TJERNLUND 1, 2 WITH UC1 UNIVERSAL CONTROL (VERSION X.06) 8504106 REV C 0705, UC1, HS1, HS2 User Manual

IMPORTANT!!! UC1 BOARD VERSION X.06 UPDATES
LED INDICATOR LIGHTS
LED #1 (Amber) Appliance call for heat. LED #2 (Blue) Safety circuit through P1 & P2 (Venter Fan Prover and/or High Limit). Indicates Venter prover is closed during run cycle.
Burner circuit is energized with Interlock Relay contact closure from terminal 3 to 4. LED #3 (Green) Power switched to Venter motor from L to MTR & M. LED #4 (Red) Status / Fault indicator. LED #5 (Red) Used as a status indicator. LED #6 (Red) 115 VAC power supplied to board.
P/N: 8505017 ©2005 TJERNLUND PRODUCTS, INC. ALL RIGHTS RESERVED REV. B 07/05
TJERNLUND PRODUCTS, INC.
1601 Ninth Street • White Bear Lake, MN 55110-6794 PHONE (800) 255-4208 • (651) 426-2993 • FAX (651) 426-9547 Visit our web site • www.tjernlund.com
IMPORTANT:
For 950-8804 UC1 Replacement Board Kits: If this is a 950-8804 UC1 board kit and you are replacing an existing UC1 board with this
new board, note Dip Switch settings on existing UC1 circuit board so that those same settings can be positioned on this replacement circuit board. NOTE: Adhere appropriate included label over existing label in UC1 or SideShot electrical box. Also adhere "Checking Memory for Last Fault Code" sticker on inside of UC1 or SideShot SS1 Series electrical box. On SS2 Series adhere to underside of electrical box.
For SideShot Series SS1 Models: The Pre-Cycle Prover Status Check is deactivated from the factory on the SS1 Series. Because of the low set point of the SS1 Fan Prover (as low as .03" w.c.) cross winds may cause the Fan Prover to close prior to a call for heat. Activating the Prover Status Check on the SS1 may cause nuisance lockouts. Important: Deactivate the Pre-Cycle Prover status check if installing this board on a new or existing SS1 installation by pushing the #9 dip switch up or “ON” to disable.
For Draft Inducers with the UC1: Natural draft or winds may be sufficient to close the fan prover switch contacts prior to a call for heat when using the PS1505 fan prover with a draft inducer. Keeping the Pre-Cycle Prover Status Check activated may cause nuisance lockouts. Important: Deactivate the Pre-Cycle Prover status check if installing this board on a new or existing draft inducer installation by pushing the #9 dip switch up or “ON” to disable.
IMPORTANT: This upgraded circuit board features:
A new #6 power LED
Constant red when 115 VAC is supplied to L & N.
A new color for the #2 LED
Constant blue when fan prover safety circuit is closed.
A revised #5 LED
With no call for heat present, flashes 3 seconds on / 3 seconds off if microcontroller is working properly.
LED # 2 now BLUE (previously GREEN)
New LED # 6 RED 115V power supplied to UC1 L & N terminals
LED # 5 RED With no call for heat, flashes 3 seconds on / 3 seconds off if microcontroller is working properly.
NEW X.06 VERSION UC1 BOARD FEATURES
LED 1 (AMBER) LED 2 (BLUE) LED 3 (GREEN) LED 4 (RED) LED 5 (RED)
LED 6 (RED) POWER LED
DRY
24 V
115 V
APPLIANCE INTERLOCK
RELAY
VENTER
MOTOR
RELAY
A B 1 2 3 4 L N
J1 J2 XL XN
P1 P2 C GND F
(1 9)
N M MTR
LED STATUS INDICATORS
LED #4 & #5 (Red) Flashing Alternately = Venter in Pre-purge. (Pre-Purge options 0, 5, 20, 35 seconds)
LED #4 & #5 (Red) Flashing in Unison = Venter in Post-Purge. (Post-Purge options 0, 30 seconds or 1, 2, 4, 8, 16 minutes)
LED #4 Flashes Continuously* = Fan Prover opened for more than 10 seconds during burner cycle.
(Venter will run for 10 minutes, attempting to make Fan Prover)
LED #5 (Red) Flashing Intermittently = With no call for heat, flashes 3 seconds on / 3 seconds off if microcontroller is working properly.
LED FAULT INDICATORS
Fault conditions are indicated by counting the number of times LED #4 (Red) flashes.
LED #4 Flashes 2 Times Fan Prover was in electrically closed position prior to venter operation. LED #4 Flashes 3 Times* Fan Prover does not close within 60 seconds after call for heat. LED #4 Flashes 4 Times* Fan Prover did not re-close after 10 minutes of Venter operation. LED #4 Flashes 5 Times* Fan Prover opened for more than 10 seconds during burner cycle but closed within 10 minutes.
* Investigate cause of Fan Prover short cycling such as; Firing burner at capacities or temperatures exceeding Venter limits,
excessive vent pipe runs, elbows directly on venter discharge, high winds, plugged / kinked Fan Prover sensing tube or a faulty Fan Prover switch. In-Forcer model’s intake screen and prefilter, if applicable, should be cleaned if necessary.
CHECKING MEMORY FOR LAST FAULT CODE
IMPORTANT: Prior to accessing the fault code memory, note the settings of the dip switches so that they can be returned to their original Pre /
Post-Purge positions. When power is supplied to the UC1 use caution when moving dip switches.
The last fault code can be retrieved at any time by setting all dip switches 1-8 to the up, or “on” position. The last fault code, or lack there of, will be indicated by counting the number of times LED 4 flashes. By moving any of the dip switches back to their original position, the fault code will be cleared. NOTE: The UC1 board must have its 115 VAC power supply present when any of the (1-8) dip switches are moved back to their original position for the fault code to clear.
IMPORTANT: Fault codes will automatically be displayed after a fault condition occurs. If the call for heat interlock signal or 115 VAC power is removed, the UC1 board will reset and the fault will be stored in memory instead of displayed. Any new fault will replace any previous fault.
Copyright © 2005, Tjernlund Products, Inc. All rights reserved. P/N 8504106
REV. C 07/05
OWNER INSTRUCTIONS, DO NOT DESTROY
Recognize this symbol as an indication of important Safety Information!
NOTE: FLUE GAS TEMPERATURES MUST NOT EXCEED 600OF
AT VENT SYSTEM INLET FOR U.S. INSTALLATIONS AND 285
O
C (550OF) AT VENT SYSTEM INLET FOR
CANADIAN INSTALLATIONS.
THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED, LICENSED SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND OPERA­TION OF THIS UNIT. READ THESE INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN IMPROPER INSTALLATION, ADJUSTMENT, SER­VICE OR MAINTENANCE POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK, CARBON MONOXIDE POISONING, EXPLOSION, OR PERSONAL INJURY OR PROPERTY DAMAGE.
!
DO NOT DESTROY. PLEASE READ CAREFULLY AND KEEP IN
A SAFE PLACE ON JOB SITE FOR FUTURE REFERENCE.
MODELS
HSJ HS1 HS2
FOR NATURAL GAS, LP OR OIL
TJERNLUND PRODUCTS, INC.
1601 Ninth Street • White Bear Lake, MN 55110-6794 PHONE (800) 255-4208 • (651) 426-2993 • FAX (651) 426-9547 Visit our web site • www.tjernlund.com
INCLUDES UC1
UNIVERSAL CONTROL
UC1 VERSION
X.06
Address all correspondence to:
Customer Service • Tjernlund Products, Inc. • 1601 Ninth Street • White Bear Lake, MN 55110-6794
Call us toll free at 800-255-4208, visit our web site @ www.tjernlund.com or email us at fanmail@tjfans.com.
TABLE OF CONTENTS
PAGE(S)
SIZING TABLES AND SPECIFICATIONS ..................................................................................................................................... 1 - 2
INSTALLATION RESTRICTIONS .......................................................................................................................................................... 2
CAUTIONS ....................................................................................................................................................................................... 2 - 3
GENERAL INFORMATION .................................................................................................................................................................... 3
SAFETY INSPECTION OF PREVIOUSLY USED APPLIANCE............................................................................................................ 3
UC1 UNIVERSAL CONTROL BOARD FEATURES ..............................................................................................................................4
LED STATUS / FAULT INDICATORS AND FAULT RETRIEVAL FROM MEMORY ...........................................................................4, 5
PRE / POST-PURGE & PRE-CYCLE PROVER STATUS CHECK SETTINGS.................................................................................5, 6
INSTALLATION ..................................................................................................................................................................................... 6
VENT SYSTEM TERMINATION U.S. INSTALLATIONS ....................................................................................................... 6
VENT SYSTEM TERMINATION CANADIAN INSTALLATIONS ........................................................................................... 7
POWER VENTER INSTALLATION ...................................................................................................................................................... 7
CODE REQUIREMENTS .......................................................................................................................................................7
INSTALLATION RESTRICTIONS.......................................................................................................................................... 8
POWER VENTER MOUNTING............................................................................................................................................. 9
DRAFT CONTROL INSTALLATION ON AN INDUCED DRAFT GAS APPLIANCE...................................................... 9 - 10
UC1 UNIVERSAL CONTROL INSTALLATION ................................................................................................................................... 10
ELECTRICAL WIRING .........................................................................................................................................................................10
WARNINGS, SEQUENCE OF OPERATION & INTERNAL SCHEMATIC ...................................................................10 - 11
UC1 WIRING CONNECTIONS TO VENTER GROUND, MOTOR AND PROVER LEADS ................................................11
MULTIPLE OR MILLIVOLT APPLIANCE INTERLOCKS .....................................................................................................11
UC1 WIRING TO GAS FIRED APPLIANCE ................................................................................................................12 - 14
UC1 WIRING TO OIL FIRED EQUIPMENT .................................................................................................................14 -16
UC1 OPERATION CHECK, DRAFT CHECK, SAFETY INTERLOCK / COMBUSTION AIR TEST..............................................16 - 17
MAINTENANCE .................................................................................................................................................................................. 18
TROUBLESHOOTING ..................................................................................................................................................................18 - 19
WARRANTY & REPLACEMENT PARTS .............................................................................................................................................19
VENTER SPECIFICATIONS
1
HS-SERIES MODEL SELECTION TABLE
POWER VENTER DIMENSIONS
IMPORTANT
Table footage is based on equivalent vent pipe length. To calculate equivalent vent pipe length, add the straight vent pipe plus 10’ for every 90
O
elbow and 5’ for every 45Oelbow.
If venting multiple appliances with one Power Venter, the total com­bined BTU/hr. input of all appliances must be added together to size the Power Venter.
60
60
60
3000 95 1.26
YES
953000 YES1.26
2243000 YES1.51
MODEL
CONTROLMOTOR
Hz R.P.M. WATTS AMPS
THERMAL
115
24/115/DRYHSJ
24/115/DRY115
24/115/DRY115
HS1
HS2
VOLTAGEVOLTAGE PROTEC.
2001018H
The UC1 Universal Control may be interlocked with Dry Contact, 24 VAC or 115 VAC heater control circuits.
UC1 UNIVERSAL CONTROL SPECIFICATIONS
INSTALLATION RESTRICTIONS
1. This device must be installed by a qualified professional installer in accordance with these instructions. If improperly installed, a hazardous condition such as explosion or carbon monoxide poisoning could result.
2. Do not install the Power Venter on incinerators, incinerating toilets, condensing type appliances or solid-fuel burning appliances.
3. The Power Venter shall only be installed on Natural Gas, LP or Oil-fired appliances.
4. Do not install the Power Venter on an appliance with an automatic valve having a manual opener unless the manual opener has been rendered inoperative or the automatic valve has been replaced with a valve not equipped with a manual opener.
5. The Power Venter may only be installed on appliances equipped with a draft hood, draft diverter or barometric draft control.
6. The Power Venter shall not be installed where flue gas temperatures exceed 600
0
F. at Power Venter inlet for U.S. or 2850C
(550
0
F) for Canadian installations.
FLUE GAS TEMPERATURE VERIFICATION:
A) Consult appliance manufacturer for temperature of gases at the appliance outlet after dilution by draft hood, draft diverter or baro-
metric draft control.
AND
B) Measure temperature of flue gases at the Power Venter inlet at time of installation. Temperature should be measured after
appliance and Power Venter have operated for at least 15 minutes, allowing flue gas temperature to stabilize.
Flue gas temperature at Power Venter inlet must not exceed 600
0
F. for U.S. or 2850C (5500F) for Canadian installations.
7. The appliance(s) may only be installed on the suction side of Power Venter.
8. The UC1 is intended for indoor installation only. Do not mount the UC1 junction box on a heat source that exceeds 140oF. Examples of improper mounting surfaces include vent pipe, top of heater casing or any place where radiant or convective heat would cause the junction box temperature to exceed 140oF (60oC).
CAUTIONS
The Power Venter must be installed by a qualified installer in accordance with these instructions and all local codes or in their absence in accordance with the latest edition of The National Fuel Gas Code (ANSI Z223.1/NFPA #54), NFPA # 31 Oil Burning Equipment, the latest edition of the National Electrical Code (NFPA#70) and the Occupational Safety and Health Act (OSHA) when applicable. Canadian installations must comply with The Natural Gas Installation Code (CAN/CGA-B149.1); Propane Installation Code (CAN/CGA-B149.2); Installation Code For Oil Burning Equipment (CAN/CSA-B139). Improper installation can create a haz­ardous condition such as an explosion, fire, electrical shock or carbon monoxide poisoning resulting in property damage, personal injury or death. “Qualified Installer” shall mean an individual properly trained and licensed in accordance with local codes.
2
Improper installation, adjustment, alterations, service or maintenance can cause injury or property damage. Refer to this manual. For assistance or additional information consult a qualified installer, service agency, gas or oil supplier.
POWER
REQUIREMENTS
EXTERNAL
POWER SWITCHING
CAPACITY
J1 / J2
JUMPER
SAFETY
CIRCUIT
ADD VENTER MOTOR
LOAD PLUS 1/2 AMP
FOR UC1 LOAD
EXTERNAL
CALL TRIGGER
METHODS
J1 / J2
P1 / P2
L / N
3 TO 4
T-BLOCK
T-BLOCK
(RELAY K1)
XL / XN
UC1 CONTROL
M & MTR
(RELAY K2)
T-BLOCK
A / B
24V 1 / 2
115V
1 / 2
OR
OR
USED TO JUMP CALL HOT (24 VAC) OR CALL LINE (115 VAC) FROM TERMINAL 1 TO TERMINAL 3.
CONNECTED TO FAN PROVER. 1 mA @ 5 VDC. DO NOT SUPPLY POWER HERE.
REMOVE J1-J2 JUMPER IF A DIFFERENT VOLTAGE SOURCE IS PROVIDED TO TERMINAL 3.
120 VAC ±10 %, 50/60 Hz
MOTOR - 1 H.P. MAX. @ 120 VAC, 50/60 Hz
USER-PROVIDED 24 VAC AT TERMINALS 1 & 2. 1 = CALL HOT, 2 = COMMON. CONTROL REQUIRES 5 mA @ 24 VAC TO TRIGGER. MOVE RED VOLTAGE JUMPER TO "24V" LOCATION.
3 mA @ 5 VDC. MOVE RED VOLTAGE JUMPER TO "DRY" LOCATION. DO NOT SUPPLY POWER.
USER-PROVIDED CONTACT CLOSURE FROM A TO B. SIZE CONTACT CLOSURE TO HANDLE
GENERAL PURPOSE - 15A @ 120 VAC, 50/60 Hz
DURING OPERATION THE CONTROL USES 50 mA MAX @ 120 VAC
MOTOR - 1 H.P. MAX. @ 120 VAC, 50/60 Hz
150 mA MAX @ 120 VAC, 50/60 Hz CAN ONLY BE CONNECTED TO TJERNLUND-SPECIFIED AUXILIARY DEVICE
CIRCUIT PROTECTION PROVIDED BY INSTALLER
GENERAL PURPOSE - 15A @ 120 VAC, 50/60 Hz
RESISTIVE - 10A @ 28 VDC PILOT DUTY - 470 VA
USER-PROVIDED 115 VAC AT TERMINALS 1 & 2. 1 = CALL LINE, 2 = NEUTRAL. CONTROL REQUIRES 1 mA @ 115 VAC TO TRIGGER. MOVE RED VOLTAGE JUMPER TO "115V" LOCATION.
D/N 9183006H
Failure to install, maintain and/or operate the Power Venter in accordance with manufacturer's instructions may result in conditions which can produce bodily injury and property damage.
Disconnect power supply from the UC1 and heating equipment when making wiring connections and servicing the Venter. Failure to do so may result in personal injury and/or equipment damage. LED #6 (RED) should be off with power removed.
1. In order to comply with the ETL Listing of the Power Venters the Fan Prover must be wired with the appliance so as to prevent the main burner(s) from firing if the Power Venter malfunctions or the flue is blocked. It is not safe to use the Power Venter as is on millivolt appliances, such as water heaters which employ a combination gas valve/temperature controller, since the Fan Prover can not be wired as described in this manual. Millivolt appliances require additional interlock controls such as our WHKE kit. See millivolt wiring diagram in this manual for more details.
2. Plan the vent system so that Code required distances are maintained from plumbing and wiring.
3. The Power Venter motor shaft must be mounted horizontally to ensure proper operation of the Fan Proving Switch and prevent motor bearing wear.
4. Make certain the power supply is adequate for the fan motor and UC1 requirements. Do not add the Power Venter to a circuit where the total load is unknown.
5. The installer must verify that the BTU/hr. input of the appliance does not exceed the recommended input of the Power Venter. See selection table on page 1 of these instructions for sizing information.
6. Flue gas temperatures must not exceed 600
0
F. at the Power Venter inlet for U.S. installations and 2850C (5500F) for Canadian installations. Ambient temperatures surrounding Power Venter must not exceed 400C (1040F). See “Flue Gas Temperature Verification”, on page 2.
7. “Safety Inspection Of a Previously Used Appliance”, below, must be performed before installation on previously used equipment.
GENERAL INFORMATION
These units have been factory tested and rated in accordance with AMCA standard 210, Test Code for Air Moving Devices.
Each Power Venter and UC1 is electrically factory line tested before shipment.
After opening carton, inspect thoroughly for hidden damage. Wheel should rotate freely. If any damage is found notify freight carrier and your distributor immediately and file a concealed damage claim.
IMPORTANT
We do not recommend using the model HSJ for oil fired equipment since the small blower wheel is more susceptible to soot buildup. We recommend using the SideShot Series for oil inputs under 1 GPH (142,000 BTU/hr.) firing rates.
*SAFETY INSPECTION OF A PREVIOUSLY USED APPLIANCE
(Perform prior to Power Venter installation)
The following procedure is intended as a guide to aid in determining that an appliance is properly installed and is in safe condition for continuing use. This procedure is based on central furnace and boiler installations and it should be recognized that generalized pro­cedures cannot anticipate all situations. Accordingly, in some cases deviation from this procedure may be necessary to determine safe operation of the equipment.
a. This procedure should be performed prior to any attempt at modifications of the appliance or installation of the Venter.
b. If it is determined there is a condition which could result in an unsafe operation, the appliance should be shut off and the owner
advised of the unsafe condition.
The following steps should be followed in making the safety inspection:
1. Visually inspect the venting system and determine there is no blockage or restriction, leakage, corrosion or other deficiencies which could cause an unsafe condition.
2a. Oil Inst
allations: Inspect burner and primary control for proper operation.
2b. Gas Inst
allations: Conduct a gas leakage test of the appliance piping and control system downstream of the shutoff valve
in the supply line to the appliance.
Inspect burners and cross overs for blockage and corrosion.
3. Applicable only to furnaces:
Inspect heat exchanger for cracks, openings or excessive corrosion. Check both the limit control
and fan control for proper operation.
4. Applicable only to boilers:
Inspect for evidence of water or combustion product leaks. Determine that the water pumps are in operating condition. Test low water cutoffs, automatic feed controls, pressure and temperature limit controls and relief valves in accordance with the manufacturer's recommendations to determine that they are in operating order.
* Excerpts from the National Fuel Gas Code (ANSI Z223.1/NFPA #54), Appendix H.
3
UC1 UNIVERSAL CONTROL BOARD FEATURES
# 1. Power supplied by board. Do not supply power to this area or control damage may result. # 2. Do not supply power to the appliance interlock block with the call selector in the “DRY” position.
Control damage may result if power is supplied.
# 3. Circuit protection must be provided by the installer. 16 Amps is the maximum current allowed for this device at terminal L.
A 15 Amp circuit breaker is recommended.
VET
I
I
LED STATUS & FAULT INDICATORS
LED INDICATOR LIGHTS
LED #1 (Amber) Appliance call for heat. LED #2 (Blue) Safety circuit through P1 & P2 (Venter Fan Prover). Indicates Venter prover is closed during run cycle.
Burner circuit is energized with Interlock Relay contact closure from terminal 3 to 4.
LED #3 (Green) Power switched to Venter motor from L to MTR & M.
LED #4 (Red) Status / Fault indicator.
LED #5 (Red) Used as a status indicator.
LED #6 (Red) 115 VAC power supplied to board.
LED STATUS INDICATORS
LED #4 & #5 (Red) Flashing Alternately = Venter in Pre-purge. (Pre-Purge options 0, 5, 20, 35 seconds) LED #4 & #5 (Red) Flashing in Unison = Venter in Post-Purge. (Post-Purge options 0, 30 seconds or 1, 2, 4, 8, 16 minutes) LED #4 (Red) Flashing Continuously* = Fan Prover opened for more than 10 seconds during burner cycle.
(Venter will run for 10 minutes, attempting to make Fan Prover)
LED #5 (Red) Flashing Intermittently = With no call for heat, flashes 3 seconds on / 3 seconds off if microcontroller is working properly.
4
LED 1 (AMBER) LED 2 (BLUE) LED 3 (GREEN) LED 4 (RED) LED 5 (RED)
LED 6 (RED) POWER LED
DRY
24 V
115 V
APPLIANCE INTERLOCK
RELAY
VENTER
MOTOR
RELAY
A B 1 2 3 4 L N
J1 J2 XL XN
P1 P2 C GND F
(1 9)
N M MTR
APPLIANCE INTERLOCK RELAY
1 HP MAX LOAD across terminals 3 & 4.
VENTER MOTOR RELAY
1 HP MAX LOAD from terminals L to MTR & M.
XL / XN AUXILIARY DEVICE POWER TERMINALS
115 VAC - Maximum of 0.15 Amps. Only connect to Tjernlund auxiliary devices.
SEE WARNING # 1.
MTR & M / N LOAD TERMINALS FROM VENTER MOTOR RELAY
Used to drive Venter Motor. 1 HP MAX LOAD across terminals MTR & M / N.
L / N - 115 VAC POWER SUPPLY BLOCK
115 VAC / 50-60 Hz Circuit protection provided by installer.
SEE WARNING # 3.
APPLIANCE INTERLOCK TERMINAL BLOCK (A-B, 1-4) A- B- Dry Contact call. 3 mA @ 5VDC.
SEE WARNING # 1.
1 - 24 or 115 VAC intercepted call.
IMPORTANT: RED voltage jumper must
match intercepted call voltage.
2 - 24V common or 115V Neutral. 3 - Common terminal to appliance relay con-
tacts. IMPORTANT: J1-J2 jumper routes call voltage at terminal 1 to 3. Remove J1-J2 jumper if a different voltage source is provided to terminal 3.
4 - Normally open terminal of appliance relay.
Will be energized from terminal 3 if safety circuit is “proven”.
J1- J2 CALL JUMPER
Used when the call signal is used as the “proven” return signal to the appliance. See wiring section for details.
APPLIANCE CALL VOLTAGE SELECTION
Place RED voltage jumper in proper location based on appliance call interlock volt­age. SEE WARNING # 2.
IMPORTANT
LED STATUS LIGHTS
See “LED Status & Fault Indicator Section” for details.
DIP SWITCH SETTINGS
Pre-Purge (1-2) Post-Purge (3-8) Prover status check (9) See “Pre / Post Purge & Prover Status Check Dip Switch Settings”.
P1 - P2 SAFETY CIRCUIT TERMINALS
1 mA @ 5VDC.
SEE WARNING # 1.
C, GND, F AUXILIARY DEVICE COMMUNICATION TERMINALS
2 mA @ 5VDC. For Tjernlund MAC1E or MAC4E auxiliary devices. SEE WARNING # 1.
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