DIRECT GAS FIRED
AIR HEATER
DF SERIES
INSTALLATION
AND OPERATION MANUAL
CUSTOM GAS
SOLUTIONS,
LEGENDARY
PERFORMANCE
Improper installation, modification, adjustment or maintenance may
WARNING
cause damage, injury or death. Carefully read the installation, start-up
and maintenance instructions before installing or servicing this unit.
GAS ODOR
If a gas odor is detected:
1: Open all windows;
2: Do not touch any switches;
3: Extinguish all open flames;
4: Immediately notify your gas supplier.
WARNING
Using or storing fuel or any other flammable liquid or gas in open
containers near this unit is dangerous.
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TABLE OF CONTENTS
TABLE OF CONTENTS ....................................................................................................... 3
CODES REGULATING DIRECT FIRED DUCT HEATERS ........................................................ 4
DF HEATERS INSTALLATION INSTRUCTIONS ................................................................... 5
1. PROFILE PLATE INSTALLATION .................................................................................. 6
2. GAS CONTROL PANEL INSTALLATION ....................................................................... 7
3. GAS PIPING CONNECTIONS ....................................................................................... 8
4. ELECTRICAL CONTROL SENSORS CONNECTIONS ....................................................... 9
5. AIR PRESSURE SWITCH CONNECTION ..................................................................... 10
6. IGNITION AND FLAME DETECTIONS CONNECTIONS ............................................... 10
7. START-UP INSTRUCTIONS ....................................................................................... 12
8. HEATER SHUTDOWN ............................................................................................... 19
9. OPERATING SEQUENCE FOR SINGLE VOLUME DIRECT FIRED HEATER .................... 20
10. OPERATING SEQUENCE FOR DOUBLE VOLUME DIRECT FIRED HEATER ............... 20
11. TROUBLESHOOTING ............................................................................................. 21
START-UP REPORT ......................................................................................................... 28
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CODES REGULATING DIRECT FIRED DUCT HEATERS
Direct fired duct heaters must be installed according to local installation code for gas
equipment and any provincial or state regulations applying to this category of
equipment.
Furthermore, when suspending this unit, the following ANSI standards must be
followed: ANSI/NFPA 409 for aircraft hangars, ANSI/NFPA 88A or ANSI/NFPA 88B and
CAN/CGA B 149 in effect for public garages. Electrical installations must meet the
standards stated in the first part of the C22.1 Canadian electrical code of with the
National Electric Code ANSI/NFPA 70 in the USA, and all local applicable codes for this
category of equipment.
All electrical installations must comply with the electric diagrams of the heater. For
more information, refer to the start-up instructions, operating and adjustments
instructions and wiring diagram supplied with the unit.
WARNING
This air heater must ALWAYS:
• Be used to heat outside air (100% fresh air). No recirculation air is allowed.
• Be used to replace air exhausted from a building or through process
equipment;
• Supply air at a temperature not exceeding 72°C (160°F) or as stated in the
applicable local code.
THIS HEATER IS NOT A SPACE HEATER AND SHOULD NOT BE
USED AS SUCH. THIS HEATER MUST NOT BE USED ANYWHERE
PEOPLE MAY SLEEP.
IMPORTANT
Allow the recommended clearances upstream and downstream of the burner.
Refer to "Profile Plate Installation" section.
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Profile plate
DF HEATERS INSTALLATION INSTRUCTIONS
There are 7 important steps to follow when installing the duct heater. Please read this
manual carefully and follow the instructions.
1. Profile plate installation.
2. Control panel installation.
3. Gas piping connections (main burner, pilot and vents).
4. Electrical control sensors connections.
5. Differential pressure switches connections.
6. Ignition wire and flame detection rod connections or ultra-violet detector
connections.
7. Start-up instructions.
Control panel
DF HEATERS TYPICAL ASSEMBLY
Burner
Gas inlet
Consult the manufacturer for any other assembly arrangement.
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*: if water coils or flat filters are installed upstream this dimension has to be increased.
1. PROFILE PLATE INSTALLATION
Install the profile plate according to the following clearances.
If heater is shipped assembled make a large enough opening in unit casing to
allow the insertion of the profile plate at the chosen location.
CLEARANCES TO BE RESPECTED
WARNING
Table of clearances
Model F G* H**
in mm in mm in mm
DF-25, -50, -75, -100
DF-150
DF-200, -300, -375 40 1016
DF-450, -550, -700 18 457 50 1270
**: if a plenum fan is used, this dimension has to be increased by 50% or consult the manufacturer.
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1 25
6 152
12 305
30 762
2. GAS CONTROL PANEL INSTALLATION
Locate the control panel so that the main gas pipeline (gas outlet) towards the burner is
upstream of the profiled plate which represents approximately a third of the width of
the control panel length.
TYPICAL PIPING SCHEMATIC OF AN INSTALLATION WITH THE PANEL
MOUNTED DIRECTLY ON UNIT
TYPICAL PIPING SCHEMATIC OF AN INSTALLATION WITH THE
PANEL REMOTELY MOUNTED FROM UNIT
NOTE: It is possible to install the control panel remotely from the profile plate. Standard
wires and tubes length provided with the heater is six feet (two meters). For installation
requiring a longer distance of wires and tubes, please consult the manufacturer.
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1,2
3. GAS PIPING CONNECTIONS
(MAIN BURNER, PILOT AND VENTS)
For units installed indoors, bleed and vent
connections must be extended to the
outdoor in accordance with local codes.
Gas piping connections
With a NPT1 pipe
diameter of this size...
¾" 1 ⅛" (29mm) 6" (152mm)
Main gas piping
1" 1 ⅜" (35mm) 6" (152mm)
1 ½" 2" (51mm) 6" (152mm)
2" 2 ½" (64mm) 6" (152mm)
3" 3 ⅝" (92mm) 6" (152mm)
Pilot piping ½" ⅞" (22mm) 6" (152mm)
Gas connection pipe size (NPT)
Gas inlet
Capacity
3
and outlet
(½ psig) Gas outlet (2 psig)
750 MBH and less ¾"
From 751 to 1000 MBH 1"
From 1001 to 2500 MBH 1 ½" 1 ½" 1 ½"
From 2501 to 5000 MBH 2" 1 ½" 2"
5001 MBH and more 3" 2" 3"
Pilot, vent and bleed valve pipe size (NPT)
Capacity Pilot line diameter Vent diameter Bleed valve
750 MBH and less
From 751 to 1000 MBH
From 1001 to 2500 MBH
From 2501 to 5000 MBH
5001 MBH and more
¼" aluminum tubing
...Drill a hole of this size
in unit wall
Pipe length extended
outside control cabinet
Gas inlet (2 psig)
Use external gas regulator to reduce to ½ psig
1,2
4
(IRI option)
Not required (2 x 2" Ø
openings are required
in cabinet for
ventilation)
¾"
1"
1 ½"
1
NPT: National pipe thread
2
This table is not intended for gas line sizing.
3
If gas pressure exceeds ½ psi (14" w.c.), a high pressure regulator capable of modulating in a ratio of 40:1 must be added
at the unit inlet in order to adequately regulate the pressure at low fire.
4
Bleed valve vent piping to the exterior must not be connected to other vents.
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4. ELECTRICAL CONTROL SENSORS CONNECTIONS
The sensors connections must be carried out by a qualified electrician,
respecting the unit’s electrical diagram and according to local codes.
The sequence of operation of the electrical diagram must never be modified
without consulting the manufacturer.
Electrical controls location (Installed by others)
WARNING
Items Description (All wires must comply with codes, and in their absence, National Electrical Code NFPA70)
1 Low temperature limit sensor (Freeze stat, optional) (BL)
2 Modulation sensor (MT1-12/TS114) (Shielded wires required)
3 High limit air temperature control (max. 160°F)(HL)
4 Air inlet temperature sensor (TDA) (Optional)
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IF DOUBLE WALL
IF DOUBLE WALL
5. AIR PRESSURE SWITCH CONNECTION
Make these connections according to the following drawing. Drill two holes of ½" In. (13
mm), then use the appropriate hardware to pass the tubes through unit wall.
RUBBER GROMMET
BLACK PLASTIC TUBE
PROFILE PLATE
RUBBER GROMMET
BLACK RING
PLASTIC TUBE
SNAPPING BUSHING
PROFILE PLATE
SUPPORT
PROFILE PLATE
SUPPORT
1/8 PIPE-1/4 TUBE ADAPTOR
ALUMINUM TUBE
SNAPPING BUSHING
BLACK TUBE
ALUMINUM TUBE
IN UNIT
CLEAR TUBE IN
CONTROL BOX
6. IGNITION AND FLAME DETECTIONS CONNECTIONS
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MIDCO
MAXON
1
3
MIDCO
MAXON
With flame detection rod
3
2
3
1
4
Components Description Wire
gauge
1
Pilot ignition wire GTO-15 Black ½" (13mm)
2 Pilot flame detection rod GTO-15 Red ½" (13mm)
3 Burner flame detection rod ( two
GTO-15 Red with
required for a capacity > 2500 MBH)
4 Pilot gas tubing - -
With ultra-violet flame detector
3
2
Color Hole diameter
to drill in wall
blue stripe
2
½" (13mm)
5
4
1
Components Description
1 Pilot ignition wire GTO-15 Black ½" (13mm)
2 Pilot ultraviolet detector
3
Burner ultra violet detector (two
required for a capacity > 2500 MBH)
4 Pilot - -
5
Use rubber grommets where wires pass through sheet metal walls.
6
Separate wires for each ultraviolet detectors
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Wire
gauge
6
#16
Supplied by
1
Color
others
2
Hole diameter
to drill in wall
⅞" (22mm)
⅞ (22mm)
5
7. START-UP INSTRUCTIONS
The following sections explain how to start-up the DF series heaters.
IMPORTANT
The following information should only be used by a qualified technician for gas
equipment installation (with qualification cards) with knowledge in electricity
and ventilation.
WARNING
Smoking is not recommended during the heater start-up.
• Voltmeter
• Ammeter
Recommended
tools
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• Temperature reading device
• Tachometer (for blower RPM)
• Air pressure gauge (0" to 2" w.c. scale)
• Gas pressure gauge (-2" to 20" w.c. scale)
Model
Natural gas
Propane
Min: 6" w.c. (1493 Pa)
Min: 6" w.c. (1493 Pa)
• GAS INLET PRESSURE ADJUSTMENT
a. Ensure that the gas inlet pressure complies with the following table:
DF 25 / 50 / 75
DF 100
DF 150 / 200 / 300 /
375 / 450 / 550 / 700
For lower gas pressure consult manufacturer.
b. Ensure that the air is completely purged from the gas piping.
c. The inlet gas pressure difference from the burner operating at high fire and
the burner OFF should not exceed 1 inch of water column (249 Pa).
Max: 14" w.c. (3484 Pa) Max: 8" w.c. (1991 Pa)
Min: 8" w.c. (1991 Pa) Min: 6" w.c. (1493 Pa)
Max: 14" w.c. (3484 Pa) Max: 8" w.c. (1991 Pa)
Min: 13" w.c. (3235 Pa) Min: 11" w.c. (2734 Pa)
Max: 14" w.c. (3484 Pa) Max: 14" w.c. (3484 Pa)
WARNING
WHILE THE BURNER IS IN OPERATION ENSURE THAT THERE ARE NO GAS LEAKS IN THE
ENTIRE PIPING USING A LEAK DETECTION FLUID OR A GAS DETECTOR.
DO NOT USE OPEN FLAME TO CHECK FOR LEAKS.
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• BURNER AIR DIFFERENTIAL PRESSURE ADJUSTMENT
NOTE: Always read the air differential pressure when air inlet filters are new and
clean.
a. For direct gas-fired burners, the airflow rate through the burner is very
important. If the air differential pressure at the burner profile plate is too high
or too low, the unit will not function properly. This could produce an excess of
carbon monoxide (CO) or trigger a FLAME FAILURE alarm.
b. To measure the differential pressure at the burner profile plate, the blower
must be in operation and discharge air temperature maintained at 70°F (21°C).
In winter, to maintain this temperature, the burner must be in operation and
the temperature selector set at 70°F (21°C).
c. Using an air pressure gauge read the differential pressure as shown in figure 1.
Figure 1
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-40
-35
-30
-25
-20
-15
-10
-5
0
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
0.4 0.5
0.6
0.7 0.8
-40
-36
-32
-28
-24
-20
-16
-12
-8
-4
0
4
8
12
16
20
24
28
32
36
40
100 110 120 130 140 150 160 170 180 190 200
d. The value of the differential pressure drop observed through the profile plate
must correspond to the value indicated in the graph below.
Outside air temperature (°F)
Static pressure drop (inches w.c.)
Outside air temperature (°C)
Static pressure drop (Pa)
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Figure 2
e. If the airflow rate measured is within specifications and, if the pressure
differential read is greater or smaller than the desired pressure drop, the
adjustment plates of the burner have to be repositioned (see figure 2).
WARNING: Shut off power supply before making any adjustment.
f. If the differential pressure reading is lower than the desired value, reduce the
opening of the profile plate by moving the adjustment plates closer to the
burner.
g. If the differential pressure reading is higher than the desired value, enlarge the
opening of the profile plate by moving the adjustment plates away of the
burner.
NOTE: For a single volume system, adjustment plates should be at an equal
distance from the burner.
h. Read the differential pressure again and repeat operations "f" and "g" as
necessary.
NOTE: The adjustment plate must not be used to adjust the final system airflow
rate. When the airflow rate requires adjustment, changing or adjusting the
blower and motor pulleys may be required.
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• PILOT ADJUSTMENT
a. The pilot is adjusted at the factory. It can also be adjusted on site by a qualified
technician following start-up instructions.
b. When adjusting the pilot gas pressure with the regulator, the main burner
should not be in operation (close the main burner gas manual valve).
c. Adjust the pilot regulator to obtain a good reading of the flame signal on the
flame safeguard control (5-10 VDC for FIREYE and 3-5 VDC for HONEYWELL).
• BURNER ADJUSTMENT: « HIGH FIRE »
a. Set the maximum capacity of the burner according to the desired maximum
temperature rise required.
Example of calculation of the maximum temperature rise:
Minimum outside temperature: -20°F (-29°C)
NOTE:
Desired final temperature: 70°F (21°C)
Temperature rise (ΔT): 90°F (50°C)
b. When the outside temperature does not allow for the simulation of the
specified temperature rise across the burner, adjust its maximum capacity
according to the required gas pressure indicated on the name plate of the unit.
Readjustment will be required when outside air temperature permits full fire.
c. The adjustment is made using the main burner pressure regulator (Figure 3).
For units with a capacity over 1000 MBH, use the regulator included in the
MAXITROL modulating valve (see MAXITROL service manual) (Figure 4).
Turn the adjustment screw clockwise to increase the gas pressure to the
burner.
Turn the adjustment screw counter clockwise to reduce the gas pressure to
the burner.
With the Maxitrol series 14 device, simply disconnect terminal 4 to obtain
the maximum burner capacity.
Figure 3 Figure 4
Regulator
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• BURNER ADJUSTMENT: « LOW FIRE »
a. After having set the burner at high fire, disconnect terminal 8 from the
MAXITROL amplifier to set the burner at low fire.
b. Set the burner at low fire with the adjusting screw intended for this purpose
and located on the MAXITROL modulating valve (see figures 5 and 6). The
burner should then be lit over its entire length.
c. After having set the burner at low fire, the unit must be turned off and then
turned back on to ensure that it is lit over its entire length. Readjustment will
be required when outside air temperature permits full fire.
Figure 5 Figure 6
Adjusting screw
M511, M611 or ES371 MR212
•
FINAL AIR TEMPERATURE ADJUSTMENT
a. Set the MAXITROL temperature selector (TD 114) to the desired final
temperature. This selector is located either in the control panel on the unit or
in the remote control station.
NOTE: When the MAXITROL temperature selector (TD 114) is installed in a
remote control station, the wires used to make the connections must be
shielded wires (with metal sheath). The length of these wires is limited to 200ft
(60m). Consult the manufacturer for longer distances.
WARNING
With an adequate leak detection fluid, ensure that there are no gas leaks in
Adjusting screw
the piping.
Make the necessary repairs if needed.
Do not let the heater operate if a gas leak is detected.
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8. HEATER SHUTDOWN
•
EXTENDED SHUTDOWN
When the heater is shutdown for an extended period of time, it is recommended that
the gas and electric power supply be shut off.
Before turning on the heater after an extended shutdown, make sure the air is purged
from the gas pipes and that the gas pressure is adequate. An inspection is
recommended to make sure that everything is in order. Redo start-up.
• HEATER EMERGENCY SHUTDOWN
When the heater must be shut down for an emergency, the main power disconnect
should be turned OFF and gas supply be shut off by closing the manual gas supply valve
located on the gas supply line to the heater.
• TURNING ON THE HEATER AFTER A FLAME FAILURE ALARM
After a flame failure alarm, the following checks must be performed:
a. Verify the alarm code on the flame supervision relay and consult the
troubleshooting section of this manual;
b. Set the main power switch to OFF;
c. Ensure that all gas supply manual valves are open;
d. Check the blower belts; replace or adjust them if necessary;
e. Check flame safeguard relay and fire rod condition;
f. Check condition of filters and replace them if necessary;
g. Ensure that nothing obstructs the air inlet and/or outlet of the heater;
h. Ensure that nothing prevents proper operation of inlet and/or outlet air
dampers;
i. Turn ON main disconnect;
j. Press the reset button of the flame safeguard relay;
k. Ensure that the air inlet and outlet dampers are operating properly;
l. Ensure that the blower motor is operating and fan is turning;
m. Ensure that the pilot ignites properly;
n. Observe main flame lighting sequence.
If the heater still does not start, call the manufacturer or an authorized service
company for assistance.
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9. OPERATING SEQUENCE FOR SINGLE VOLUME DIRECT FIRED HEATER
(For guidance only)
Starting up the burner
a. Create a heating demand.
b. If outside temperature is under 70°F, the outside temperature sensor (TDA)
allows for the FIREYE flame safeguard to be energized.
c. Authorization for pilot to ignite is complete when the low and high air pressure
differential and high temperature limit switches are closed.
d. The burner starts.
e. The MAXITROL controller modulates the burner to maintain the selected set
point of the temperature selector.
10. OPERATING SEQUENCE FOR DOUBLE VOLUME DIRECT FIRED HEATER
(For guidance only)
Starting up the burner
a. Create a heating demand.
b. If outside temperature is under 70°F, the outside temperature sensor (TDA)
allows for the FIREYE flame safeguard to be energized.
c. The burner starts.
d. In low volume mode, when airflow is reduced either by the inlet damper or by
a VFD, the profile plate damper opens partially and modulates to maintain the
required air pressure drop across the burner.
e. In high volume mode, when airflow is increased either by the inlet damper or
by a VFD, the profile plate damper opens wider and modulates its position to
maintain the required air pressure drop across the burner.
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11. TROUBLESHOOTING
FIREYE FLAME SAFEGUARD RELAY
•
The FIREYE flame safeguard relay has five (5) lights that show that the operating
sequence is normal and also to indicate burner malfunctions.
• Normal operating sequence
a. The OPR CTRL light is ON when there is a heating demand and terminal 7 is
energized.
b. The AIR FLOW light is ON when all the safety devices as well as the low and
high air pressure and high temperature limit switches are closed, and terminal
6 is energized.
Notes:
c. The PTFI light is ON only during the pilot ignition cycle.
d. The FLAME light is ON only when the flame safeguard relay detects a flame
signal and is not in alarm mode.
e. The ALARM light flashes when a malfunction is detected.
f. The last 6 alarm codes are stored in the relay's memory. A plug-in display is
required to read them.
a. When an alarm occurs, the ALARM light that corresponds to the malfunction
flashes at one-second interval. The status of the other four lights indicates the
type of malfunction (see table on next page).
b. Pressing the reset button brings the flame safeguard relay back to its normal
operating mode.
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Trouble
Trouble description
OPR
• Warning light status (Fireye)
The table below lists the most common flame failure codes concerning the operation of
the unit. (Consult the installation and operation manual of the flame relay manufacturer
for any code not listed in this table).
(CONSULT THE FIREYE TROUBLESHOOTING TABLE TO ESTABLISH THE DIAGNOSTIC).
code
6 Frequency noise
7 Flame failure (PTFI)
19 Flame failure (MTFI)
21 Open air pressure switch
54 Ground fault
55 Faulty programmer
56 Faulty amplifier
(alarm)
CTRL
AIRFLOW PTFI FLAME ALARM
*
*
*
*
*
*
*
Light:
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*
= ON
= OFF
= Flashing
• HONEYWELL FLAME SAFEGUARD RELAY
The HONEYWELL flame safeguard relay has five (5) lights that show that the
operating sequence is normal and also to indicate burner malfunctions. When
flashing the ALARM light indicates a burner malfunction. To identify the anomaly,
use the HONEYWELL S8700 keyboard display module.
• Normal operating sequence
a. The POWER light flashes to indicate that the flame safeguard is energized and
that there is no heating demand.
b. The PILOT light is ON when there is a heating demand and the pilot control
valve coil as well as the ignition transformer is energized.
c. The FLAME light is ON when the flame safeguard relay detects a pilot flame
signal for 10 seconds.
d. The MAIN light is ON when the flame safeguard relay detects a stable flame
signal for 10 seconds and all safety devices, low and high air pressure as well as
high temperature limit switches is closed between terminals 6 and 7.
e. The ALARM lights flashes when a malfunction is detected. Refer to the
troubleshooting check list to establish diagnostic.
Note: Pressing the reset button brings the flame safeguard relay back to its normal
operating mode.
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NOTE: Refer to the normal operating sequence and the service check list below to identify
possible causes of problems.
The Honeywell S7800A Keyboard module displays the following trouble codes which
are the most important ones with regard to the operation of the heater.
(Refer to the manufacturer for any code not listed below.)
FIREYE AND HONEYWELL TROUBLESHOOTING CHECK LIST
SYMPTOMS ACTIONS
✓ THE BLOWER IS NOT IN OPERATION.
✓ THE BURNER IS NOT IN OPERATION.
✓ THE FRESH AIR DAMPER IS CLOSED.
1. Turn ON main disconnect switch.
2. Check the input voltage.
3. Check 120-volt secondary circuit fuse.
4. Check the position of the switch on the remote control panel; it should be set to BURNER.
5. Check the contactor indicating that the exhaust fan is in operation.
6. Press down the reset button of the (FIREYE or HONEYWELL) flame safeguard relay if an
ALARM light flashes.
7. Check the adjustment of the overload relay of the blower motor; re-adjust it if necessary.
8. Check the freeze protection control; its contact opens after around 300 seconds if the
supplied temperature remains under 42°F. To start the heater, set the burner and blower
switch located on the remote control panel to STOP and then to BURNER
9. Refer to the manufacturer.
✓ THE BLOWER IS NOT IN OPERATION.
✓ THE BURNER IS NOT IN PERATION.
✓ THE FRESH AIR DAMPER IS OPEN.
✓ THE BLOWER IS IN OPERATION.
✓ THE BURNER IS NOT IN OPERATION.
✓ THE FLAME SAFEGUARD RELAY IS
OPERATING NORMALLY.
✓ FREQUENCY NOISE
CODE 6 FIREYE
✓ FLAME FAILURE (PTFI)
CODE 7 FIREYE
CODE 28 HONEYWELL
NOTE: The flame safeguard relay goes
into alarm mode during the pilot
ignition cycle.
✓ FLAME FAILURE (MTFI)
CODE 19 FIREYE
CODE 17 HONEYWELL
NOTE: The flame safeguard relay goes
into alarm mode during the main
burner ignition period.
✓ FLAME FAILURE
CODE 19 FIREYE
NOTE: The flame safeguard relay goes
into alarm mode during the first 10
seconds of the ignition cycle.
1. Make sure that the fresh air damper switch is closed.
2. Refer to the manufacturer.
1. Check if the auxiliary contact of the blower motor starter works.
2. Check selector position on the remote control panel; it should be set to BURNER.
3. Check the outside temperature thermostat; it prevents the burner from running if the
outside temperature is over 70°F.
4. Check the burner purge time delay relay.
5. Refer to the manufacturer.
1. Check if a high voltage source is located near the flame safeguard relay.
2. Check electrical wiring from the building junction box to the heater.
3. Refer to the manufacturer.
1. Check gas supply to the pilot.
2. Check pilot ignition transformer.
3. Check flame signal intensity (pilot only; it should range between 5 and 10 VDC for FIREYE or
between 3 and 5 VDC for HONEYWELL).
4. Check if manual and electric pilot gas supply valves are open.
5. Check condition of the flame rod ceramic; replace the flame rod if necessary.
6. Check or replace the flame safeguard relay amplifier.
7. Refer to the manufacturer.
1. Check if there has been a gas supply cut-off while the heater was in operation.
2. Check the inlet gas pressure while the burner is in operation.
3. Check the intensity of the flame signal (while the burner is in operation; it should be
between 5 and 10 VDC for FIREYE or between 3 and 5 VDC for HONEYWELL over the entire
modulation range).
4. Refer to the manufacturer.
1. Check the main burner pipes and the electrical connections.
2. Check condition of the flame rod ceramic; replace the flame rod if necessary.
3. Check the intensity of the flame signal (between 5 and 10 VDC for FIREYE or between 3 and
5 VDC for HONEYWELL).
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FIREYE AND HONEYWELL TROUBLESHOOTING CHECK LIST
SYMPTOMS ACTIONS
✓ OPEN AIR PRESSURE SWITCH
CODE 21 FIREYE
CODE 32 HONEYWELL
NOTE: While the heater is in
operation, the safety contacts
located between terminals 6 and 8 of
the FIREYE relay and terminals 6 and
7 of the HONEYWELL relay must be
closed.
✓GROUND FAULT
CODE 54 FIREYE
✓FAULTY PROGRAMMER
CODE 55 FIREYE
✓FAULTY AMPLIFIER
CODE 56 FIREYE
✓ VOLTAGE DROP
CODE 5 HONEYWELL
✓ GROUND FAULT
CODE 109 HONEYWELL
There are three safety devices in series between terminals 6 and 7 of the HONEYWELL flame
safeguard relay and between terminals 6 and 8 of the FIREYE flame safeguard relay.
A) Low air pressure switch
(set at 0.2 inch of water)
The low air pressure switch
will open when there is
insufficient airflow and cause
an alarm.
Its contacts are normally
open (N.O.) when the blower
starts and it closes if the
differential pressure at the
burner exceeds 0.25 inch of
water (see the Start-up
Instructions section for more
information on the
adjustment of the burner
profile plate).
B) High air pressure switch
(set at 1.2 inches of water)
The high air pressure switch
will open when there is
excessive airflow and cause
an alarm.
Its contacts are normally
closed (N.C.) and open if the
differential pressure at the
burner exceeds 1.2 inches of
water (see the Start-up
Instructions section for more
information on the
adjustment of the burner
profile plate).
C) Safety high temperature
limit switch (set at 160°F)
Its contacts are normally
closed (N.C.) and opens
when the temperature of the
air after the burner exceeds
160°F.
1. Check for proper grounding of the heater. Check for proper grounding of the flame
safeguard relay.
2. Check for faulty ground in the wiring between the heater and the electrical distribution
panel.
3. Refer to the manufacturer.
1. Replace the programmer.
2. Refer to the manufacturer.
1. Replace the amplifier.
2. Refer to the manufacturer.
1. While heater is in operation, check voltage at relay.
2. Check electrical connections and relay installation.
3. Refer to the manufacturer.
1. Check for proper grounding of the flame safeguard relay.
2. The main current and neutral wires are inverted.
3. Refer to the manufacturer.
AT START UP
1. The static pressure drop in
the air ducts exceeds the
specifications.
2. Check the size of the
pulleys and adjust or change
them if necessary.
3. Adjust the opening of the
profile plate if necessary.
4. Check the blower rotation.
AT START UP OR WHEN THE HEATER IS IN USE
1. The duct work static pressure drop does not meet the
specifications.
2. Check size of pulleys and adjust or change them if
necessary.
3. Adjust profile plate opening if necessary.
4. Replace the defective switch.
5. Refer to the manufacturer.
AT START UP OR WHEN THE HEATER IS IN USE
1. Check air temperature after the burner (the safety high
temperature limit switch opens at 160°F).
2. Check modulation of the Maxitrol valve and controls as well
as the amplifier and temperature signal.
3. Check gas pressure at the burner when set at high fire.
4. Replace defective switch.
5. Refer to the manufacturer.
WHEN HEATER IS IN USE
1. Check condition of filters.
2. Check condition of belts.
3. Look for duct work
modifications.
4. Check fresh air damper
operation.
5. Replace the defective
switch.
6. Refer to the manufacturer.
DF Series installation manual 25 www.nagasinnovation.com
LOW FIRE - PULSATING
8. Incorrect low fire adjustment.
8. Make sure that low fire is
8. Adjust the low fire.
MAXITROL TROUBLESHOOTING CHECK LIST
SYMPTOMS POSSIBLE CAUSE ON-SITE CHECK ACTIONS
NO GAS FLOW 1. Modulating valve Improperly
installed or defective
CONTINUOUS LOW FIRE
(ELECTRONIC PROBLEM)
CONTINUOUS LOW FIRE
(NO ELECTRONIC
PROBLEM)
2. No voltage to the amplifier.
3. Open circuit in TD114
(circuit or wiring)
4. Short circuit in TS114,
(circuit or wiring)
5. Defective amplifier
6. Short circuit or open circuit in
the amplifier coil
7. Missing, jammed or improperly
installed valve plunger.
1. The arrow on the side of the
valve must point in the direction
of the gas flow.
2. Check for 24 VAC supply at
amplifier terminals 7 and 8.
3. Check for loose or broken wires
between amplifier terminals 1
and 2 and between TD114
terminals 1 and 3.
4. Connect the test resistor
between terminals 3 and 4 of the
amplifier and disconnect the
wiring. Follow Maxitrol analysis
procedure.
5. Perform checks 2, 3 and 4.
6. With control wires
disconnected, check the
resistance at the connecting
terminals of the modulating
valve.
7. Check the plunger; it should
move freely upward.
1. Install the valve properly.
2. Verify the power source.
3. Tighten connections or replace
wiring.
4. If a modulating signal is read,
check TS114 for short circuits.
Replace the TS114 if necessary.
5. If steps 2, 3 and 4 do not solve
the problem and a modulating
signal is still not read, replace the
amplifier.
6. Replace the modulating valve
head if the resistance is not
approximately 45-55 ohms for the
M511 or ES371 valves and
approximately 60-80 ohms for the
MR212 valve.
7. Clean the plunger or replace it
if necessary. Install it according to
the instructions provided.
OR ERRATIC FLAME OR
IMPROPER CAPACITY
CONTINUOUS HIGH FIRE
(ELECTRONIC PROBLEM)
CONTINUOUS HIGH FIRE
(NO ELECTRONIC
PROBLEM)
ABNORMAL HIGH FIRE 15. Gas inlet pressure too low.
9. Excessive negative pressure at
burner
10. Short circuit in TD114
(circuit or wiring)
11. Open circuit in TS114/TS1007
(circuit or wiring).
12. Jumper not connected
between terminals 2 and 3 of the
amplifier.
13. Foreign object holding the
valve open.
14. Jammed plunger.
16. Incorrect adjustment of
regulator outlet pressure.
properly adjusted. There should
be a low flame throughout the
burner.
9. Shut off main gas supply and
check the suction at the elbow
located before the burner while
the blower is in operation; the
negative pressure should not
exceed 1.5 inches of water for the
M511.
10. Check for short circuits at
amplifier terminals 1 and 2 and
TD114 terminals 1 and 3.
11. Check TS114 for open circuits.
Follow step 4.
12. Make sure jumper is
connected.
13. Remove valve bottom plate
and inspect valve plunger and
seat.
14. Check the plunger; it should
be clean, smooth and move freely
in the valve.
15. Make sure that the minimum
inlet pressure recommended by
the manufacturer is respected.
16. Adjust the gas inlet pressure
according to the manufacturer’s
specifications.
9. If the negative pressure
exceeds 1.5 inches of water,
check for clogged filters or air
inlet restrictions. Refer to the
manufacturer for other
suggestions.
10. Correct wiring if necessary.
11. If a modulating signal is read,
check TS114 for open circuits.
Replace the TS114 if necessary.
12. Correct the wiring.
13. Clean the seat. Clean the
valve or replace it if necessary.
14. Clean the plunger or replace if
necessary.
15. Increase the inlet pressure if
possible.
16. Adjust the regulator to obtain
the required pressure.
DF Series installation manual 26 www.nagasinnovation.com
MAXITROL TROUBLESHOOTING CHECK LIST
SYMPTOMS POSSIBLE CAUSE ON-SITE CHECK ACTIONS
ERRATIC OR PULSATING
FLAME
INCORRECT DISCHARGE
AIR TEMPERATURE
BURNT OUT
TRANSFORMER
DISCHARGE AIR
TEMPERATURE TOO LOW
WHEN THE ROOM
THERMOSTAT CONTROLS
THE BURNER
NO REACTION FROM THE
MODULATING VALVE
WITH 20 VDC BETWEEN
TERMINALS 3 AND 4
17. Signal instability (hunting)
18. Air turbulence or TS114
installed in improper location
19. Control system wiring running
along high voltage wires, causing
induction
20. Faulty amplifier or incorrect
input voltage
21. Incorrect wiring
22. System improperly adjusted
23. Air stratification
24. The room thermostat controls
the burner.
25. Short circuit in the amplifier
coil
26. Short circuit between the
amplifier and the modulating
valve
27. Second temperature set point
too low
28. Insufficient burner capacity
29. Faulty modulating valve
30. Broken wires between the
amplifier and the modulating
valve
17. Adjust the amplifier sensitivity
counter clockwise.
18. Follow step 4. Turn the TD114
button to check the entire
modulation range.
19. Temporarily connect the
TD114, TS114 and MR212 with
new wires. Observe the burner
operation.
20. Follow step 18. Note the DC
voltage at the amplifier terminals.
21. Check the electric
connections.
22. The temperature sensed by
the TS114 does not correspond to
the TD114 setting.
23. The temperature sensed by
the TS114 does not correspond to
the desired average discharge air
temperature.
24. Disconnect the room
thermostat from terminal 2 of the
TD114.
25. Check the resistance of the
modulating valve head (with red
wires disconnected on the
MR212).
26. Check wiring.
27. Check the setting of the
second control point inside the
TD114.
28. Make sure that the heater
operates at high fire and that the
gas inlet pressure corresponds to
the manufacturer’s specifications.
29. Read voltage directly on the
modulating valve; if 24 VDC, the
valve is faulty.
30. Read voltage between
terminals 5 and 6 of the amplifier;
if 24 VDC, check for broken wires
leading to the modulating valve.
17. If the flame is unstable, adjust
the sensitivity of the amplifier to
obtain an even flame.
18. If the flame remains unstable
over the entire modulation range,
change the location of the TS114.
19. If normal operation is
restored, isolate the affected
wires from the wires causing
induction.
20. If the DC voltage is unstable
over the entire modulation range,
replace the amplifier. If unstable
operation is noted over a small
part of the range (2 or 3 volts
only), this might indicate the
occurrence of surges. Refer to the
Maxitrol manufacturer.
21. Correct wiring.
22. Adjust the TD114.
23. Move the TS114 to a location
where the temperature
corresponds to the desired
average temperature.
24. Make sure that the
temperature corresponds to the
TD114 set point. Check the room
thermostat setting and check
wiring for short circuits.
25. Replace the modulating valve
head if the resistance is under 40
ohms.
26. Correct the wiring if a short
circuit is found.
27. Set at desired temperature.
28. If the heater operates at high
fire, the control signal cannot be
increased. The burner may not be
of sufficient capacity to provide
the desired temperature rise.
29. Replace modulating valve.
30. Correct wiring.
DF Series installation manual 27 www.nagasinnovation.com
DIRECT FIRED HEATERS "DF SERIES"
2121 Nobel Tel: 1-888-514-8007
Ste-Julie Fax: 1-450-649-8756
J3E 1Z9 E-mail: msney@nagasinnovation.com
START-UP REPORT
Company: ____________________________________ Project: _______________________________________
Technician: ____________________________________ Project manager: ____________________________
Contractor: ____________________________________ Address: _______________________________________
Manufacturer Infos
Model number: __________________________________________ Serial number: _______________________
Gas leak: No wire located upstream of the burner:
Note: ____________________________________________________________________
Gas pressure: _________ _________ _________ _________ _________ _________
Differential pressure: _______ _______ Flame signal: ______ VDC
Low volume High volume
Adjustments
Low limit stat (freezestat): ______ºF Low limit delay: ______sec.
Inlet duct thermostat: ______ºF Pre-purge delay: ______sec.
Start-up delay on low fire: ______sec Inlet temperature thermostat: ______sec.
Profile plate openings: _______ X _______ _______ X _______
(Main - fixed) (Auxiliary motorized)
Start-up completed: If no, why? (or others):
STOP LOW F IRE HIGH FIRE STOP LOW FIRE HIGH FIRE
|___________________ INLET GAS PRESSURE _______ ________| |____________ GAS P RESSURE AT THE MANIFOLD______|
Inspection
Start-up
____________________________________________________________________________________________________
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____________________________________________________________________________________________________
____________________________________________________________________________________________________
____________________________________________________________________________________________________
____________________________________________________________________________________________________
____________________________________________________________________________________________________
____________________________________________________________________________________________________
____________________________________________________________________________________________________
____________________________________________________________________________________________________
Signature : ___________________________ Date : ____________________
DT Series - Start-up report 28 www.nagasinnovation.com
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