Tjernlund HSJ, HSJ1, HSJ2 User Manual
Copyright © 2003, Tjernlund Products, Inc. All rights reserved. P/N 8504106
REV. B 05/03
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 NEW UC1
UNIVERSAL CONTROL
VERSION
X.04
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 & 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 #5 (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.
VETI
I
LED STATUS & FAULT INDICATORS
LED INDICATOR LIGHTS
LED #1 (Amber) Appliance call for heat.
LED #2 (Green) Safety circuit through P1 & P2 (Venter Fan Prover) is verified “Open” upon start-up. Indicates Venter prover is
closed during run cycle. Burner circuit is energized with 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) 115 VAC power supplied to board. Also used as a status indicator.
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)
4
APPLIANCE CALL
VOLTAGE SELECTION
Place RED voltage jumper in
proper location based on
appliance call interlock voltage. SEE WARNING # 2.
IMPORTANT
LED 1 (AMBER)
LED 2 (GREEN)
LED 3 (GREEN)
LED 4 (RED)
LED 5 (RED)
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
J1- J2 CALL
JUMPER
Used when the call signal is
used as the “proven” return
signal to the appliance. See
wiring section for details.
L / N - 115 VAC POWER
SUPPLY BLOCK
115 VAC / 50-60 Hz
Circuit protection provided by installer.
SEE WARNING # 3.
MTR & M / N LOAD TERMINALS
FROM VENTER MOTOR RELAY
Used to drive Venter Motor.
1 HP MAX LOAD across terminals MTR & M / N.
XL / XN AUXILIARY DEVICE
POWER TERMINALS
115 VAC - Maximum of 0.15 Amps.
Only connect to Tjernlund auxiliary devices.
SEE WARNING # 1.
APPLIANCE INTERLOCK
RELAY
1 HP MAX LOAD across
terminals 3 & 4.
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.
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”.
LED STATUS LIGHTS
See “LED Status & Fault
Indicator Section” for details.
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”.
VENTER MOTOR RELAY
1 HP MAX LOAD from
terminals L to MTR & M.
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 causes of Fan Prover not making, i.e; 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.
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.
PRE / POST PURGE AND PROVER STATUS CHECK DIP SWITCH SETTINGS
Remove power to UC1 and heating equipment when installing, servicing or changing dip switch settings. Failure to do so may result in
personal injury and/or equipment damage. LED #5 (RED) should not be on if 115 VAC supply power is removed from the control.
Pre-purge
Used for a Venter with longer vent runs to get draft fully established throughout the vent system prior to burner ignition. Also beneficial for negative pressure prone environments. IMPORTANT: Nuisance equipment lockouts may occur if Venter pre-purge is running
in conjunction with and is longer than any equipment timing circuit. Pre-purge settings must be shorter than burner control lockout
time unless wired prior to burner control timing circuit (i.e. aquastat / thermostat).
Post-purge
A Venter post-purge has been factory set at 2 minutes. Confirm that dip switch #5 is in the up or "on" position. Oil fired equipment
requires that the post-purge be long enough to eliminate post cycle nozzle drip odor. A longer post-purge may be necessary for longer
vent runs or high heat retention, refractory lined combustion chambers. A shorter post-purge may be desired for gas installations.
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.
5
Pre-Purge
Post-Purge
Pre-Cycle
Prover Status
Check Activated
DIP SWITCH NUMBERING
1
ON
ON
POST-PURGE SETTINGS (SEE “POST-PURGE” ABOVE PRIOR TO SETTING)
ON
2
3
4
5
6
7
8 9
4348657 35678 345678 3 75468
4348657 35678 345678
4 Minutes 8 Minutes 16 Minutes
1 Minute0 Seconds 30 Seconds 2 Minutes
ON
PRE-PURGE SETTINGS (SEE “PRE-PURGE” ABOVE PRIOR TO SETTING)
12 12 12 12
0 Seconds 5 Seconds 20 Seconds 35 Seconds
1 9
LED 1 AMBER
LED 2 GREEN
LED 3 GREEN
LED 4 RED
LED 5 RED
ON
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