air collector must be removed. Generally, it is easier to remove the
collector with the inch diameter tube still attached by disconnecting the tube at the other end.
At the maximum rate position, the sliding blade should be
full open, but it should not be forced against the left side
piece of the air box.
The control rod bracket that connects the air and gas valves
must be correctly positioned on the control rod so t he
bracket will be firmly held under tension against i ts stop
when the actuator is in the minimum rate position, and so the
sliding blade will open fully without making contact at the
end of the stroke. When modulating towards the minimum
rate position the actuator will continue to travel after the
bracket contacts the stop, flexing the vertical end of the control rod so the bracket is held under tension. To correctly
locate the bracket on the rod, first adjust the air damper linkage so there will be a gap per dimension "D", Figure 10a,
when the bracket is bottomed out against the end of the
valve. Second, loosen both set screws on the bracket assembly so the bracket is free to slide on the rod. Third, position
the actuator to the maximum rate position. Position the sliding blade to the wide open position.
14 IM 685-1
Grasp the rod and while applying some thrust to the rod in
the direction of the actuator to take up any free play, and
with the bracket in alignment with the linkages that connect
to it, tighten the two set screws. Return the actuator to the
minimum rate position.
The adjustable plate (2), Figure 10a is positioned to provide
an opening per dimension "F".
Figure 10. Air and Gas Control Linkage
PROFILE
PLATE
!
PRIMARY AIR
COLLECTOR
#
ADJUSTABLE
PLATE
"
E
F
D
Actuator Crankarm
The actuator crankarm should not require adjustment. The
radius indicated by "G" dimension, Figure 10b will result in a
complete stroke from minimum to maximum, and provide the
correct amount of over travel to bottom out the linkage
bracket at the minimum rate position. Do not attempt to modify firing rates, etc. by changing the radius of the crackarm.
Switch Adjustment
Switches LS1 and LS2 prove maximum and minimum position of the control rod. These switches are located in the control box switch compartment and have a limited ran ge of
adjustment. When the two nuts that secure the switches are
loosened, the switch will pivot on the inner stud and the
outer stud can be moved up and down . Adjust he switches
such that when the collar mounted on the actuator rod is
moved into position and pushes in the lever on the switch,
the switch will click to the "made" position, but the lever
will not bottom out against the switch body. When properly
adjusted the lever can move an additional 0.02 inches, as
proven by slipping a feeler gauge between the switch lever
and the collar when in the "made" position. The collar on the
control rod should be adjusted so the switch lever it is actuating will rest squarely on the outer surface of the collar but
only 0.03 inches from the edge. If the collar is located for an
engagement that is longer than 0.03 inches, the collar may
not reach the actuator on the other switch when at the other
end of its stroke.
10º
MIN
G
RATE
90º
Figure 10b
Model
HT***
020 .005 .116 .50 3.30
025 .005 .125 .83 3.30
032 .005 .101 .82 3.30
040 .005 .101 1.25 3.30
050 .020 .099 1.25 3.30
064 .020 .136 1.60 3.30
065 .020 .136 1.60 3.30
079 .020 .106 1.88 3.30
080 .020 .106 1.88 3.30
100 .020 .110 2.44 3.30
110 .020 .136 1.05 4.28
140 .020 .136 3.30 4.28
150 .020 .140 3.30 4.28
200 .020 .140 4.40 4.28
DE F G
Altitude Considerations
For altitudes of 2000 feet and higher, the gas burner must be
derated 4% for every 1000 feet of altitude.
Example: Model HT080 at an altitude of 3000 feet is derated
(0.04 x 3 = 0.12). At 1000 mbh input (1000 x 0.12 = 120
mbh), the actual input is (1000 - 120 = 880 mbh) at 3000 feet.
The method of derating the burner is to reduce the manifold
pressure. Multiply the Maximum Rate Manifold Pressure
shown under Column 8 in Table 5 by the following altitude
factors:
2000 feet = 0.845 5000 feet = 0.640
3000 feet = 0.774 6000 feet = 0.578
4000 feet = 0.706 7000 feet = 0.518
IM 685-1 15
Gas Valve Pressure Regulator Adjustment
The high turndown burner uses combination gas controls to
provide redundant on-off gas control and pressure regulation.
A burner will have from one to six of these controls piped in
parallel, depending on the BTU rating of the burner. When
two or more valves are in parallel, their pressure regulators
must be adjusted so the valves maintain the specified manifold pressure and are balanced so each valve handles its share
of the load. To determine that the valves are balanced, the
manifold pressure must be measured and adjustments made
at both maximum and minimu m capacity. As the burner modulates from maximum capacity down to minimum capacity, it
is normal for the manifold pressure to rise. This is because
the pressure loss through the valve and fittings is being
reduced as the flow rate is reduced. If one (or more) valve is
not in balance with the others, th e pressure at the m inimum
rate will rise higher than normal.
While the burner is operating and only one combination gas
control is open, increase the firing rate of the burner. As the
firing rate is increased, the manifold pressure will be relatively constant until the gas flow rate exceeds the capacity of
that single valve and the manifold pressure starts to drop off.
The pressure adjustments should be made at the maximum
gas flow rate just before the manifold pressure starts to drop
off, and the following should be considered:
1. .The manifold pressure does not always immediately
respond to regulator adjustments. Wait a few seconds after
making an adjuster movement for the regulator to respond
and equalize.
2. .When making an adjustment, rotate the adjuster CCW
until the manifold pressure is below the desired set point,
and then slowly rotate the adjuster CW and nudge the
pressure up to the desired set point.
Clockwise rotation of the pressure adjusting screw on the
combination gas controls will increase the pressure set point,
and counter-clockwise rotation will reduce the pressure set
point (see Figure 11).
Figure 11. Combination Gas Controls
PRESSURE REGULATOR ADJUSTMENT
INLET
PRESSURE
TAP
INLET
GAS
CONTROL
KNOB
(SHOWN AT "ON")
(UNDER CAP SCREW)
ON
OFF
OUTLET
OUTLET
PRESSURE
TAP
Adjustment Procedure for Parallel Valves
When a manifold pressure adjustment is required, the first
step is to adjust the pressure regulator of each combination
gas control to the minimum rate manifold pressure (Table 5,
Column 10) while only that valve is operational and it is handling approximately its normal maximum rate CFH of gas.
The manual shutoff valve knobs are used to control gas flow
so just one valve is operating at a time.
To determine a firing rate suitable for this adjustment, first
modulate the burner down to the minimum rate. At this flow
rate, only the valve with the highest pressure regulator set
point will be operational; the other valves will be shut down
by their integral pressure regulators because the manifold
pressure is slightly higher than their set point. While the
burner is operating at that minimum firing rate, slowly close
all but one of the manual shutoff valve knobs on the combination gas controls. With care, this can be done without the
burner losing flame and shutting down. Watch the manifold
pressure manometer as each valve is being closed. If the
manifold pressure starts to drop rapidly in response to th e
knob movement, it indicates this combination gas co ntrol has
the higher pressure adjustment and is supplying the gas to the
manifold. Leave this valve open, and continue closing the
remaining valves until only that one valve is open, and then
adjust that combination gas control first.
3. .If the regulator cannot be adjusted up to the required set
point, or if that set point seems to be the highest pressure
the regulator can be adjusted to, the flow rate used for this
procedure is too high and must be reduced by repositioning the actuator to a lower firing rate, or the gas supply
line pressure is too low.
After adjusting valve 1, open valve 2. If opening the additional valve does not cause the manifold pressure to go up,
increase the pressure regulator setting of valve 2 until an
increase is observed. That indicates the valve has started
functioning. Then slowly close the first valve. Proceed to
adjust valve 2. Repeat this procedure until all valves have
been adjusted.
Open the manual shut off knobs on all the combination gas
controls and modulate the burner up to the maximum firing
rate. The resulting manifold pressure should be close to the
Maximum Rate Manifold Pressure indicated in Table 5, Column 6. If further adjustment is required, it should not be necessary to go through the entire procedure again. If the
manifold pressure is to be increased, mak e small but equa l
(about 1/4 revolution) CW rotations of the pressure adjusting
screw on every combination gas control and check the resulting manifold pressure, both at maximum and minimum rate.
Check Manifold Pressure at Minimum Rate
When several combination gas controls are in parallel and are
handling a low flow rate, the combination gas control with
the highest set point is essentially handling all the gas.
Observe the gas manifold pressure at the minimum rate. If it
is higher than the pressure specified under Column 10 in
Table 5, locate and adjust the dominant combination gas control. Test each combination gas control by slowly manipulating the manual shutoff knob toward the closed position while
observing the manifold pressure. The pressure will only
respond to movement of the knob on the dominant valve. The
manifold pressure will drop as the gas flow is throttled back,
using the knob on the combination gas control to partially
close that manual valve.
16 IM 685-1
Generally, a valve will he found that has an effect, and very
little adjustment will cause a reduct ion in the m inimum rat e
manifold pressure. Reduce the pressure adjustment of that
dominant valve by slowly rotating the adjuster CCW until
the manifold pressure no longer drops in response to that
adjuster movement. If the manifold pressure is still high after
that first adjustment, another valve may have become the
dominant valve and that may also have to be isolated and
adjusted to get down to the specified minimum rate manifold
pressure. After making this type of adjustment, it is necessary to recheck the maximum firing rate manifold pressure
and perhaps readjust it, making very small but equal adjuster
movements on each valve.
Combustion Testing
Proper start-up and maintenance requires periodic combustion tests and the systematic recording of those test results
for future reference. Before making combustion air adjustments, check for proper input rate.
Verify Input Rate
To determine the input rate, it is necessary to know the BTU
per cubic foot of gas being used. If this is not known, contact
the gas supplier. Check input rate by timing the gas meter
dial with all other appliances and their pilot lights off.
To verify the input rate using the gas meter, use a stopwatch
and time one revolution of the dial. Calculate the input with
the following formula:
MBH Input= A x B x 3.6
C
Where: A = BTU/cu. ft. of gas
Typical: Natural gas= 1000, LP gas=2500
B = Cu. ft. per revolution of meter dial
C = Seconds required for 1 revolution of meter dial
Check CO
, CO & Stack Temperature
2
Flue gas samples are to be taken from inside one of the secondary tubes. If the sample is taken from the flue box rather
than the tube, the sample will be diluted with outside air and
lower readings will result. If flue gas temperature is to be
measured, this must be done in the flue box, not in the tube.
The temperature gradient within the tubes will cause high
readings near the center of the tube and low readings near
the edge. Measure temperatures within the flue box where a
good mix will be present. The flue box includes two 5/16"
holes for test purposes. One hole lines up with the end of a
secondary tube for taking flue gas samples. The other hole,
through the side of the flue box, is for thermometer insertion.
Figure 12a Figure 12b
Measure
Temperature
Co
2
Sample
300º
400º
500º
600º
Temperature Gr ad ient
within Tube
Typical Readings:
CO
9½ to 10½ percent at maximum rate
2
4 to 7 percent at minimum rate
CO .005 percent (50 PPM) or less
Cleaning Heat Exchangers
Models 032 thru 200 (see Figure 13)
1. Remove the flue box front wrap (1) and the rear inspec-
tion cover (3).
2. .Remove and clean the turbulator (2)‚ from each tube and
clean the flue box.
3. .Clean each tube with a 2
½" round flue brush.
4. .Remove the brushings and if required clean the combustion chamber and header through the rear inspection doo r
port.
Figure 13. Models 032 thru 200 Heat Exchanger
1
2 1/2 Round Flue Brush With 7 Foot Handle
3
2
Condensate Drain
If the CO
cated, see “Troubleshooting Chart” on page 22 and refer to
Sections 4.1 and 4.2.
and/or CO readings are not within the range indi-
2
5. .Reinstall the inspection cover (3). Snug the screws but
do not overtighten and crush the insulation.
6. .Reinstall a turbulator (2)
in each tube approximately
flush with the tube ends. The end of the turb ulators are
formed such that the end will bind within the tube end
and lock the turbulator in place.
7. .Reinstall flue box front wrap (1)
IM 685-1 17
.
Models 020 thru 025 (see Figure 14)
1. To gain access to the inside of the combustion chamber,
detach the burner from the furnace and set it on the floor
of the vestibule (see Figure 14, Item (3)). The burner is
attached to the furnace studs with four nuts. Conduit
lengths allows this movement of the burner without disconnecting wiring. The union on the gas line must be
opened.
2. .Remove the flue box front wrap (1) .
3. .Remove and clean the turbulator (2) from each tube and
clean the flue box.
4. .Clean each tube with a 2
½" round flue brush.
5. .Remove the brushings and if required clean the combustion chamber and header through the burner mounting
tube.
6. .Reinstall the burner.
7. .Reinstall a turbulator in each tube approximately flush
with the tube end, locking them in place with the wedge
clips on each turbulator.
8. .Reinstall flue box front wrap (1).
Figure 14. Models 020 thru 025 Heat Exchanger
2 1/2 Round Flue Brush With 4 Foot Handle
Wind De fl ector
1
2. .Low CO
Readings - Low CO2 readings that cannot be
2
corrected can be caused by air leaking into the heat
exchanger and diluting the flue gas. If this is suspected,
take two consecutive CO
readings, one with the supply
2
fan running and one with the supply fan off. If the CO
increases with the supply fan off, it could indicate leak-
age. Note that CO
samples must be taken from inside a
2
tube, not just from inside the flue box.
Checking for Leaks
3. .Open up the rear casing panel while the unit is shut off
and visually inspect the heat exchanger.
4. .Visually inspect the heat exchanger while the burner is
operating, looking for light coming through holes. The
burner must be operated for only a few minutes with the
supply fan off. The heat exchanger can become hot
enough to cause severe burns. take care not to touch it.
5. .Perform consecutive CO
tests with supply fan off and
2
on. See Item 2 under "Leakage Symptoms."
6. .Smoke Bomb Test - Cover the flue box openings, open
the rear casing panel so the heat exchanger is accessible,
toss a smoke bomb into the heat exchanger through the
rear inspection port, replace the port cover, and with a
bright light look for smoke leaking through the heat
exchanger. Remove the remains of the smoke bomb and
uncover the flue box openings before attempting to operate the furnace.
2
3
2
Condensate Drain
Leakage Symptoms
1. Odor - Odors in the building are usually brought in
through the outdoor air intakes and do not indicate leakage from the furnace. Check for down draft conditions
and check for location of the flue exhausts of other equipment that may be pulled into the outdoor air intake. A
major and obvious furnace rupture can be a source of
odor. In general, small leaks in a furnace will not be a
source of odor because the pressure created by the supply
fan is greater than the pressure inside the furnace. Therefore, when the supply fan is operating, leakage will be
into the furnace, not out of the furnace and into the air
stream. If the control system is such that the furnace
comes on and warms up the heat exchanger before the
supply air fan comes on, and there is odor when the supply fan first comes on, this could be caused by leakage.
During the time the furnace is on and the supply fan is off,
the leakage would be out off the furnace. Then, when the
supply fan came on, it would blow those products of combustion into the supply duct.
Note: In most cases small leaks in the heat exchanger are not
a source of danger. Because the pressure created by the supply fan is greater than that inside the heat exchanger, the
leakage will be into the heat exchanger, not out of the heat
exchanger and into the airstream.
Causes of Failures
1. Improper Application - The furnace rating plate
specifies a "Minimum Airflow CFM." The furnace must
not be operated when airflow is below this minimum
cfm. If the furnace is being used on a variable air volume
system, the control system must be such that the furnace
will not operate when the supply fan cfm has fallen
below this minimum specified cfm. The furnace rating
plate also specifies a "Maximum MBH Input" which
must not be exceeded. See “Verify Input Rate” on
page 17.
2. Control Failure - The limit control does not function
properly and shuts off the burner when the heat
exchanger temperature becomes excessive. In most
situations, a properly controlled unit will never require
the limit control to shut off the unit. The limit control
should be a backup control; a problem attributed to a
limit failure generally indicates a control problem in
addition to the limit failure.
18 IM 685-1
3. Excessive Condensation - Applications which will pro-
duce condensation require an all stainless steel heat
exchanger to be resistant to the effects of this condensation and to give longer heat exchanger life. The likelihood
of condensation increases with:
a. Colder supply air temperature across the secondary
tubes, as on units taking in a lot of outdoor air in
colder weather.
b. Lower heat flow through the secondary tubes, as on
modulating burners when operating at reduced
input.
c. High airflow across the s econdary tubes such as any
application with a low temperature rise furnace.
4. Chemical Deterioration - Refrigerant leaks, some aero-
sol can propellants, fumes from dry cleaning establishments, beauty shops, swimming pools, and o thers, often
have detrimental effects on heat exchangers when they
get into the combustion air supply and thereby into the
combustion. Even fumes from nearby roof exhaust fans
can cause problems.
5. Inadequate or Distorted Airflow - Internal baffles that
have been repositioned or that have loosened up and
moved can distort the airflow and cause failures. Construction rubbish, shipping cartons, and insulation that
has come loose can end up inside a unit and block airflow to part of the furnace, resulting in a failure. Or these
items can alter the air or heat flow to the fan limit or
some other control and contribute to a failure.
Replacing Heat Exchanger
1. Remove the complete flue box, the casing panel through
which the flue tubes pass, and the rear inspection cover.
Open the hinged rear door.
2. The burner is mounted on and supported by the heat
exchanger studs with four nuts. When removing the heat
exchanger, the burner must either be removed or blocked
in place. Remove the four burner mounting nuts and the
two exchanger bolts located 2" above the upper burner
mounting nuts.
3. When it is necessary to remove any air baffles surround-
ing the heat exchanger, carefully note the locations and
clearances of these baffles before removing them so they
can be replaced in the exact same position.
A modulating burner will produce more condensate than an
on-off burner. As the firing rate of the burner is reduced, the
flue gas temperature will he reduced, and if it is reduced
below its dew point condensate will be produced.
A furnace that is heating a high percentage of outside air will
also produce more condensate. The colder the air contacting
the heat exchanger, the lower the resulting flue gas temperature, and consequently the more condensate.
Do not think a furnace has a problem because it produces
condensate anymore than you would think a cooling coil has
a problem because it produces condensate. However, suitable
steps should be taken to manage the flow of the condensate
produced.
Most condensate will be produced in the secondary tubes
where flue gas will sweep it into the flue box. Condensate
will also come from the combustion chamber. All models
have a piped combustion chamber condensate drain, and
Models 032-200 have a rear inspection cover that provides
access to the drain line.
Condensate will also drip from the drains in the two outer
corners of the flue box, and from the drip shield below the
rear cleanout port. Condensate should not be running down
the unit, except at times the wind may blow the dripping condensate mentioned above. The drip shield below the rear
cleanout port must be correctly installed as shown in the following section.
Rear Inspection Cover
The rear inspection cover is equipped with a stainless steel
drip shield to keep condensate away from the side of the unit
if condensate drips out of the inspection cover. (see Figure
15). The shield (1) must fit snugly against the bottom of the
cleanout port tube (2) at (3) so condensate (4) cannot run
back along the underside of the tube and into the unit or
down the side of the rear panel.
Note: If an excessive amount of condensate is dripping
from the rear inspection cover, check the condensate drain for blockage and clean if necessary.
Inspect the rear condensate drain annually for
blockage.
Figure 15a. Rear Inspection Cover (models 032 - 200)
4. Remove the two bottom bolts at the back of the heat
exchanger.
5. Withdraw the heat exchanger through the back of the casing.
Furnace Condensation
A furnace will produce condensation when the flue gas temperature falls below its dew point temperature. A more efficient furnace will transfer more of its heat into the building,
and leave less heat in the flue gas. This results in a lower flue
gas temperature and more condensate.
IM 685-1 19
Combination Fan and Limit Control
The fan limit control is a hydraulic action type with a remote
sensing element and connecting capillary tube. The sensing
element is locked into a bracket located on one of the heat
exchanger tubes about halfway toward the back of the fur
nace, on the side away from the blower. One corner of the
bracket is bent aside to remove the element.
Normal setting of the FAN control: FAN On=125°F., Fan
Off=100°F.
The LIMIT control must never be set higher than the temperature listed below. If the burner is shutting off on high limit at
these settings, it indicates that there is a problem with the fur
nace not getting enough air or it is being overfired.
Tabl e 4. LI MI T cont ro l set po ints
-
BURNER
MODEL
020 215 079 181
025 160 080 229
032 196 100 170
040 154 110 222
050 229 140 168
064 185 150 194
065 232 200 151
LIMIT CONTROL
SET POINT
BURNER
MODEL
LIMIT CONTROL
-
SET POINT
20 IM 685-1
Maintenance
Planned maintenance is the best way to avoid unnecessary
expense and inconvenience. Have this system inspected at
regular intervals by a trained and experienced service techni
cian. The following service intervals are typical for average
situations but will have to be adjusted to suit your particular
circumstances.
Fuel pressure settings, control settings, and linkage adjustments should be made only by persons thoroughly experienced with the burner and control system, and must not be
tampered with by persons without such experience.
Always replace covers on burner controls and boxes as the
electrical contacts are sensitive to dust and dirt. Perform
maintenance of flame safeguard, controls, gas valves, and
other such components in accordance with instructions con
tained in the manufacturer's bulletins.
Monthly
1. Check air filters and main supply fan drives, replacing if
required.
2. .Check flame signal with a keyboard display module or a
DC voltmeter.
Yearly
3. .Gas Train - Check all valves, piping, and conn ections for
-
leakage. Remove burner gun assembly. Inspect, and if
required, clean the flame rod, ignition electrode, main
burner disc, and blast tube. Check tightness of linkage fas
teners and bolts that could work loose from vibration and
movement.
4. .Combustion - Check quality of combustion. Test CO
and CO and look for irregularities in fire shape. If combustion characteristics have changed since the last test,
determine the cause. Changes in input, changes in the
BTU content of gas being supplied, reduced combustion
air due to dirty blower wheel, or flue passages in need of
-
cleaning can all cause changes in CO
readjustment seems necessary, do not make the adjustment
reading. When a
2
without first trying to determine if the required change is
not an indication that some thing else is in need of correc
tion.
5. .Flame Safeguard - Perform a flame failure check and
"pilot" turndown test. See control manufacturer's bulletin
for further information.
-
2
-
Twice Yearly
1. Burner Air - Check burner fan wheel for dirt build-up and
lint. Check combustion air intake louver and flue box for
dirt buildup and accumulation of wind borne debris.
2. .Cleaning - Inspect flue tubes and combustion chamber,
cleaning as required. Keep burner vestibule clean. Dirt and
debris can result in burner air blockages.
6. .Motor - Motor life will be increased by proper oiling.
There are provisions in both end shields for relubrication.
Re-oil each bearing with 150 drops (approximately 1 tea
spoon) SAE-20 oil.
7. .If the burner is to be out of service for the summer, turn
off the burner control switch and close the manual gas
cocks.
8. .Inspect Rear Condensate Drain for leakage.
-
IM 685-1 21
Troubleshooting Chart
The RM7895A flame safeguard is equipped with five LEDs
to aid in the diagnosis of burner operation and problems. In
addition, a Keyboard Display Module is available and is a
valuable aid for indicating flame signal DC volts, fault messages, sequence status, etc. See "Flame Safeguard
(RM7895A)" for additional information on the Keyboard
Display Module and for a description of the function of the
LEDs.
BURNER MOTOR DOES NOT RUN (AFTER 10 SECOND "INITIATE" PERIOD AND WITH SWITCH AT AUTO):
1.1 Power LED is off. a. Power is not getting to burner
1.2 Entire unit seems to be off. a. Burner power comes from the main control panel which has a main disconnect switch, a stepdown transformer with primary
1.3 Supply fan will operate. a. Check the manual reset limit control located between the filters and the supply fan and reset if required.
1.4 Power LED is on. a. Push the reset button on the flame safeguard.
1.5 Resetting flame safeguard
does not start motor after
the 10 second "Initiate"
period is completed.
BURNER MOTOR RUNS, BUT...
2.1 Burner motor runs valve
actuator travels to the maximum rate position and
stays there, the Keyboard
Display Module indicates
"Purge Hold".
2.2 Burner motor runs, valve
actuator travels to the maximum rate position and stays
there, the Keyboard Display Module goes through
the prepurge countdown. At
approximately 20 seconds,
Relay (R21) does not energize.
2.3 Bur ner motor runs,
prepurge appears normal,
LED marked PILOT comes
on for 10 seconds, then the
flame safeguard locks out
on flame failure.
winding fuses, a 120V secondary winding fuse, and an on-of f service switch. If any of these wer e open , the bur ner as well as
the supply fan would be inoperative. The control system also has firestat type temperature sensors which will shut down the
entire unit if supply or return air temperatures exceed set points. On some control systems the firestats only lock out the supply and return fans. Check main control schematic as these would not be burner problems.
b. Check that the control system has energized relay R20 located in the main control panel.
a. Push the reset button on the burner motor. (Note: If motor is hot and probably tripped, it has to cool sufficiently before it can
be reset.)
b. Test for line voltage across burner terminal 8 and NB. If powered, the problem is with the burner motor or its associated con
trols. On Models 1 100-20 00, te rminal 8 on ly contr ols a con t acto r and burner mo tor power comes from its own circuit breaker.
If terminal 8 is dead, check for power across terminals 1 and NB.
c. IF VOLTAGE IS ZERO: The power is being interrupted by the limit control, the manual reset high or auto reset low gas pres-
sure switches (if included), or relay contacts (R20). Consult the schematic and determine the interruption.
d. If voltage is satisfactory across terminals 1 and NB and t erminal 8 does not become energized af ter 10 seconds, and pressing
the safety reset button has no effect, replace the RM7895A.
a. Switch LS2 is not being actuated by the collar on the control rod when at the maximum rate position.
b. The air proving switch AS is not sensing burner fan pressure. Check the connecting tube, setpoint, and wiring. If LS2 and AS
are functioning, 120 volts can be measured across terminals 7 and L2 on the flame safeguard when the burner fan is running.
a. Timer TD10 is not 'making' after 20 seconds. Check that there is 120 volts on TD10 tab 1 when the actuator is at the maxi-
mum rate position. TD10 tab 2 should become energized 20 seconds after tab 1 is powered.
b. Relay R21 is not being energized by TD10, check for power across C1 and C2 after TD10 has become energized and repl ace
R21 if indicated.
a. Flame is not igniting or is not being detected by the flame safeguard. Check that the manual gas valves are open. Check for
manifold pressure at Tap (1), Figure 16, during the 10 seconds the LED marked Pilot is on:
1. If zero, verify that there is pressure at Tap (2), Figure 16, during the same 10 second period. If so, check that LS1 is bei ng
actuated by the collar on the control rod when at the low fire position. Check that the manual knob on GV1 is not closed
and power is supplied to valve.
2. If manifold pressure is normal, check for disconnected or sh orted flame rod or ig nition l ead wire. W at ch the ig nition att empt
through inspection window on burner and check that spark is in the appropriate location. If not, this indicates a short. If
flame is observed but not detected by the flame safeguard, remove the burner gun assembly and check the flame rod,
lead wire, and connections.
3. Check the flame safeguard with a flame simulator:
a. Close main gas test cock.
b. Plug the flame simulator into the flame safeguard.
c. When the LED marked PILOT comes on, touch the simulator G post to ground. If the LED marked FLAME now comes
on, the flame safeguard is working, but it is not receiving an adequate flame signal. If the LED marked FLAME did not
come on, replace the R7847A amplifier and/or the RM7895A flame safeguard.
4. If there is spark but no flame, check for faults that would cause way too much air or too little gas.
Some of the steps listed in this troubleshooting chart will be
unnecessary if a Keyboard Display Module is used, as that
module will pinpoint many problems.
22 IM 685-1
BURNER MOTOR RUNS, FLAME IGNITES...
3.1 Burner motor starts, a normal prepurge cycle occurs,
the LED marked FLAME
comes on momentarily and
then goes out.
3.2 Burner ignites, the flame
safeguard does not lock out
but the burner remains at
the minimum rate.
a. The flame is momentarily proving itself to the flame safeguard. It must be proven at the end of the 10 second trial for ignition
period.
b. On a new start-up, this could indicate the gas lines have not been sufficiently purged of air.
c. Improper flame rod position.
d. Defective or improperly installed pressure regulator that passes enough gas during the off cycle to build up pressure for light
off but when the valve opens quickly drops pressure.
a. The temperature control system has contacts that turn the burner on and separate contacts that control firing rate. Verify that
the contacts that control firing rate are calling for an increase rate.
b. Verify that Relay R23 is functioning properly.
BURNER OPERATES; HOWEVER ...
4.1 Combustion tests indicate
and/or CO are not
CO
2
within the expected range.
a. Measure gas manifold pressure at Port (1), Figure 16, both at the maximum and minimum firing rate and correct if required.
See Table 5, Column (9) and (10).
b. Measure the burner air pressures at Port (4) and (5), Figure 16. If readings are significantly dif ferent, from Table 5, Columns
(6), (7), and (8) determine why. Possible reasons include a clogged blower wheel, air leaks, or loosened components that
could cause variations.
c. Combustion test should be performed when the furnace is at operating temperature (typically after 10 to 15 min.)
d. Models 040 and larger have multiple valves in parallel. Determine that they are all functioning. While operating at maximum
rate use the manual operator to momentarily close the valves one at a time while observing the manifold pressure. If a reduc
tion in manifold pressure does not occur the valve was not open before the test.
4.2 At maximum firing rate, the
burner runs rough.
a. Gas manifold pressure is too high and furnace is being fired above its rated capacity. See "Verify Input Rate". Also check CO2
and CO levels.
b. The heat exchanger needs cleaning. Increased pressure drop through heat exchanger reduces airflow and affects
combustion.
c. Inspect gun assembly and blast tube for warpage or deterioration.
4.3 Flame is not symmetrical
as observed through rear
inspection window.
4.4 Nuisance tripping of the
flame safeguard.
a. Too high airflow relative to gas flow . Check gas manifold pressure. Check CO2 level.
b. Gun disc is not perpendicular to the blast tube, or gun disc is warped or otherwise out of alignment.
a. Check gas pressure situation. Marginal pressure during normal times can become low pressure during time of peak demand
and lead to trip-outs, etc. Pressures higher than that for which the gas train is designed can also cause problems. Line pres
sure should not exceed 13.9' W.C. (½ psi) into the combination gas controls. Pressures higher than this require an additional
stepdown regulator to maintain the pressure below 13.9" W.C. even at "no flow" conditions. The preferred pressure to the
combination gas controls is 7.0 in. W.C. A regulator that does not shut off tight at "no flow" will allow a small amount of gas to
leak past and eventually the high pressure will build up on the downstream side, thus exceeding the rating of the gas train
components.
b. Undersized piping can also cause problems by delivering reduced pressure during times of maximum demand.
c. Check the flame signal while modulating from minimum to maximum firing rate.
d. Check the ignition electrode gap and orientation. Check the porcelain for cracks or other defects.
e. Observe the flame signal DC volts when turning on the burner switch. Any indica tions before the ignition cycle could indicate
a short to ground. This could be an intermittent situation from moisture conditions. With line gas cock closed any movement
during the ignition attempt would indicate ignition interference.
f. Check supply voltage and if suspicion warrants arrange to have a recording voltmeter connected to the burner for a period
of time.
g. Marginal flame signal. Adjust flame rod position.
h. Check the ground path from FSG terminal G to the burner gun assembly. A wire runs from G to the ground screw on the left
side of the burner air box. The path continues through the variable orif ice va lve thro ugh the unio n to the burn er gun assembly.
4.5 Main flame comes on at low
fire, but as actuator
attempts to reposition for an
increased firing rate the
flame goes out. Then the
sequence is repeated.
4.6 At the instant spark comes
on, the flame safeguard
drops out and restarts the
a. Check the burner fan air proving switch and tube. As the burner air control valve opens further to provide more air for an
increased firing rate, the static pressure inside the air valve box is reduced. This is the pressure being sensed by the air prov
ing switch, and if it falls below its set point the burner will drop out. The adjustment screw is located next to the wiring box
cover. Turn screw CCW to reduce set point.
b. Use a manometer to determine if the gas pressure at the orifice is dropping prior to the flame going out. If gas pressure is
dropping, check for a plugged vent on a gas pressure regulator or something that restricts the gas flow in the line so only a
low firing rate can occur. Al so see 4.1d.
a. Ignition interference. Flame rod or its wire is sensing voltage from ignition. Also verify that ignition electrode spark gap is
within specifications.
pre-purge cycle.
4.7 When the flame safeguard
is powered it locks out and
a. Purge card missing or bad, terminals are energized that should not be at that stage, or there is an internal system fault.
Replace purge card or RM7895A as indicated.
the ALARM LED comes on.
-
-
-
IM 685-1 23
Typical Parts List -60 Hz
QTY.
1 0342492-00 Emerson 4526 020 — 080 Burner Fan: Motor 1/4 hp, 3450 rpm
1 0322486-00 Emerson 457 100 — 150 Motor 1/2 hp, 3450 rpm
1 0322484-00 Emerson 458 200 Motor 3/4 hp, 3450 rpm
1 0348611-02 Beckett 22031-07 020 — 080 Burner Fan Wheel: 6.25 x 3.438 (.500”)
1 0348611-01 100 — 150 7.09 x 3.160(.625")
1 0342480-04 200 7.50 x 3.160 (.625")
1 0330038-00 Antones SMP 4130 020 — 200 Air Switch
1 0344826-00 Allison 1092 020 — 200 Ignition Transformer
1 0733371-01 W/R 5A75-1 0 032 — 200 Fan Limit Control
1 0733371-02 W/R 5A75-12 020 — 025 Fan Limit Control
1 0733008-01 HW RM7895A1014 020 — 200 Flame Safeguard (less amplifier & timer)
1 0733009-01 HW R7847A1033 020 — 200 Amplifier Only (3 seconds)
1 073301O-03 HW ST7800A1054 020 — 200 Timer Only (60 seconds)
1 0733007-02 HW Q7800A1005 020 — 200 Subbase for Flame Safeguard
1 0598677-01 020 — 200 Flame Rod Assembly
1 0347430-02 020 — 100 Flame Rod Lead Wire Assembly
1 0347430-03 110 — 200 Flame Rod Lead Wire Assembly
1 0598678-01 020 — 200 Ignition Electrode Assembly
1 0347429-02 020 — 100 Ignition Electrode Cable
1 0365185-02 110 — 200 Ignition Electrode Cable
1 0964148-01 020 Burner Gun Assembly
1 0964148-02 025 Burner Gun Assembly
1 0964148-03 032 Burner Gun Assembly
1 0964148-04 040 Burner Gun Assembly
1 0964148-05 050 Burner Gun Assembly
1 0964148-06 064 — 065 Burner Gun Assembly
1 0964148-08 079 — 080 Burner Gun Assembly
1 0964148-10 100 Burner Gun Assembly
1 0964148-1 1 110 Burner Gun Assembly
1 0964148-12 140 Burner Gun Assembly
1 0964148-13 150 Burner Gun Assembly
1 0964148-14 200 Burner Gun Assembly
1 0373788-02 020 — 040 Blast Tube Assembly, 4.00 x 20°
1 0341017-03 050 Blast Tube Assembly, 5.00 x 20°
1 0341017-07 064 — 100 Blast Tube Assembly, 5.00 x 27½°
1 0341017-06 110 — 140 Blast Tube Assembly, 7.00 x 27½° (Sm)
1 0351647-01 150 — 200 Blast Tube Assembly, 7.00 x 27½° (Lg)
1 0341020-00 020 — 100 Blast Tube Gasket, 4-5"
1 0341019-00 110 — 200 Blast Tube Gasket, 7"
3 0196430-00 RBM 91 -131006-13000 020 — 200 Relay R20, R21, R23, DPDT 120 volt
1 0274007-00 RBM 184-20202-101J 020 — 200 Relay R22, SPST/NO 120 volt
1 0274007-00 RBM 184-20202-101J 110 — 200 Contactor M29
1 0282101-06 SSAC TAC1420 020 — 200 Timer TD10
2 0599753-01 OMRON V-10G5-1C24-K 020 — 200 Switch LS1 & LS2
1 0335367-00 McGill 0140-4000 020 — 200 Switch S3, Toggle 4PST
1 0004981-00 020 — 200 Grommet 0.380 ID, Base Air Tube
1 0599887-00 050 — 100 Grommet 0.750 ID, Pri Air Tube
1 0599888-00 110 — 200 Grommet 1.125 ID, Pri Air Tube
1 0479361-01 HW M6161A1004 020 — 200 Actuator, Floating
1 — 6 0733365-04 HW VR4305M4540 020 — 200 Combination Gas Control
1 0598613-01 020 — 200 Control Rod, Sliding Bushing
1 0594700-01 020 — 200 Shoulder Screw
1 0598621-10 020 — 200 Crank Arm Extension
1 0964149-01 020 — 200 Air Damper Flex Link
MCQUAY
PART NO.
VENDOR
VENDOR
PART NO.
USED ON
MODELS HT ***
DESCRIPTION
24 IM 685-1
Capacities and Adjustments
Note 2
5 — 10
Note 2
2 — 3
Inlet Pressure (PSI)
Gas Connection Size (IP)
To 0.5
4
Figure
Burner
Supply
Manifold
In Valve
Air Pressure (In. W.C.) Gas Pressure (in. W.C.)
In Box
Amps
Current
Running
Line
Tap (2)
Note 1, 2
Measure @
Rate
Note 5
@ Min.
Rate
Measure at Tap (1)
@ Max.
10
12
During
At Port 5
Prepurge
@ Max. Rate
Burner
Operating
@ Max. Rate
6
SUPER MOD
11
2
3
1
7
9
8
Figure16a.
5
Measured: At Port 4
During
Prepurge
@ Max. Rate
FSG
TR
Max.
Deg F
Furnace
Min.
CFM
Rate
Note 3
Input MBH or CFH
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15)
Table 5.
Burner
@ Min.
@ Max.
No.
Model
Rate
Note 4
020 250 12.5 2,300 80 1.59 1.48 3.80 3.01 3.12 4.5 3.4 0.75 0.75 0.75
025 312 15.6 3,800 61 1.95 1.95 3.71 3.46 3.55 5.5 3.5 0.75 0.75 0.75
040 500 25.0 6,000 61 2.69 2.74 3.29 4.14 4.39 5.0 3.6 1.00 1.00 1.00
050 625 31.3 4,600 100 2.43 2.49 3.42 2.98 3.25 5.5 3.6 1.00 1.00 1.00
032 400 20.0 2,950 100 2.30 2.34 3.50 2.94 3.21 6.0 3.5 0.75 0.75 0.75
065 812 40.6 5,970 100 1.62 1.55 3.44 2.89 3.33 7.0 3.8 1.25 1.25 1.25
064 800 40.0 9,600 61 2.04 2.15 3.50 2.86 3.22 7.0 3.8 1.25 1.25 1.25
110 1375 68.8 10,100 100 2.50 2.60 4.45 2.90 3.50 5.0 7.8 1.50 1.25 1.25
079 1000 50.0 12,000 61 1.62 1.64 3.66 3.45 3.84 6.5 4.0 1.25 1.25 1.25
080 1000 50.0 7,340 100 1.45 1.40 3.48 3.14 3.45 6.5 4.0 1.25 1.25 1.25
100 1250 62.5 15,000 61 1.63 2.09 4.60 3.20 3.72 6.5 7.5 1.25 1.25 1.25
140 1750 87.5 21,000 61 2.25 2.45 4.45 2.80 3.30 5.0 7.8 1.50 1.25 1.25
150 1875 93.8 13,700 100 2.32 2.50 4.50 3.10 3.60 5.0 8.4 1.50 1.25 1.25
200 2500 125.0 30,000 61 2.60 3.65 4.90 3.70 4.10 6.0 11.2 2.00 1.50 1.25
Notes:
gas train. For IRI, FM, Etc. add 1.00 in. W.C.
oz./sq. in.) require an additional high pressure
regulator.
1. Pressure to obtain 100% input with standard UL
2. Gas inlet pressures over 0.50 PSI (13.9 in. W.C.,8
3. CFH of natural gas @ 1000 BTU/cu. ft.
100% of this value.
4. At minimum firing rate the MBH should be 90 to
multiple valves are not in balance. See section on
"Gas Valve Pressure Regulator Adjustment".
5. This is approximate. A higher reading indicates
Key:
(1) Gas Manifold Pressure Tap (1/8 inch l.P.)
(2) Gas Line Pressure Tap (1/8 inch l.P.)
(3) Gas Pressure Regulator Adjustment
(4) Burner Box Air Pressure Port
(5) Air Valve Pressure Port (On Box Bottom)
(6) Firing Rate Indicator Scale
(7) Optional Additional Gas Valve(s)
(8) Optional High Pressure Regulator
(9) Optional Low Gas Pressure Switch
(10) Optional High Gas Pressure Switch
(11) Combination Gas Control
(12) Shoulder Screw Attaching Bushing To Crankarm
IM 685-1 25
Performance & Service History
Table 6.
Date of Readings
Description of
Firing
Reading
Rate
Gas Manifold Pressure (In. W.C.)*
Gas Line Pressure (In. W.C.)*3Flame Signal (DC Volts)4Ambient Temperature (Deg. F)5Flue Gas Temperature (Deg. F)6Flue Gas CO
1
2
Max. Rate
(percent)
2
Flue Gas CO (PPM)8Air Pressure i Box (In. W.C.)9Burner Motor VoIts10Burner Motor Amps
Scale = 100
7
Gas Manifold Pressure (In. W.C.)*
Gas Line Pressure (In. W.C.)*13Flame Signal (DC Volts)14Ambient Temperature (Deg. F)15Flue Gas Temperature (Deg. F)16Flue Gas CO
Mid. Rate
11
12
(percent)
Scale = 50
2
Flue Gas CO (PPM)18Air Pressure in Box (In. W.C.)
Gas Manifold Pressure (In. W.C.)*20Gas Line Pressure (In. W.C.)*21Flame Signal (DC Volts)22Ambient Temperature (Deg. F)23Flue Gas Temperature (Deg. F)24Flue Gas CO
17
19
(percent)
2
Reference Number: (1)
Flue Gas CO (PPM)26Air Pressure in Box (In. W.C.)
Scale = 5
Min. Rate
25
(1) Initial Startup of Furnace
(Summarize
any service
work
performed)
Comments
27
28
* Tap Locations are shown as (2) and (9) on Figure 16.
26 IM 685-1
Notes:
IM 685-1 27
13600 Industrial Park Boulevard, P.O. Box 1551, Minneapolis, MN 55440 USA (612) 553-5330
28 IM 685-1
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