TJERNLUND PAI-3,PAI-4,PAI-5, PAI-6,PAI-7 User Manual
COMMERCIAL COMBUSTION AIR
IN-FORCER
TM
MODELS
PAI-3 PAI-4 PAI-5
PAI-6 PAI-7
Copyright © 2001, Tjernlund Products, Inc. All rights reserved. P/N 8504036
REV. A 05/01
OWNER INSTRUCTIONS, DO NOT DESTROY
Recognize this symbol as an indication of important Safety Information!
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.
!
PLEASE READ CAREFULLY AND KEEP ON JOB
SITE FOR FUTURE REFERENCE.
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
TABLE OF CONTENTS
Description and Specifications ....................................................................................................................................1, 2
Installation Restrictions....................................................................................................................................................2
Cautions ..........................................................................................................................................................................2
IN-FORCER Selection Table ...........................................................................................................................................3
Safety Inspection of a Previously Used Appliance..........................................................................................................4
Commercial IN-FORCER Terminology ............................................................................................................................4
Intake Hood Locations - Wall or Roof Mount ..................................................................................................................5
Installation
Tools Required ...............................................................................................................................................................5
Installation of Intake Hood
Roof Mount of Intake Hood...........................................................................................................................5, 6
Wall Mount of Intake Hood................................................................................................................................6
IN-FORCER Mounting.....................................................................................................................................................7
Electrical Wiring
IN-FORCER Internal Wiring Schematic ............................................................................................................8
IN-FORCER Fan Prover and Motor Isolation Relay Diagram ..........................................................................8
24 VAC Wiring with Single Appliance ...............................................................................................................9
115 VAC Wiring with Single Appliance..............................................................................................................9
Oil Wiring with Single Appliance .....................................................................................................................10
Oil & Gas Wiring with up to Four Appliances & the Optional MAC-4 .............................................................10
System Operation Check Out........................................................................................................................................11
Maintenance ..................................................................................................................................................................11
Trouble Shooting .........................................................................................................................................11, 12, 13, 14
How To Obtain Service, Warranty & Replacement Parts........................................................................................14, 15
IN-FORCER Fan Curves...............................................................................................................................................15
IN-FORCER
TM
is a trademark of Tjernlund Products, Inc. for IN-FORCER air intakes.
DESCRIPTION
The IN-FORCER combustion air intake systems are designed and Listed for use with atmospheric or induced combustion gas and oil
heating equipment. The IN-FORCER functions as the source of combustion air, eliminating the need for louvered openings. The
IN-FORCER assures intake air is supplied by monitoring the air flow with a Fan Proving Switch. The main burner will be interrupted if
a malfunction occurs.
ICATIONS
DIMENSIONS & SPECIFICATIONS
PAI-3 Motor: 115/1/60, 3000 RPM, 95 watts, 1.26 FLA, Thermal Protection
PAI-4 Motor: 115/1/60, 3300 RPM, 166 watts, 1.51 FLA, Thermal Protection
PAI-5 Motor: 115/1/60, 1725 RPM, 1/4 HP, 5.4 Amps, Thermal Protection
PAI-6 Motor: 115/1/60, 1725 RPM, 1/3 HP, 5.8 Amps, Thermal Protection
PAI-7 Motor: 115/208/230/1/60, 1725 RPM, 1 HP, 12.6/6.3/6.2 Amps, Thermal Protection
24-Volt Control Circuits: All models require a relay to activate the IN-FORCER motor. Tjernlund P/N 950-1040 is applicable to all
models except the PAI-7. The PAI-7 requires P/N 950-1016.
115 Volt Control Circuits: IN-FORCERS may be directly wired into a heating appliance control circuit as long as the contacts of the
circuit can handle the additional load of the IN-FORCER motor. For installations that require a relay, Tjernlund P/N 950-0480 is applicable to all models except the PAI-7. The PAI-7 requires P/N 950-0483.
1
INTAKE HOOD DIMENSIONS IN-FORCER POWERED INTAKE DIMENSIONS
Fan Proving Switch: Do not exceed 3 FLA or 1/10 HP through proving switch contacts. You may add one of relays listed on bottom
of page 1 to isolate the proving switch contacts if the load being switched exceeds the maximum rating.
High Limit: Manual reset N/C contacts, open at 160° +
8° F, 14 FLA @120 VAC. The high limit switch will deactivate the IN-FORCER
if temperature adjacent to high limit reaches the set point. Reset button is located on inside of cabinet on electrical box side of IN-FORCER.
GENERAL INFORMATION
1. These units have been factory tested and rated in accordance with AMCA Standard 210, test code for air moving devices.
2. Each IN-FORCER is electrically factory line tested before shipment.
3. After opening carton, inspect thoroughly for hidden damage. Fan wheel should rotate freely. If any damage is found, notify freight
carrier and your distributor immediately and file a concealed damage claim.
INSTALLATION RESTRICTIONS
1. Observe proper location of Intake Hood as described on page 5.
2. If IN-FORCER outlet is mounted lower than seven feet above the utility room floor, a minimum 2 foot section of pipe must be
installed on the discharge side of the IN-FORCER to prevent accidental contact with operating blower wheel.
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 or the equipment supplier.
CAUTIONS
1. Failure to install, maintain and/or operate the IN-FORCER in accordance with manufacturer’s instructions may result in conditions
that can produce bodily injury and property damage.
NOTE: Cold climate installations must adhere to warning #4 and #7.
2. The IN-FORCER must be installed by a qualified installer (an individual properly licensed and/or trained) in accordance with all
local codes or in their absence, in accordance with the appropriate National Fire Protection Association #31, #54, #211 and the
National Electric Code.
3. The IN-FORCER motor shaft must be mounted horizontally, with discharge also facing horizontally to prevent motor bearing wear
and ensure proper operation of the Fan Proving Switch.
4. Do not discharge onto water pipes or other equipment which may be affected by temperature extremes.
5. Disconnect power supply when making wire connections and servicing the IN-FORCER. Failure to do so may result in personal
injury and/or equipment damage.
6. Make certain the power source is adequate for the IN-FORCER requirements. Do not add the IN-FORCER to a circuit where the
total electrical load is unknown.
7. To prevent potentially damaging low mechanical room temperatures, it is recommended that a low temperature limit be installed.
8. WARNING: To reduce the risk of fire or electric shock, do not use this fan with any solid state speed control device.
9. WARNING: To reduce the risk of electric shock and injury to persons, do not use in a window.
10. WARNING: To reduce the risk of fire, electric shock, or injury to persons, observe the following:
a.) Installation work and electrical wiring must be done by qualified person(s) in accordance with all applicable codes and
standards, including fire-rated construction.
b.) Sufficient air is needed for proper combustion and exhausting of gases through the flue (chimney) of fuel burning equipment
to prevent back drafting. Follow the heating equipment manufacturer’s guideline and safety standards such as those
published by the National Fire Protection Association (NFPA), and the American Society for Heating, Refrigeration, and Air
Conditioning Engineers (ASHRAE), and the local code authorities.
c.) When cutting or drilling into wall or ceiling, do not damage electrical wiring or other hidden utilities.
The IN-FORCER CFM outputs will assure that adequate combustion air is supplied if the appliance is functioning properly. However,
in the event that there is an appliance malfunction, such as a cracked heat exchanger or clogged flue, there is no guarantee that additional combustion air will eliminate carbon monoxide spillage into the equipment room.
2
IN-FORCER APPLICATION AND SELECTION TABLE
Verify that the total BTU/hr input of the heating appliance(s) falls within the range specified below. Check maximum duct length and
appropriate duct diameter with the IN-FORCER Selection Table below.
ECIFIN-FORCER SELECTION TABLE
IN-FORCER SELECTION TABLE
MAX. DUCT LENGTH IN EQUIV. FEET indicates how much duct may be used at the given diameter based on the four types of heating equipment.
All duct before and after the IN-FORCER must be added. To calculate equivalent duct length, add the straight duct plus 10’ for every 90
0
elbow and 5’
for each 450elbow. Values in the chart assume rigid metal duct. Consult flex duct manufacturer for de-rating percentage if using flex duct. The resistance for any combination of ducts and diffusers cannot exceed the maximum equivalent duct length shown in selection table.
If interlocking IN-FORCER with more than one appliance of the same type, add the BTU/HR. input of each appliance to determine IN-FORCER model
and maximum equivalent duct length and diameter. If interlocking IN-FORCER with different types of equipment consult Tjernlund Technical Customer
Service @ 1-800-255-4208 for further information.
3
SAFETY INSPECTION OF A PREVIOUSLY USED OIL APPLIANCE
S
(Perform prior to IN-FORCER 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 IN-FORCER.
B. If it is determined there is a condition which could result in 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.
2. Inspect burner and primary control for proper operation.
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.
SAFETY INSPECTION OF A PREVIOUSLY USED GAS APPLIANCE
(Perform prior to IN-FORCER 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 IN-FORCER.
B. If it is determined there is a condition which could result in 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. Conduct a gas leakage test of the appliance piping and control system downstream of the shutoff valve in the supply line to the
appliance.
2. Visually inspect the venting system and determine there is no blockage or restriction, leakage, corrosion and other deficiencies
which could cause an unsafe condition.
3. Shut off all gas to the appliance(s).
4. Inspect burners and crossovers for blockage and corrosion.
5. Applicable only to furnaces:
Inspect heat exchanger for cracks, openings or excessive corrosion. Check both the limit control and
fan control for proper operation.
6. 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.
IN-FORCER TERMINOLOGY
4
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