NOT FOR RESIDENTIAL USE
CANADA: 100% OUTSIDE AIR ONLY
WARNING
Installation must be done by a contractor qualified
in the installation and service of gas-fired heating
equipment or your gas supplier.
Improper installation, adjustment, alteration, service
or maintenance can result in death, injury or
property damage. Read the Installation, Operation
and Service Manual thoroughly before installing or
servicing this equipment.
WARNING
FOR YOUR SAFETY
If you smell gas:
1. Open windows.
2. DO NOT try to light any appliance.
3. DO NOT use electrical switches.
4. DO NOT use any telephone in
your building.
5. Extinguish any open flame.
6. Leave the building.
7. Immediately call your local gas
supplier after leaving the building.
Follow the gas supplier’s
instructions.
8. If you cannot reach your gas
supplier, call the Fire Department.
Fire Hazard
Keep all flammable objects, liquids and
vapors the minimum required clearances to combustibles away from
equipment.
Some objects will catch fire or explode
when placed close to equipment.
Failure to follow these instructions can
result in death, injury or property
damage.
Weather-Rite™ XT-Series
Direct, Gas-Fired, Industrial
Air Handler
Installation, Operation &
Service Manual
XT112
XT115
XT118
XT125
© 2017 Weather-Rite LLC
XT130
Installer
Please take the time to read and understand
these instructions prior to any installation.
Installer must give a copy of this manual to the owner.
Owner
Keep this manual in a safe place in order to provide
your service technician with necessary information.
Weather-Rite LLC
1100 Seven Mile Road NW
Comstock Park, MI 49321
Telephone: +1.612.338.1401
Fax: +1.616.784.0435
Toll Free: 800.589.3691
www.weather-rite.com
P/N WR121100NA Rev F 2/17
Conçus pour les applications non-résidentielles
Canada: seulement avec
100% d’ air externe
ATTENTION
Linstallation doit être effectuée par un installateur
éprouvé/contractant qualifié dans linstallation et la
maintenance du système de chauffage par infrarouge
activé au gaz.
Linstallation, lajustement, laltération, le démarrage
ou lentretien inadéquat peuvent causer la mort, des
blessures ou des dégâts matériels. Lire entièrement
le manuel dinstallation, dopération et dentretien
avant linstallation ou l'entretien de cet équipement.
Installateur
Prenez le temps de lire et comprendre ces instructions
avant toute installation.
Linstallateur doit remettre au propriétaire
un exemplaire de ce manuel.
Propriétaire
Gardez ce manuel dans un endroit sûr pour
fournir des informations au réparateur
en cas de besoin.
Weather-Rite LLC
1100 Seven Mile Road NW
Comstock Park, MI 49321
Téléphone: +1.612.338.1401
Fax: +1.616.784.0435
Numéro sans fraís: 800.589.3691
www.weather-rite.com
AVERTISSEMENT
POUR VOTRE SECURITE
Si vous sentez une odeur de gaz:
1. Ouvrir les fenêtres.
2. N’essayer pas d’allumer un appareil.
3. N’utiliser pas d’interrupteurs
électriques.
4. N’utiliser pas de téléphone dans votre
bâtiment.
5. Eteindre flamme nue.
6. Quitter le bâtiment.
7. Après avoir quitté le bâtiment, appelez
immédiatement votre fournisseur local
de gaz.
Suivre les instructions du fournisseur
de gaz.
8. Si vous ne pouvez pas joindre votre
fournisseur de gaz, appeler le service
d’incendie.
Risque d’incendie
Garder tous les objets, liquides ou vapeurs
inflammables à la distance minimale de
l’unité de chauffage requise avec les
matériaux combustibles.
Certains objets prendront feu ou exploseront
s’ils sont placés à proximité de l’unité de
chauffage.
Le non respect de ces instructions peut
entraîner la mort, des blessures corporelles
ou des dommages matériels.
Weather-Rite™ XT-Series
L’appareil de traitment de l’air à
combustion directe, au gaz pour
les applications industrielles
Manuel d'installation,
d'opération,
et d'entretien
XT112
XT115
XT118
XT125
XT130
© 2017 Weather-Rite LLC
P/N WR121100FC Rev F 2/17
TABLE OF CONTENTS
SECTION 1: Air Handler Safety..............................................1
1.1 Description of Operation...............................................1
1.2 Inspection and Setup ................................................... 1
1.3 Safety Labels and Their Placement .............................2
1.4 California Proposition 65 ..............................................2
SECTION 2: Installer Responsibility .....................................3
2.1 Wall Tag .......................................................................3
2.2 Corrosive Chemicals....................................................3
2.3 National Standards and Applicable Codes ..................4
2.4 Required Equipment .................................................... 4
SECTION 3: Critical Considerations ..................................... 5
3.1 Required Clearances to Combustibles......................... 5
3.2 Purge of Supply Duct...................................................6
3.3 Hardware .....................................................................6
SECTION 4: National Standards and Applicable Codes .....7
4.1 Gas Codes...................................................................7
4.2 Installation Codes ........................................................7
4.3 Aircraft Hangars ...........................................................7
4.4 Parking Structures and Repair Garages...................... 7
4.5 Electrical ......................................................................7
4.6 Venting......................................................................... 7
4.7 High Altitude ................................................................7
SECTION 5: Specifications ....................................................8
SECTION 6: Lifting an Air Handler ......................................10
6.1 Lifting an Air Handler ................................................. 10
SECTION 7: Roof Curb ......................................................... 12
7.1 Roof Curb Assembly and Installation ........................ 12
7.2 Air Handler Mounting to Roof Curb ........................... 14
SECTION 8: Legs For Horizontal Mounting ........................ 15
8.1 Leg Mounting............................................................. 15
8.2 Leg Mounting - Horizontal Air Handler....................... 15
SECTION 9: Upright Installation.......................................... 16
9.1 Upright Leg Assembly................................................16
9.2 Upright Installation..................................................... 16
9.3 Attaching Air Handler.................................................16
SECTION 10: Filter Section ..................................................21
10.1 Filter Section Support Assembly Installation (XT-115 -
XT-130)....................................................................................21
10.2 Filter Section Installation - Horizontal Air Handlers.. 22
10.3 Filter Section Installation - Upright Air Handlers.......22
SECTION 11: Inlet Hood ....................................................... 23
11.1 Inlet Hood Assembly.................................................23
SECTION 12: Dampers ........................................................30
12.1 Discharge Damper.................................................. 31
12.2 Inlet Damper ...........................................................31
SECTION 13: Discharge Heads and Splash Plates............ 32
13.1 Three-Way Discharge Head Installation .................. 32
13.2 Splash Plate Installation........................................... 33
SECTION 14: Duct Considerations......................................35
14.1 Inlet D
uct Work ........................................................35
14.2 Return Duct Work ....................................................35
14.3 Discharge Duct Work...............................................35
SECTION 15: Gas Piping......................................................36
15.1 Gas Manifolds..........................................................36
15.2 Gas Piping and Pressures .......................................36
15.3 Gas Manifold Venting...............................................36
15.4 Gas Piping ............................................................... 39
15.5 Pressure Test Ports..................................................39
15.6 Line Pressure Test - Leak Testing ............................39
SECTION 16: Electrical......................................................... 40
16.1 Disconnect Fuse Sizing ..........................................41
16.2 Wiring and Electrical Connections ...........................41
16.3 Remote Panel .......................................................... 41
16.4 Motor Current Draw ................................................. 41
16.5 Control Current Draw............................................... 42
16.6 Safety Systems........................................................ 42
16.7 Interlocks ................................................................. 45
16.8 Control Options........................................................ 45
SECTION 17: Sequence of Operation ................................. 47
17.1 Air Handler Configuration ......................................... 47
17.2 HVAC Remote Panels and Panel Options................ 49
17.3 Basic Air Handler Sequence of Operation................ 51
SECTION 18: Direct Fired Burner........................................ 55
18.1 Direct Fired Burner Ignition...................................... 56
18.2 Direct Fired Burner Flame Proving (Flame Rod)...... 57
SECTION 19: Direct fired process air heaters .................... 58
19.1 Direct Fired Process Air Heater Models................... 59
19.2 Installer's Responsibilities........................................ 59
19.3 Installer's Responsibility for Process Heaters Connected
to Paint Booths ....................................................................... 60
SECTION 20: Start-up Procedures ...................................... 61
20.1 Installation of Recirculating Air Handler................... 62
20.2 Mechanical .............................................................. 62
20.3 Electrical.................................................................. 63
20.4 Airflow...................................................................... 63
20.5 Gas Piping and Initial Pressure Settings.................. 64
20.6 Safety Shut Off Valve Check.................................... 66
20.7 Temperature Control System Calibration................. 66
SECTION 21: Maintenance................................................... 69
21.1 General .................................................................... 70
21.2 Unit Exterior ............................................................. 70
21.3 Blower Section ........................................................ 70
21.4 Manifold and Controls .............................................. 73
21.5 Burner ..................................................................... 73
21.6 Optional Equipment ..................................................74
SECTION 22: Replacement Parts ........................................ 75
SECTION 23: Troubleshooting ............................................ 79
23.1 Initial Checks ........................................................... 80
23.2 Motor and Blower ................................................... 80
23.3 Burner..................................................................... 81
23.4 Temperature Controls ............................................. 82
23.5 A1014 Amplifier - Field Checklist ............................ 83
23.6 A44 Amplifier - Field Service Checklist................... 85
™
SECTION 24: WEATHER-RITE
XT-Series Start-Up Proce-
dures...................................................................................... 87
™
SECTION 25: The WEATHER-RITE
XT-Series Warranty .. 89
© 2017 Weather-Rite LLC
Printed in
the U.S.A.
SECTION 1: AIR HANDLER SAFETY
Yo ur Safety is Important to Us!
This symbol is used throughout
the manual to notify you of
possible fire, electrical or burn
hazards. Please pay special
attention when reading and
following the warnings in these
sections.
Installation, service and, at a minimum, annual
inspection of air handlers must be done by a
contractor qualified in the installation and service of
gas-fired heating equipment.
Read this manual carefully before installation,
operation or service of this equipment.
This air handler is designed for heating nonresidential indoor spaces. Do not install in residential
spaces. These instructions, the layout drawing, local
codes and ordinances and applicable standards that
apply to gas piping, electrical wiring, ventilation, etc.
must be thoroughly understood before proceeding
with the installation.
Protective gear is to be worn during installation,
operation and service in accordance to the
Occupational Safety and Health Administration
(OSHA). Gear must be in accordance to NFPA 70E,
latest revision w
hen working with electrical
components. Thin sheet metal parts have sharp
edges. To prevent injury, the use of work gloves is
recommended.
Before installation, check that the local distribution
conditions, nature of gas and pressure and
adjustment of the appliance are compatible.
The equipment must be applied and operated under
the general concepts of reasonable use and installed
using the best building practices.
This piece of equipment is not intended for use by
persons (including children) with reduced physical,
sensory or mental capabilities, or lack of experience
and knowledge, unless they have been given
supervision or instruction concerning use of the
equipment by a person responsible for their safety.
Children should be supervised to ensure that they do
not play with the equipment.
For additional copies of the Installation, Operation
and Service Manual, please contact Weather-Rite
LLC.
Gas-fired eq
uipment is not designed for use in
atmospheres containing flammable vapors or dust or
atmospheres containing chlorinated or halogenated
hydrocarbons. Recirculated room air may be
SECTION 1: AIR HANDLER S AFETY
hazardous if containing flammable solids, liquids,
and gases; explosive materials; and/or substances
which may become toxic when exposed to heat (i.e.
refrigerants, aerosols, etc.).
1.1 Description of Operation
This air handler is a direct, gas-fired, fresh-air piece
of equipment. It is designed for indoor or outdoor
installation with fresh outdoor air delivered to the
burner. Air handlers are designed to operate in
temperatures as low as -30° F (-34° C). The air
handler is factory-tested to fire with natural gas or
LPG (check the air handler's rating plate for
information on the appropriate gas). The burner
flame will modulate to maintain the selected
discharge air temperature or room air temperature,
depending on the selected controls. See Page 49,
Section 17.2. For maximum temperature rise, See
Page 66, Table 18.
The air handler may be provided with several
different controls and options to meet various
application requirements. Be sure to read this entire
manual before installation and start-u
p.
1.2 Inspection and Setup
The air handler is shipped fully assembled. The air
handler was inspected and operated prior to
shipment. Immediately upon receipt of the air
handler, check the fuel and electrical characteristics
of the air handler and verify that they match the fuel
and electrical supply available. Verify that the
specifications on the air handler rating plate match
the order. Check the air handler for any damage that
may have occurred during shipment. If any damage
is found, file a claim with the transporting agency. Do
not refuse shipment. Check the installation location
to ensure proper clearances to combustibles. See
Page 5, Section 3.1.
Any small options which do not come attached to the
air handler (i.e. remote panel) will be found inside the
air handler.
Larger accessories (i.e. legs, stand, filter section,
inlet hood) may either ship with the air handler or
separately. Check the bill of lading for information.
If the air handler must be temporarily stored (i.e. job
site is not ready for installation of the air handler), the
air handler should be set on 4" x 4" (10 cm x 10 cm)
pieces of timber on the ground in a protected area.
Cover the air handler to protect it from the
environment. Weather-Rite LLC will not be held
responsible for any damages that may occur from
outdoor storage.
1
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
1.3 Safety Labels and Their Placement
Product safety signs or labels should be replaced by
product user if they are no longer legible. Please
contact Weather-Rite LLC or your WEATHER-RITE
™
independent distributor to obtain replacement signs
or labels.
1.4 California Proposition 65
In accordance with California Proposition 65 require-
ments, a warning label must be placed in a highly
visible location on the outside of the equipment (i.e.,
near equipment's serial plate). To order additional
labels, please contact Weather-Rite LLC or your
™
WEATHER-RITE
independent distributor.
2
SECTION 2: INSTALLER R ESPONSIBILITY
WARNING
Explosion Hazard
Equipment must have access to
uncontaminated air at all times.
Failure to follow these instructions can result
in death, injury or property damage.
CAUTION
Product Damage Hazard
Do not use equipment in area containing
corrosive chemicals.
Refer to appropriate Material Safety Data
Sheets (MSDS).
Failure to follow these instructions can result
in product damage.
SECTION 2: INSTALLER RESPONSIBILITY
The installer is responsible for the following:
• To install and commission the air handler, as well
as the gas and electrical supplies, in accordance
with applicable specifications and codes.
Weather-Rite LLC recommends the installer
contact a local building inspector or Fire Marshal
for guidance.
•To use the information given in a layout drawing
and in the manual together with the cited codes
and regulations to perform the installation.
• To install the heater in accordance with the
clearances to combustibles.
•To furnish all needed materials not furnished as
standard equipment.
• To plan location of supports.
• To provide access to
air handler
for servicing.
• To provide the owner with a copy of this
Installation, Operation and Service Manual.
• To never use heater as support for a ladder or
other access equipment and never hang or
suspend anything from heater.
•To ensure there is adequate air circulation around
the air handler and to supply air for combustion,
ventilation and distribution in accordance with
local codes.
• To assemble or install any accessories or
associated duct work using best building
practices.
• To properly size supports and hanging materials.
• To ensure heater is placed in an approved
application.
2.1 Wall Tag
A laminated wall tag is available for the heater as a
permanent reminder of the safety instructions and
the importance of the required clearances to
combustibles. Please contact Weather-Rite LLC or
™
your WEATHER-RITE
independent distributor to
obtain the wall tag. Affix the tag on a wall near the
heater (e.g. thermostat or control system).
A copy of the wall tag (P/N 91040118) is illustrated on
the back cover. For an immediate solution, you may
affix this copy on the wall near the heater.
Know your model number and installed configuration.
Model number and installed configuration are found
on the rating plate and in the Installation, Operation
and Service Manual.
2.2 Corrosive Chemicals
Weather-Rite LLC cannot be responsible for ensuring
that all appropriate safety measures are undertaken
prior to installation; this is entirely the responsibility of
the installer. It is essential that the contractor, the
sub-contractor, or the owner identifies the presence
of combustible materials, corrosive chemicals or
halogenated hydrocarbons* anywhere in the
premises.
* Halogenated Hydrocarbons are a family of chemical
compounds characterized by the presence of halogen elements
(fluorine, chlorine, bromine, etc.). These compounds are
frequently used in refrigerants, cleaning agents, solvents, etc. If
these compounds enter the air supply of the burner, the life span
of the air handler components will be greatly reduced. The location of the outside air supply must be carefully chosen to supply
outside air, free of these compounds, to the burners whenever
the presence of these compounds is suspect. Warranty will be
invalid if the air handler is exposed to halogenated hydrocarbons.
3
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
2.3 National Standards and Applicable Codes
All equipment must be installed in accordance with
the latest revision of the applicable standards and
national codes. This refers also to the electric, gas
and venting installation. Note: Additional standards
for installation in public garages, aircraft hangars, etc.
may be applicable.
2.4 Required Equipment
When lifting of the equipment is required, the
installing contractor is responsible for supplying or
arranging for the appropriate lifting equipment so that
the air handler and accessories may be placed in a
safe manner.
The qualified installer or service technician is
responsible for having the appropriate equipment for
the safe installation and start-up of a direct-fired air
handler. Tools required to commission the equipment
include, but are not limited to, the following:
• Various screwdriver types and sizes
• Various adjustable wrenches
• Torque wrenches
• Pipe wrenches sized appropriately for the gas
train components
• Drill motor and various drills
• U-tube manometer or gas pressure gauge
• Volt meter
• Clamp style ammeter
• Belt tension gau
ge
• Caulk (non-silicone)
4
SECTION 3: CRITICAL CONSIDERATIONS
WARNING
Fire Hazard
Keep all flammable objects, liquids and
vapors the minimum required clearances to
combustibles away from equipment.
Some objects will catch fire or explode when
placed close to equipment.
Failure to follow these instructions can result
in death, injury or property damage.
SECTION 3: CRITICAL CONSIDERATIONS 3.1 Required Clearances to Combustibles
Clearances are the required distances that
combustible objects must be away from the air
handler to prevent fire hazards. Combustibles are
materials that may catch on fire and include common
items such as wood, paper, rubber, fabric, etc.
Maintain clearances to combustibles at all times
for safety.
Check the clearances on each air handler being
installed to make sure the product is suitable for your
application and the clearances are maintained.
Clearances to combustibles are 12" (30.5 cm) on the
control enclosure side and 6" (15.2 cm) on all other
surfaces. Read and follow the safety guidelines
below:
• Locate the air handler so that the air intakes are
not too close to any exhaust fan outlets, gasoline
storage, propane tanks or other contaminants that
could potentially cause dangerous situations.
WARNING
• Keep gasoline or other combustible materials
including flammable objects, liquids, dust or
vapors away from this air handler or any other
piece of
• Maintain clearances from heat sensitive material,
equipment and workstations.
equipment
.
Explosion Hazard
Fresh air supply duct and burner housing
must be purged with fresh air four times
before every ignition.
Explosive vapors will ignite if not evacuated
before ignition attempt.
Failure to follow these instructions can result
in death, injury or property damage.
Clearances to combustibles do not denote
clearances for accessibility. Minimum clearance for
access is 48" (122 cm). Minimum clearance for
accessibility applies to the control enclosure, blower
access panel and filter access panel (when
equipped).
The stated clearances to combustibles represent a
surface temperature of 90° F (50° C) above room
temperature (90° F [50° C] plus ambient
temperature). Building materials with a low heat
tolerance (i.e. plastics, vinyl siding, canvas, tri-ply,
etc.) may be subject to degradation at lower
temperatures. It is the installer’s/owner’s
responsibility to assure that adjacent materials are
protected from degradation.
• Maintain clearances from vehicles parked below the
air handler. See Page 7, Section 4.4.
5
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
8.8
10.9
3.2 Purge of Supply Duct
If this heating unit is to be installed indoors, and its
outdoor air supply ducted from outdoors, ANSI
Standards Z83.4/CSA 3.7, Z83.18 and Z83.25/CSA
3.19 require that all supply duct shall be purged a
minimum of four times prior to any ignition attempt. If
the volume of the outdoor air supply duct exceeds
the heating unit’s ability to complete the required four
air changes prior to ignition, you must contact the
factory to purchase an extended purge card of the
appropriate duration to meet this requirement.
3.3 Hardware
Unless otherwise specified, all hardware must be
torqued to settings on Page 6, Table 1.
Note: Inlet hood opening shall not be installed with
inlet opening facing into the prevailing wind direction
in order to help prevent the possibility of moisture
entrainment.
Table 1: Recommended Torque Settings
Bolt Head
Grade Marking
Nut Grade
Marking
Bolt Size Grade 2 Grade 5
10-24 27 in•lb 42 in•lb
1/4-20 65 in•lb 101 in•lb
5/16-18 11 ft•lb 17 ft•lb
3/8-16 19 ft•lb 30 ft•lb
Bolt Head
Grade Marking
8.8 10.9
Nut Grade
Marking
Bolt Size Grade 8.8 Grade 10.9
M5 6Nm 9Nm
M6 10Nm 15Nm
M8 25Nm 35Nm
M10 50Nm 75Nm
M12 85Nm 130Nm
M16 215Nm 315Nm
6
SECTION 4: NATIONAL STANDARDS AND APPLICABLE CODES
4.1 Gas Codes
The type of gas appearing on the nameplate
must be the type of gas used. Installation must
comply with national and local codes and
requirements of the local gas company.
United States: Refer to NFPA 54/ANSI Z223.1 latest revision, National Fuel Gas Code.
Canada: Refer to CSA B149.1- latest revision,
Natural Gas and Propane Installation Code.
SECTION 4: NATIONAL STANDARDS AND APPLICABLE C ODES
4.4 Parking Structures and Repair Garages
Installation in garages must be in accordance
with the following codes:
United States: Refer to Standard for Parking
Structures, NFPA 88A - latest revision or the
Code for Motor Fuel Dispensing Facilities and
Repair Garages, NFPA 30A - latest revision.
Canada: Refer to Natural Gas and Propane
Installation Code, Standard CSA B149.1 - latest
revision.
4.2 Installation Codes
Installations must be made in accordance with
the Standard for the Installation of AirConditioning and Ventilating Systems, NFPA
90A - latest revision for the installation of air
conditioning and ventilating systems.
4.3 Aircraft Hangars
Installation in aircraft hangars must be in
accordance with the following codes:
United States: Refer to Standard on Aircraft
Hangars, NFPA 409 - latest revision.
Canada: Refer to Natural Gas and Propane
Installation Code, Standard CSA B149.1 - latest
revision.
4.5 Electrical
Electrical connection to air handler must be in
accordance with the following codes:
United States: Refer to National Electrical
®
Code
, NFPA 70 - latest revision. Wiring must
conform to the most current National Electrical
®
Code
, local ordinances, and any special
diagrams furnished.
Canada: Refer to Canadian Electrical Code,
CSA C22.1 Part 1 - latest revision.
4.6 Venting
The venting must be installed in accordance
with the requirements within this manual and
the following codes:
United States: Refer to NFPA 54/ANSI Z223.1latest revision, National Fuel Gas Code.
Canada: Refer to CSA B149.1 - latest revision,
Natural Gas and Propane Installation Code.
4.7 High Altitude
These air handlers are approved for
installations up to 2000' (609.6 m) (in the US)
and 4500' (1371.6 m) (in Canada) without
modification. Consult factory if US installation is
above 2000
is above 4500
'
(609.6 m) or Canadian installation
'
(1371.6 m).
7
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
SECTION 5: SPECIFICATIONS
Estimated weight table apply to both upright and
horizontal units of the same model. See Page 8,
Ta b l e 2 .
Unless otherwise requested, all direct-fired air
handlers are set-up to accept an external static
attached ductwork. See Page 9, Table 4 and Table 5
for static pressure accessories. If more external static
pressure is required, this needs to be requested with
the order as required motor horsepower (HP) may
increase from the specifications given on Page 8,
Ta b l e 3 .
pressure (ESP) of 1 in wc (2.5 mbar). The external
static pressure is the sum of all accessories and any
Table 2: Estimated Shipping Weights
Model
Air Handler* 589 267 994 451 1290 585 1946 883 2877 1305
Filter Section** 118 54 210 95 282 128 407 185 439 199
Filtered Mix Box** 301 137 443 201 539 245 800 363 1156 524
Inlet Hoods 145 66 276 125 346 157 499 226 539 244
Upright Legs*** 75 34 99 45 137 62 176 80 214 97
Horizontal Legs*** 102 46 102 46 102 46 102 46 102 46
Moisture Limiters**** N/A N/A 120 54 120 54 210 95 260 118
Skid 147 67 249 113 324 146 486 220 719 326
* Includes Casing, Motor, Control Panel and Manifold
** Includes Weight of Filters
*** Total Quantity of 4 legs
**** Mounted to Intake Hood
XT-112 XT-115 XT-118 XT-125 XT-130
lbs kg lbs kg lbs kg lbs kg lbs kg
Table 3: Performance
Motor HP at Noted External
Airflow
3
CFM (m
1,000 (1,700) XT-112 1111162 66 70 97 86 7.1 (17.6) 0.75 (19)
2,000 (3,400) XT-112 2222260 66 70 194 173 7.1 (17.6) 0.75 (19)
3,000 (5,100) XT-112 2222260 65 70 292 259 7.1 (17.6) 0.75 (19)
4,000 (6,800) XT-112 3 3 3 3 3 62 65 70 389 345 7.1 (17.6) 0.75 (19)
5,000 (8,500) XT-115 3 3 3 3 3 58 63 68 594 486 7.1 (17.6) 1.0 (25)
6,000 (10,200) XT-115 5 5 5 5 5 58 62 67 712 583 7.1 (17.6) 1.0 (25)
7,000 (11,900) XT-115 5 5 5 5 5 59 62 66 831 680 7.1 (17.6) 1.0 (25)
8,000 (13,600) XT-115 5 5 5 5 5 60 63 66 950 777 8.9 (22.1) 1.0 (25)
9,000 (15,300) XT-115 7.5 7.5 7.5 7.5 7.5 61 64 67 1,069 874 11 (27.3) 1.0 (25)
10,000 (17,000) XT-115 7.5 7.5 7.5 7.5 7.5 62 65 68 1,188 972 13.4 (33.3) 1.0 (25)
11,000 (18,700) XT-118 7.5 7.5 7.5 7.5 7.5 64 66 68 1,306 1,069 7.7 (19.2) 1.25 (32)
12,000 (20,400) XT-118 7.5 7.5 7.5 7.5 7.5 66 68 69 1,425 1,166 8.9 (22.1) 1.25 (32)
13,000 (22,100) XT-118 10 10 10 10 10 67 69 CF 1,544 1,263 10.3 (25.6) 1.25 (32)
14,000 (23,800) XT-118 10 10 10 10 10 69 CF CF 1,663 1,361 11.7 (29.1) 1.25 (32)
16,000 (27,200) XT-125 10 10 10 10 10 70 72 76 1,900 1,555 6.9 (17.2) 1.5 (38)
18,000 (30,600) XT-125 15 15 15 15 15 70 74 77 2,138 1,749 8.3 (20.6) 1.5 (38)
20,000 (34,000) XT-125 15 15 15 15 15 70 74 77 2,376 1,944 9.9 (24.6) 1.5 (38)
22,500 (38,200) XT-125 20 20 20 20 20 71 74 77 2,673 2,187 12.2 (30.3) 1.5 (38)
25,000 (42,500) XT-125 25 25 25 25 25 72 75 77 2,970 2,430 14.7 (36.6) 1.5 (38)
27,500 (46,700) XT-130 25 25 25 25 25 71 73 75 3,267 2,673 7.7 (19.2) 2.0 (51))
30,000 (51,000) XT-130 25 25 25 25 25 73 75 76 3,564 2,916 8.9 (22.1) 2.0 (51)
32,500 (55,200) XT-130 30 30 30 30 30 75 76 77 3,861 3,159 10.2 (25.4) 2.0 (51)
35,000 (59,500) XT-130 40 40 40 40 40 77 77 79 4,158 3,402 11.7 (29.1) 2.0 (51)
37,500 (63,700) XT-130 40 40 40 40 40 78 79 79 4,455 3,645 13.4 (33.3) 2.0 (51)
40,000 (68,000) XT-130 50 50 50 50 50 80 CF CF 4,752 3,888 15.2 (37.8) 2.0 (51)
All information provided in this table is based on the assumption that unit is installed at an altitude below 2000 feet (609.6 meters).
CF = Consult Factroy
** dBA is measured at 10' (3 m) from unducted discharge.
*** Maximum Inlet Gas Pressure:
/h)
Model
Static Pressure (in wc)
00.250.50 0.75 1.00 0 0.50 1.00 NG LPG
Model XT-112 = 14 in wc (34.9 mbar)
Model XT-115-XT-130 = 5 psi (344.7 mbar)
dBA at Noted External
Static Pressure
(in wc)**
Heat Output at
Maximum
Temperature Rise
(Btu/h) x 1000
Minimum
Inlet Gas
Pressure
in wc
(mbar)***
Manifold
Size in NPT
(mm)
8
Table 4: Estimated Pressure Drop of Accessory Components
Inlet Hood with
Moisture Limiters
Model
XT-112
XT-115
XT-118
XT-125
XT-130
Airflow Range Inlet Hood with Filters Filter Section
in wc (mbar) in wc (mbar) in wc (mbar) in wc (mbar) in wc (mbar)
1,000-
2,000
3,000-
4,000
5,000-
6,000
7,000-
10,000
11,000-
14,000
16,000-
17,000
18,000-
25,000
27,500-
30,000
32,500-
40,000
(1,700-
3,400)
(5,100-
6,800)
(8,49510,200)
(11,400-
17,000)
(18,700-
23,800)
(27,200-
28,883)
(30,600-
42,500)
(46,772-
51,000)
(55,200-
68,000)
0.25 0.62 0.25 0.62 - - 0.05 0.12
0.40 1.0 0.50 1.25 - - 0.05 0.12
0.25 0.62 0.25 0.62 0.10 0.25 0.05 0.12
0.40 1.0 0.50 1.25 0.10 0.25 0.05 0.12
0.40 1.0 0.50 1.25 0.10 0.25 0.05 0.12
0.25 0.62 0.25 0.62 0.10 0.25 0.05 0.12
0.40 1.0 0.50 1.25 0.10 0.25 0.05 0.12
0.35 0.87 0.75 1.87 0.10 0.25 0.05 0.12
0.40 1.0 0.85 2.12 0.10 0.25 0.05 0.12
Table 5: Estimated Pressure Drop of Accessory Components (continued)
Model
XT-112
XT-115
XT-118
XT-125
XT-130
Airflow RangeDischarge Heads Splash Plate Inlet/Discharge Damper
in wc (mbar) in wc (mbar) in wc (mbar) in wc (mbar)
1,000-
2,000
3,000-
4,000
5,000-
6,000
7,000-
10,000
11,000-
14,000
16,000-
17,000
18,000-
25,000
27,500-
30,000
32,500-
40,000
(1,700-
3,400)
(5,100-
6,800)
(8,495-
10,200)
(11,400-
17,000)
(18,700-
23,800)
(27,200-
28,883)
(30,600-
42,500)
(46,772-
51,000)
(55,200-
68,000)
0.10 0.25 0.05 0.12 0.10 0.25
0.10 0.25 0.05 0.12 0.10 0.25
0.10 0.25 0.05 0.12 0.10 0.25
0.10 0.25 0.05 0.12 0.10 0.25
0.10 0.25 0.05 0.12 0.10 0.25
0.10 0.25 0.05 0.12 0.10 0.25
0.10 0.25 0.05 0.12 0.10 0.25
0.10 0.25 0.05 0.12 0.10 0.25
0.10 0.25 0.05 0.12 0.10 0.25
SECTION 5: SPECIFICATIONS
Inlet Hood with
Bird Screen
9
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
WARNING
Crush Hazard
Use proper lifting equipment and practices.
Failure to follow these instructions can result
in death, injury or property damage.
Spreader Bar
SECTION 6: LIFTING AN AIR HANDLER
The air handler must be installed in compliance with
all applicable codes. The qualified installer or service
technician must use best building practices when
installing the air handler and any optional equipment.
This piece of equipment requires at least 4 CFM (6.8
3
m
/h) of outside air per 1,000 Btu/h (0.293 kW). Any
air handler that recirculates air from the heated
space must use the return air opening to prevent any
return air from passing over the burner.
Before installation, check that the local distribution
condition, nature of gas and gas pressure, and the
current state of adjustment of the equipment are
compatible. If filters are not installed (via inlet hood or
filter section), an air strainer (provided by others)
must be installed on the inlet of the air handler with
openings less than or equal to 5/8" (16 mm) in
diameter. Air inlets must be installed in such a
manner that their lowest edge is 19" (500 mm) above
any surface. This applies to roof curbs, upright
stands and suspended air handlers.
6.1 Lifting an Air Handler
6.1.1 Preparing to Lift the Air Handler
Prior to lifting the air handler, the following steps must
be performed:
1. R e m o ve all packaging or banding that attached the air handler to the skid and ensure that the air handler is no longer bound to the skid.
2. Remove all of the accessories or packages that
were shipped on the same skid, inside the air
handler or inside the control enclosu
3. Inspect the air handler to:
• Verify that there is no damage as a result of
shipping.
•Ensure that it is appropriately rated for the
utilities available at the installation site.
• Verify that the lifting lugs are intact
undamaged and secured to the air handler.
•Ensure factory-installed hardware is
torqued as specified.
4. Prepare the installation location to be ready to accept the air handler (i.e. roof curb, mounting stand or legs).
5. Verify the lifting equipment can handle the air handlers weight and the required reach. See Page 8, Table 2.
6.1.2 Lifting a Horizontal Air Handler (All Models)
Lift the air handler into place installing appropriate
hardware (supplied by others) into all lifting lug holes
on the unit base. For model XT-112, lifting lug holes
are 1.5" (3.81 cm) diameter. For models XT-115 - XT130, lifting lug holes are 2.0" (5.1 cm) diameter. Use
spreader bars to ensure that the lifting cables clear
the sides of the air handler. The air handler must be
kept level during the lift to prevent tipping, twisting or
falling. If lifted improperly, product damage may
occur.
Next, refer to the applicable portions of Section 7,
See Pages 12 - 14 for specific mounting instructions.
For mounting of accessories, refer to the applicable
portions of Page 21, Section 10.1 through Page 32,
Section 13.
FIGURE 1: Lifting a Horizontal Air Handler
re.
10
SECTION 6: LIFTING AN AIR H ANDLER
Step 1
Remove These
Lifting Lugs
Step 2
Step 3
Step 4
Spreader Bar
INLET
INLET
INLET
INLET
6.1.3 Lifting an Upright Air Handler
All air handlers are shipped in the horizontal position.
Prior to lifting an upright air handler, the following
steps must be performed (See Page 11, Figure 2):
Step 1: The air handler must be lifted using the two
lifting lugs on the top of the discharge end and the
two lifting lugs on the inlet end, using a spreader bar
across the long axis. Lift the air handler off the skid
and place it on a flat, clean, dry surface.
FIGURE 2: Lifting an Upright Air Handler
Step 2: Remove the lifting lugs on the inlet end of the
air handler and re-install hardware.
Step 3: Use all four lifting lugs on the discharge end
of the air handler to enable the air handler to be lifted
into the upright position.
Step 4: Lift the air handler into upright position.
Step 5: Next, refer to the applicable portions of Page
16, Section 9 for specific mounting instructions.
11
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
SECTION 7: ROOF CURB
WARNING
Crush Hazard
Use proper lifting
equipment and
practices.
Failure to follow these instructions can result in death, injury or property damage.
Roof curbs are shipped unassembled and require field assembly.
NOTE: Before installation, verify that you have the correct roof curb and that all required components are
present. If any are missing, contact your WEATHER-RITE
7.1 Roof Curb Assembly and Installation
Assemble roof curb according to the assembly drawing, on Page 13, Figure 3. Supplied hardware must be
torqued to recommended specifications on Page 6, Table 1.
Place the curb on the roof in the position in which it will be installed. Check that the diagonal measurements
are within 1/8" (3 mm) of each other. To ensure a weatherproof seal between the air handler and the curb,
the curb must be level with no twist from end to end. Shim level as required and secure curb to roof deck
using best building practices. The curb is self-flashing. Install roofing material as required.
Falling Hazard
Use proper safety
equipment and practices to avoid falling.
Severe Injury Hazard
Use proper lifting
practices and equipment.
Equipment and
accessories are
heavy.
™
independent distributor.
Cut/Pinch Hazard
Wear protective gear
during installation,
operation and
service.
Edges are sharp.
NOTE: Check the installation location to ensure proper clearances to combustibles and clearance for
access. See Page 5, Section 3.1.
12
FIGURE 3: Roof Curb Assembly
Model
Dimensions Weight* Weight**
ABCDElbs kg lbs kg
XT-112
(in)
24.3 80.2 21.3 128.1 48.9 96 43 140 63
(cm)
61.7 203.7 58.7 325.5 121.8
XT-115
(in)
39.3 105.1 36.3 155.5 51.4 133 60 179 81
(cm)
99.8 267.0 96.8 395.1 128.1
XT-118
(in)
45.1 96.3 42.1 143.2 47.9 130 59 173 78
(cm)
114.6 244.6 111.6 363.8 119.2
XT-125
(in)
51.9 114.7 48.9 182.7 68.0 153 69 216 97
(cm)
131.8 291.3 128.8 464.1 172.7
XT-130
(in)
76.1 151.8 73.1 215.4 64.6 210 94 268 121
(cm)
193.3 385.6 190.3 547.1 161.5
SECTION 7: ROOF CURB
***Cross Brace
***Side panels are split
End Panel
(Inlet or Discharge)
Top Mounting Flange
Side Panel
Caulk required for outside perimeter
of roof curb at bolted joints.
NOTE:
*Blower and Burner Section
**Blower, Burner and Mixbox
*** Split sides and Cross Brace for Model XT-130
• Curb is shipped unassembled.
• A and B are outside dimensions for the top of the curb.
• Curb material is 14 gauge galvanized steel.
• Nuts and bolts (3/8" x 1") are furnished.
• Caulk all joints before assembling. (Caulk provided by others)
13
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
Air Handler
Roof Curb
Fastening Detail
7.2 Air Handler Mounting to Roof Curb
After the curb has been installed, the air handler may be placed on the curb. See Page 14, Figure 4. After the
air handler is in place, the installer must fasten the air handler to the curb. This is accomplished by drilling
holes down through the floor of the air handler and into the curb. At least three #12 sheet metal screws
(supplied by others) equally spaced on each side must be used to attach the air handler to the curb. After the
curb has been installed, the air handler may be placed on the curb. There must be a 1/8" (.3 cm) x 2" (5.1
cm) neoprene closed cell, adhesive-back gasket (supplied by others) between the top of the curb and the
base surface of the air handler to prevent moisture from leaking into the building from either driving rains or
melting snow. The installer is responsible for tying the air handler to the curb per all applicable codes.
FIGURE 4: Curb Mounting
14
SECTION 8: LEGS FOR HORIZONTAL MOUNTING
WARNING
SECTION 8: LEGS FOR HORIZONTAL MOUNTING
Crush Hazard
Use proper lifting
equipment and
practices.
Failure to follow these instructions can result in death, injury or property damage.
8.1 Leg Mounting
Legs can be used when mounting an air handler on a
concrete slab or directly on the floor. Legs are
available for all models in the horizontal
configuration.
8.2 Leg Mounting - Horizontal Air Handler
The 46" (116.8 cm) legs must first be mounted to the
air handler before being mounted to the concrete
slab or floor. To attach the legs with the air handler
must first be lifted with the provided lifting lugs. See
Page 10, Section 6.1 for safe lifting practices. In each
corner of the bottom of the air handler, four legmounting holes will be found.
Falling Hazard
Use proper safety
equipment and practices to avoid falling.
Severe Injury Hazard
Use proper lifting
practices and equipment.
Equipment and
accessories are
heavy.
occupies each of the bolt locations. Place the leg on
the inside of the corner and attach with the previously
removed hardware. Missing hardware needs to be
added at each bolt location. The required hardware is
a 5/16"-18 x 1" grade 5 bolt, a 5/16" flat washer, and
a 5/16"-18 grade 5 flange nut.
To attach the legs to a concrete slab, the base of
each leg is eq
capable of accepting 5/8" nuts must be installed in
the concrete slab.
The air handler may now be placed down over the
slab studs. The legs should then be bolted down with
5/8" nuts.
uipped with two 1" holes. Studs
Cut/Pinch Hazard
Wear protective gear
during installation,
operation and
service.
Edges are sharp.
The legs can now be mounted one at a time to the
inside of the corner by removing the hardware that
15
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
SECTION 9: UPRIGHT INSTALLATION
WARNING
Crush Hazard
Use proper lifting
equipment and
practices.
Failure to follow these instructions can result in death, injury or property damage.
9.1 Upright Leg Assembly
It is recommended that two individuals are used for
the assembly process.
9.2 Upright Installation
To attach the legs to a concrete slab, it must be
secured with the use of studs, embedded in the
concrete. Four 5/8" studs (minimum) must be
installed in the slab, one for each corner of the stand.
The stand has four 3/4" (19.0 mm) holes drilled
through the stand pads. Fasten the stand to the slab
with four 5/8" hex nuts and lock washers (provided by
others).
9.3 Attaching Air Handler
Once the stand is secured to a concrete slab, the air
handler may be placed on the stand. Prior to lifting
the air handler, apply the foam tape and remove the
Falling Hazard
Use proper safety
equipment and practices to avoid falling.
Severe Injury Hazard
Use proper lifting
practices and equipment.
Equipment and
accessories are
heavy.
attaching hardware as described below. The ½"
(12.7 mm) thick double-sided urethane foam tape
(provided by others) must be applied to the top edge
of the stand. Remove the lifting lugs and re-install the
hardware. See Page 21, Figure 10. Lift the air
handler on to the legs. See Page 10, Section 6.1 for
safe lifting practices. Once the air handler is placed
on the legs, secure it with the prov
hardware recommended torque settings. After
placing the air handler on the legs, seams between
the mounting legs and the air handler must be
properly caulked (caulk provided by others).
NOTE: If using a filter section with an upright air
handler and legs, the filter section must be set into
the legs before the air handler is mounted on the
legs. The 1/2" (12.7 cm) thick double-sided urethane
foam tape should be applied between the legs and
the filter section. See Page 22, Section 10.3.
Cut/Pinch Hazard
Wear protective gear
during installation,
operation and
service.
Edges are sharp.
ided attaching
16
SECTION 9: UPRIGHT I NSTALLATION
Step 1: Assemble using the provided hardware: 3/8" bolts, nuts and lock washers. Assemble the legs with
the top upside down on a flat surface. See Page 17, Figure 5.
FIGURE 5: Step 1
Step 2: Attach the mounting feet to each leg using supplied hardware. See Page 17, Figure 6. FIGURE 6: Step 2
17
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
Step 3: With the top frame upside down, insert and attach the first two legs.
Note: All legs are identical and not all the holes will be used on each leg. See Page 18, Figure 7.
FIGURE 7: Step 3
18
SECTION 9: UPRIGHT I NSTALLATION
Step 4: Next attach the horizontal support(s), and repeat process for the other two remaining legs. See Page
19, Figure 8.
FIGURE 8 : Step 4
19
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
Control Side
Filter Access
Return
Air
Step 5: Attach remaining support braces taking note of the support location to proper orient for your air handler's configuration. See Page 20, Figure 9.
FIGURE 9: Step 5
20
SECTION 10: FILTER SECTION
NOTE: 1) CONTRACTOR/INSTALLER MUST MAKE
APPROPRIATE ALLOWANCES FOR DUCT
CONNECTIONS.
2) SUPPORT LEG IS REQUIRED WHEN A FILTER
SECTION AND INLET HOOD ARE ORDERED.
3) SUPPORT LEG IS PROVIDED FOR USE WITH
STANDARD 19" (50 cm) ROOF CURB. SUPPORT
LEG FOR USE WITH STANDARD 46" (116.8 cm)
LEGS PROVIDED BY OTHERS.
SECTION 10: FILTER S ECTION
WARNING
Crush Hazard
Use proper lifting
equipment and
practices.
Falling Hazard
Use proper safety
equipment and practices to avoid falling.
Severe Injury Hazard
Use proper lifting
practices and equipment.
Cut/Pinch Hazard
Wear protective gear
during installation,
operation and
service.
Equipment and
accessories are
Edges are sharp.
heavy.
Failure to follow these instructions can result in death, injury or property damage.
10.1 Filter Section Support Assembly Installation (XT-115 - XT-130)
It is best to assemble the support base and support arms to the filter section prior to attaching the filter
section to the air handler but can also be assembled to a previously installed filter section.
legs to the bottom of the filter section (air entering edge) using the hardware supplied.
Refer to Page 21, Figure
Attach the support
10.
FIGURE 10: Filter Section Support Assembly
21
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
10.2 Filter Section Installation - Horizontal Air Handlers
10.2.1 Filter Section Installation
For installation directly onto the inlet of the air
handler, foam tape (provided by others) must be
applied to the filter section sides and bottom. Attach
the sides of the filter section to the factory installed
riv-nuts on the inlet of the air handler with the
supplied hardware. Additional TEK screws may be
used along the top and flange of the filter section to
seal the bottom seam. Caulk (provided by others) all
seams between the filter section and air handler.
FIGURE 11: Filter Section Installation on Horizontal Air Handler
10.3.2 Filter Installation
Install the proper filters as required for the air
handler’s configuration. See Page 22, Table 6.
Table 6: Filter Quantities
Permanent Aluminum Mesh Pleated / Polyester*
Model Size Quantity
XT-112
XT-115
XT-118
XT-125
XT-130
(in)
(cm)
(in)
(cm)
(in)
(cm)
(in)
(cm)
(in)
(cm)
25 x 25 x 2
(63.5 x 63.25 x 5.1)
20 x 20 x 2
(50.8 x 50.8 x 5.1)
24 x 20 + 20 x 20 [5 each]
(60.9 x 50.8 + 50.8 x 50.8)
25 x 25 x 2
(63.5 x 63.25 x 5.1)
24 x 20
(60.9 x 50.8)
2
6
10
12
24
10.3 Filter Section Installation - Upright Air Handlers
10.3.1 Filter Section Installation
To install a filter section on an upright air handler that
is mounted on legs, the filter section must be
installed in the leg assembly prior to placing the air
handler (See Page 16, Section 9 for proper leg
mounting). Place the filter section so that the outward
flange is on the top side. Set the filter section into the
leg assembly. Place ½" foam tape (supplied by
others) along the perimeter of the top of the flange.
Place the air handler on the leg assembly per the
mounting instructions.
22
SECTION 11: INLET HOOD
Top Roof
Top Rain Gutter X2
Top Left
Bottom Left
Bottom Rain
Gutter X2
Bottom
Filter Rail
X8
Bottom
Right
Top
Right
Bottom
Roof
SECTION 11: INLET HOOD
WARNING
Crush Hazard
Use proper lifting
equipment and
practices.
Falling Hazard
Use proper safety
equipment and practices to avoid falling.
Severe Injury Hazard
Use proper lifting
practices and equipment.
Cut/Pinch Hazard
Wear protective gear
during installation,
operation and
service.
Equipment and
accessories are
Edges are sharp.
heavy.
Failure to follow these instructions can result in death, injury or property damage.
Inlet hoods are shipped unassembled and must be assembled prior to installation. The inlet hood may be
installed either onto the inlet of the air handler or to an outside wall. After installing an inlet hood, all hardware
must be torqued according to recommended specifications on Page 6, Table 1. In addition, all seams must
be caulked (provided by others).
NOTE: Check to be sure that all required components are present. If any are missing, contact your
WEATHER-RITE
™
independent distributor.
11.1 Inlet Hood Assembly FIGURE 12: Inlet Hood with Filter Racks
23
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
Roof
Left Panel
Rain
Gutter X2
Bottom
Right
Panel
FIGURE 13: Inlet Hood
For an air handler supplied with a filter section a single hood is provided. For an air handler with inlet hood
mounted filters, two hoods are provided. To install inlet hood on an exterior wall, drill holes 8" (20.3 cm) in the
flanges of the inlet hood and mount with lag bolts (provided by others).
The following hardware is supplied for the assembly of the inlet hoods; #10 TEK self tapping screws, 3/8"
nuts/bolts/washers, 3/16" rivets and foam gasket tape.
Step 11.2 Inlet Hoods with Filter Rack Assembly
Step 11.2.1 Seal around the perimeter of the inlet of the air handler with the provided foam gasket tape.
Step 11.2.2 Mount the upper inlet hood right and left side (flanges will be facing out), with the bolts and wash-
ers provided.
24
SECTION 11: INLET HOOD
Step 11.2.3 Attach the upper hood roof with the provided TEK screws along the left and right side and upper
edge to the air handler.
Step 11.2.4 Attach the bottom filter rail for the upper inlet hood to the hood using the provided rivets.
25
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
Step 11.2.5 Mount the lower inlet hood right and left side (flanges will be facing out), with the bolts and wash-
ers provided and the upper edge of these sides to the lower portion of the upper hood with the TEK screws
provided.
Step 11.2.6 Attach the bottom filter rail for the lower inlet hood and attach to the left and right side of the hood and to the air handler using the provided TEK screws.
26
SECTION 11: INLET HOOD
Step 11.2.7 Attach the lower hood roof with the provided TEK screws along the left and right side.
27
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
Step 11.2.8 Attach the remaining filter rails and the rain gutters to the upper and lower hood sides with the
provided rivets.
Step 11.2.9 Attach filter retaining latches with the provided rivets.
Step 11.2.10 Caulk seam between air handler and inlet hood.
Step 11.2.11 Load filters into the inlet hood, checking to see that each filter is in the proper orientation by ver-
ifying that the arrow on the side of the filter points in the direction of air flow. All of the arrows should be point-
ing towards the air handler when installed in the proper orientation. Once filters are installed, close filter clips
installed previously
28
SECTION 11: INLET HOOD
Step 11.3 Inlet Hoods for Air Handler with Filter Section
Step 11.3.1 Seal around the perimeter of the inlet of the filter section with the provided foam gasket tape.
Step 11.3.2 Attach the left and right side of the inlet hood (flanges facing in) to the top of the inlet hood using
the TEK screws provided.
Step 11.3.3 Attach the inlet hood to the filter section using the nuts/bolts/washers provided. Bolt it to each corner of the filter section. Use the provided TEK screws to attach the inner flanges to the right and left side of the filter section.
Step 11.3.4 Attach the rain gutters to both sides of the inlet hood using the provided rivets.
Step 11.3.5 Caulk seam between filter section and inlet hood.
29
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
SECTION 12: DAMPERS
WARNING
Crush Hazard
Use proper lifting
equipment and
practices.
Failure to follow these instructions can result in death, injury or property damage.
Falling Hazard
Use proper safety
equipment and practices to avoid falling.
Severe Injury Hazard
Use proper lifting
practices and equipment.
Equipment and
accessories are
heavy.
Cut/Pinch Hazard
Wear protective gear
during installation,
operation and
service.
Edges are sharp.
30
SECTION 12: DAMPERS
C
E
C
D
A
B
C
C
F
NOTE:1) CONTRACTOR/INSTALLER MUST MAKE
APPROPRIATE ALLOWANCES FOR DUCT
CONNECTIONS.
2) NUMBER OF LOUVERS WILL VARY.
3) MOUNTED DOWNSTREAM OF AIR HANDLER IN
DUCT WORK. DOES NOT MOUNT DIRECTLY TO
AIR HANDLER. FIELD WIRED TO PROVIDED
TERMINALS ON CONTROL PANEL.
AIR FLOW
Model A B C D E F
Weight
lbs (kg)
XT-112
in 18.6 15.6 1.5 16.5 13.5 8.0
25 (11)
cm 47.2 39.6 3.8 41.9 34.2 20.3
XT-115
in 28.0 25.0 1.5 26.1 23.1 8.0
51 (23)
cm 71.1 63.5 3.8 66.2 58.6 20.3
XT-118
in 30.8 27.8 1.5 30.6 27.6 8.0
65 (29)
cm 78.2 70.6 3.8 77.7 70.1 20.3
XT-125
in 34.3 31.3 1.5 34.6 31.6 8.0
83 (38)
cm 87.1 79.5 3.8 87.8 80.2 20.3
XT-130
in 39.8 36.8 1.5 39.8 36.8 8.0
111 (50)
cm 101.0 93.4 3.8 101.0 93.4 20.3
12.1 Discharge Damper
Discharge dampers are shipped loose. Discharge dampers are designed to be mounted downstream of the air handler in ductwork. A qualified contractor/installer must make appropriate allowances for duct connections.
To install the discharge damper on an interior wall, drill holes every 8" (20.5 cm) in the flanges on all four sides of the discharge damper to accommodate lag bolts (provided by others).
Discharge dampers are not recommended to be mounted directly to the air handler.
FIGURE 14: Motorized Discharge Damper (XT-112 - XT-130)
12.2 Inlet Damper
Inlet dampers are factory mounted to the inlet of the air handler (covering the inlet opening). The inlet damper has four outward-turned flanges. Based on air handler style, damper may include upper and lower damper.
31
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
E
A
B
C
E
E
D
E
Model ABCDE
Weight
lbs kg
XT112
(in)
(cm)16(40.6)
35.5
(90.2)
22.8
(57.9)
13.6
(34.5)
2.0
(5.1)
40 18
XT115
(in)
(cm)
23.4
(59.4)
55.7
(141.5)
35.2
(89.4)
25.3
(64.3)
2.0
(5.1)
50 23
XT118
(in)
(cm)
27.8
(70.6)
55.7
(141.5)
35.8
(90.9)
27.8
(70.6)
2.0
(5.1)
84 38
XT125
(in)
(cm)
34.5
(87.6)
77.3
(196.3)
47.7
(121.2)
32.4
(82.3)
2.0
(5.1)
120 54
XT130
(in)
(cm)
37.4
(95.0)
86.8
(220.5)
51.8
(131.6)
37.4
(95.0)
2.0
(5.1)
160 73
SECTION 13: DISCHARGE HEADS AND SPLASH PLATES
WARNING
Crush Hazard
Use proper lifting
equipment and
practices.
Falling Hazard
Use proper safety
equipment and practices to avoid falling.
Failure to follow these instructions can result in death, injury or property damage.
13.1 Three-Way Discharge Head Installation
All discharge heads are shipped assembled. The
discharge head is designed for mounting to the face
of the air handler (covering the discharge opening) or
to an interior wall. All discharge heads must be field
supported (by others). The discharge head has four
outward-turned flanges. If the discharge head is to
be installed to the face of the air handler, install
hardware (provided by others) on all four sides of the
discharge head.
To install the discharge head on an interior wall, drill
holes every 8" (20.5 cm) in the flanges on all four
sides of the discharge heads to accommodate lag
bolts (supplied by others). Sheet metal (supplied by
others) may be required. See Page 32, Figure 15 for
the three-way discharge head available.
Severe Injury Hazard
Use proper lifting
practices and equipment.
Cut/Pinch Hazard
Wear protective gear
during installation,
operation and
service.
Equipment and
accessories are
Edges are sharp.
heavy.
FIGURE 15: Three-Way Discharge Head
32
SECTION 13: DISCHARGE HEADS AND SPLASH P LATES
Model A B C
(min)C(max)
XT-112 (in)
(cm)
25.5
(64.8)
27.6
(70.1)
15.0
(38.1)
20.0
(50.8)
XT-115 (in)
(cm)
37.0
(94.0)
35.1
(89.2)
18.0
(47.5)
27.0
(68.6)
XT-118 (in)
(cm)
39.8
(101.1)
39.6
(100.6)
18.0
(47.5)
27.0
(68.6)
XT-125 (in)
(cm)
43.3
(110.0)
43.6
(110.7)
25.0
(63.5)
38.0
(96.5)
XT-130 (in)
(cm)
48.7
(123.7)
48.7
(123.7)
30.0
(76.2)
45.0
(114.3
)
13.2 Splash Plate Installation
The splash plate is designed to hang directly from a horizontal air handler with a bottom discharge. Before
the splash plate can be installed on the air handler, first drill four holes in the air handler floor. These holes to
be centered over the entire blower discharge opening. These holes should be approximately 5/8" (15.9 mm)
in diameter to accommodate 1/2" hanger rods (supplied by others). These holes should be located as shown
in the diagram on Page 34, Figure 17.
To attach all of the hanger rods to the splash plate, start by threading a flanged nut onto each hanger rod.
Then, slip each hanger rod down through a hole located in each corner of the splash plate. Next, feed a
flanged nut onto the rod below the splash plate See Page 33, Figure 16. The hanger rods should be attached
to the air handler in the same manner as the splash plate, with a flanged nut on both sides of the air handler
floor. Adjusting the nuts will level the splash plate. Torque hardware after leveling.
FIGURE 16: Splash Plate
33
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
A
B
Blower
Discharge
Centerline
Model A B
XT-112
(in)
24.6 22.5
(cm)
62.5 57.1
XT-115
(in)
32.1 34.0
(cm)
81.5 86.4
XT-118
(in)
36.6 36.8
(cm)
93.0 93.4
XT-125
(in)
40.6 40.3
(cm)
103.1 102.3
XT-130
(in)
45.7 45.7
(cm)
116.0 116.0
FIGURE 17: Mounting Hole Locations
34
SECTION 14: DUCT CONSIDERATIONS
Cut/Pinch Hazard
Wear protective gear
during installation,
operation and
service.
Edges are sharp.
Falling Hazard
Use proper safety
equipment and practices to avoid falling.
WARNING
Failure to follow these instructions can result
in death, injury or property damage.
SECTION 14: DUCT CONSIDERATIONS
The air handler has been designed to operate at the
specific air volume and external static pressure that
was ordered (air handlers set-up to accept an
external static pressure (ESP) of 1 in wc (2.5 mbar).
This static pressure is generated by any additional
components that are added to the heater (i.e. inlet
hood, filter section, dampers, ductwork, discharge
heads, etc). Additional static pressure beyond that
ordered will affect the performance of the air handler
and lessen the air volume that can be delivered.
Proper engineering methods need to be employed
when calculating duct and component static pressure
(i.e. 2009 ASHRAE Handbook - Fundamentals,
Chapter 21). Accessory pressure drops are available
on See Page 9, Table 4 and Table 5.
The system ductwork must comply with Sheet Metal
and Air Conditioning Contractors Nationals
Association (SMACNA) or any other recognized
standards.
As a general rule, all discharge ducts should have a
straight run of at least 3 hydraulic duct diameters
after the air handler before adding any fittings,
elbows, restrictions, etc. Return ducts should have
the same straight r
Hydraulic duct diameter for round ducts in inches:
Dh = d
Dh: hydraulic diameter
d: round duct inside diameter
Hydraulic duct diameter for rectangular ducts (in
inches):
Dh = (2*H*W)/(H+W)
un before attaching to the unit.
Dh: hydraulic diameter
H: rectangular duct inside height
W: rectangular duct inside width
The air handler is not designed to support the weight
of ductwork. Ductwork must be constructed in a
fashion that is self-supporting. Ductwork should be
straight, elbows should be minimal and any
transitions should be smooth.
Depending on the options ordered with the air
handler, flanges (either external or internal) may be
provided to facilitate connection of ductwork. In
cases where flanges are not provided, flat surfaces
on the exterior skin of the air handler are pro
facilitate connection of ductwork.
14.1 Inlet Duct Work
Inlet duct work height and width must be no smaller
than the air handler inlet height and width and supply
only fresh air to the air handler.
14.2 Return Duct Work
Return duct work height and width must be no
smaller than the air handler inlet height and width
and supply only fresh air to the air handler.
14.3 Discharge Duct Work
Discharge duct work height and width must be no
smaller than the air handler discharge height and
width.
vided to
35
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
WARNING
Explosion Hazard
Leak test all components of gas piping
before operation.
Gas can leak if piping is not installed
properly.
Do not high pressure test gas piping with air
handler connected.
Failure to follow these instructions can result
in death, injury or property damage.
SECTION 15: GAS PIPING
15.1 Gas Manifolds
All gas piping to the air handler must comply with:
United States: Refer to NFPA 54/ANSI Z223.1 - latest
revision, National Fuel Gas Code.
Canada: Refer to CSA B149.1 - latest revision,
Natural Gas and Propane Installation Code.
The air handlers are available with three gas manifold
options.
• American National Standards Institute (ANSI)
compliant manifold: (
XT-112.
See Page 37, Figure 19
See Page 37, Figure 18
for XT-115 - XT-
130.
•Factory Mutual (FM)-compliant manifold:
(
See Page 37, Figure 18
Figure 20
for XT-115 - XT-130.
• XL compliant manifold: (
for XT-112.
See Page 38, Figure 21
for XT-112.
See Page 38,
See Page 37, Figure 18
for XT-115 -
XT-130.
15.2 Gas Piping and Pressures
The air handler is equipped with a gas manifold
suitable for connection to supply pressure of up to:
•14 in wc maximum (34.9 mbar) (Model XT-112)
•5 p.s.i. maximum (XT-115 - XT-130 with FM or XL
compliant manifold).
When gas supply exceeds the above-listed maximum
gas pressures, an additional high pressure gas
36
for
regulator will be required to assure that the correct
gas pressure is supplied to the regulator. Pressure
should be measured between the high pressure gas
regulator and safety shut off valve. Minimum gas
pressure as indicated on data plate must be
measured with the burner operating in high fire.
Table 7: Gas Manifold Size
Model
Gas NPT
Connection
XT-112 XT-115 XT-118 XT-125 XT-130
¾" 1" 1¼" 1½" 2"
15.3 Gas Manifold Venting
Vent valves fitted on XL compliant manifolds must be
piped to the atmosphere outside the structure and in
accordance with applicable codes. This is the
responsibility of the installer.
15.3.1 Main Gas Regulator Venting
The main regulator used on 1¼" and larger manifolds
must be piped to the atmosphere outside the
structu
re. This is the responsibility of the installer.
15.3.2 Vent Line Installation
The following may be used as a guideline for
installation, but all applicable codes and regulations
must be followed.
•Natural gas and LPG are toxic and flammable
substances. They must be released where they
will not cause personal injury or property damage.
The end of the vent line must be located where it
is safe to release gas.
• Pipe the vent line outside the structure.
• Use as short a vertical run of pipe as possible.
• Do not run pipe from a high point to a lower point
to avoid obstacles.
• Use a minimum number of bends.
• Do not downsize the pipe from the origination
point (must be same size or larger).
•Make sure vent line is free from obstructions.
• Do not group lines together into a common
header.
•The outside termination must have a
weatherproof cap or be directed downward for
protection from the elements and must be
screened to prevent the entry of any objects.
FIGURE 18: ANSI/FM/XL-Compliant Manifolds (XT-112)
NOTE: Vent valves must be piped to the atmosphere outside the structure and in accordance with
applicable codes.
Alternate
Inlet
Inlet
By Others
Combination Valve
Manual Gas
High Gas Pressure Regulator (Optional)
Burner
Modulating Valve With Pressure Regulator
Manual Gas Valve (Burner)
Valve (Pilot)
Drip
Leg
Off Valve
Safety Shut Off Valve
Safety Shut
Manual Gas
Valve (Main)
Union
(By Others)
Alternate
Inlet
Inlet
Drip
Leg
By Others
High Gas Pressure Regulator (Optional For ANSI-Compliant Manifolds and supplied for FM and XL-Compliant Manifolds)
Regulator With Dual Safety Shut Off Valve
Manual Gas
Valve (Main)
Union
(By Others)
Manual Gas
Valve (Pilot)
SECTION 15: GAS PIPING
Vent to Atmosphere (FM and XL Manifold)
Modulating Valve
Manual Gas Valve (Burner)
Burner
Combination Valve
FIGURE 19: ANSI-Compliant Manifold (XT-115 - XT-130)
37
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
Alternate
Inlet
Inlet
By Others
Vent to Atmosphere
Vent to Atmosphere
Ps
Manual Gas
Modulating Valve With
Pressure Regulator
High Gas Pressure Regulator (Optional)
Manual Gas Valve (Burner)
Valve (Pilot)
High Gas Pressure Switch
Drip
Leg
Burner
Visual Indicator
Pilot
Regulator
Pilot
Solenoid
Vent to Atmosphere
Manual Gas
Valve (Main)
Union
(By Others)
Safety Shut
Off Valve
Safety Shut
Off Valve
NOTE: Vent valves must be piped to the atmosphere outside the structure and in accordance with
applicable codes.
Alternate
Inlet
Inlet
By Others
Manual Gas
High Gas Pressure Regulator (Optional)
Valve (Pilot)
Drip
Leg
Ps
Modulating Valve With
Pressure Regulator
Manual Gas Valve (Burner)
High Gas Pressure Switch
Burner
LOW GAS
PRESSURE
SWITCH
Low Gas Pressure Switch
Pilot
Regulator
Pilot
Solenoid
Off Valve
With Actuator
Block Valve
With Actuator
Safety Shut
Vent
Valv e
Vent to Atmosphere
Vent to Atmosphere
Vent to Atmosphere
Vent to Atmosphere
Manual Gas
Valve (Main)
Union
(By Others)
NOTE: Vent valves must be piped to the atmosphere outside the structure and in accordance with
applicable codes.
FIGURE 20: FM-Compliant Manifold (XT-115 - XT-130)
FIGURE 21: XL-Compliant Manifold (XT-115 - XT-130)
38
SECTION 15: GAS PIPING
Burner
Modulating Valve
Manual Gas Valve (Burner)
Plugged Taping
To Measure Burner Pressure
Burner
Modulating Valve
Manual Gas Valve (Burner)
Plugged Taping
15.4 Gas Piping
The gas manifold extends through the side of the
control cabinet for models XT-112 - XT-130. The
factory piping terminates with a female pipe
connection in the manual gas valve. The manual
main gas shutoff valve is shipped loose for field
installation. A union must also be installed (supplied
by others) between the supplied manual gas valve
main and the first tee pipe. Be sure that the fuel
supply pipe connected at this point is large enough to
ensure the proper gas flow and line pressure at the
inlet of the air handler. The piping must comply with:
United States: Refer to NFPA 54/ANSI Z223.1 - latest
revision, National Fuel Gas Code.
Canada: Refer to CSA B149.1 - latest revision,
Natural Gas and Propane Installation Code.
Gas supply piping must conform to best building
practices and local codes. During installation of the
gas piping, be sure that no piping restricts
accessibility to the air handler or its removable
access doors.
FIGURE 22: Plug Tapping (XT-112)
FIGURE 23: Plug Tapping (XT-115 - XT-130)
Lockable manual shut-off val
installer in compliance with Occupational Safety and
Health Administration (OSHA) regulations.
15.5 Pressure Test Ports
There are 1/8" (3.2 mm) and 1/4" (6.4 mm) pressure
test ports located on the manifold. The test ports are
available to measure the manifold inlet gas pressure
and the burner gas pressure during burner setup.
15.5.1 Manifold Inlet Gas Pressure
The pressure port for measuring manifold inlet
pressure is located on the inlet side of the first safety
shutoff valve. Refer to the unit rating plate for the
acceptable inlet gas pressure.
15.5.2 Burner Gas Pressure
A pressure tap is used to measure negative airflow at
the burner and to set high fire gas pressure. On air
handlers equipped with a M611 modulating valve, the
pressure tap is located on a tee between the M611
valve and the burner. See Page 39, Figure 22 and
Page 68, Figure 37. On air handlers equipped
the MR212 modulating valve, the pressure tap could
be located on the downstream side of the MR212
valve, on a T-fitting coming off the outlet pressure tap
on the MR212 valve or between the MR212 valve
and the burner. See Page 39, Figure 23 and Page 67,
Figure 35.
ve must be added by the
with
15.6 Line Pressure Test - Leak Testing
The air handler and its individual shut-off valve must
be disconnected from the gas supply piping systems
during any pressure testing of that system at test
pressures in excess of 14 in wc (34.9 mbar). The air
handler must be isolated from the gas supply piping
system by closing its individual manual gas valve that
is located immediately upstream of the safety sh
ut-off
gas valve.
39
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
DANGER
Electrical Shock Hazard
Disconnect electric before service.
More than one disconnect switch may be
required to disconnect electric from
equipment.
Equipment must be properly grounded.
Failure to follow these instructions can result
in death or electrical shock.
SECTION 16: ELECTRICAL
Each air handler is equipped with a wiring diagram
which will vary depending on the type of remote
panel and/or options supplied.
Air handlers can also be supplied as building
management system (BMS)-ready. In this case, a
remote panel is not supplied.
Note: Spark testing or shorting of the control wires
by any means will render the transformers
inoperative.
Each unit is equipped with a fused rotary disconnect.
The rotary disconnects are for copper wire only.
40
SECTION 16: ELECTRICAL
16.1 Disconnect Fuse Sizing
The fuse classification must be determined by the service disconnect rating plate and all applicable codes.
Fuse sizing is determined by the motor size, control current and supply voltage. Fuses that are being
replaced must be replaced with the same type, size and class of fuse that was supplied with the air handler.
For additional information or to confirm original fuse specifications, consult the factory.
Table 8: Minimum and Maximum Fuse Size by Motor Size and Supply Voltage
Electrical Characteristics
Motor Size HP(kW) 208/3/60 230/3/60 460/3/60 575/3/60 230/1/60
2(1.5) 7.3-10.2 6.9-9.6 3.4-4.8 2.6-3.6 13.3-18.6
3(2.2) 10.1-14.2 9.3-13.0 4.6-6.5 3.7-5.2 17.3-24.2
5(3.7) 15.4-21.6 15.1-21.1 7.5-10.6 6.1-8.5 24.3-34.0
7.5(5.6) 23.1-32.4 21.3-29.8 10.6-14.9 8.3-11.6 32.3-45.2
10(7.5) 30.4-42.6 28.1-39.3 14.0-19.7 10.6-14.8 40.3-56.4
15(11.2) 42.4-59.4 39.3-55.0 19.6-27.5 16.8-23.5 20(14.9) 51.4-72.0 49.3-69.0 24.6-34.5 19.8-27.7 25(18.6) 66.4-93.0 61.3-85.8 30.6-42.9 24.5-34.3 30(22.4) 78.4-109.8 73.3-102.6 36.6-51.3 29.6-41.4 40(29.8) - - 47.6-66.7 38.0-52.6 -
50(37.3) - - 59.5-83.3 48.1-66.7 -
16.2 Wiring and Electrical Connections
All electrical wiring and connections, including
electrical grounding, must comply with:
United States: Refer to National Electrical Code
®
,
NFPA 70 - latest revision. Wiring must conform to the
®
most current National Electrical Code
, local
ordinances, and any special diagrams furnished.
Canada: Refer to Canadian Electrical Code, CSA
C22.1 Part 1 - latest revision.
Check rating plate on air handler for supply voltage
and current requirements.
If any of the original control wire supplied with the air
handler must be replaced, replace it with type MTW
105°C, 600 V, 16 gauge wire or equivalent, except for
temperature control wiring, which must be a minimum
of 20 AWG Type Beldon 5401FE CMR 75C shielded
or equivalent.
For all other wires, replace with the equivalent size
and type of wire that was originally provided with the
air handler.
16.3 Remote Panel
The remote panel must be wired as shown on the
electrical schematic. For wire gauge sizes, see Page
41, Table 9. All power supply and motor wiring must
be minimu
m type THWN with a 167° F (75° C)
temperature rise.
16.3.1 Remote Panel Mounting Distance
If the interconnection wiring between the remote
panel and the air handler control enclosure is run in a
single conduit, the wire run can be as long as 100'
(30 m). For longer wire runs, consult the factory. If the
interconnection wiring between the remote panel and
the air handler control enclosure is run in two
conduits (separating the shielded cable and the 120
V power supply for the remote panel), the wire run
can be as long as 200' (60 m). For longer wire runs,
consult the factory. Care should be used to avoid
running the interconnect wiring near large industrial
loads or high voltage wire runs as that may further
limit the length of the interconnect wire run.
Table 9: Control Voltage Wiring For All Control Systems
Volts Wire Gauge Max Wire
120 18 150' (45 m)
120 16 250' (75 m)
120 14 350' (106 m)
NOTE: Wiring for temperatu
re controls must be run in
shielded cable as indicated on the wiring diagram.
16.3.2 Low Voltage Control Wiring
Low voltage (24 V - AC/DC) control wiring in excess
of 100' (30.5 m) in length should be in its own
separate conduit run to prevent interference.
16.4 Motor Current Draw
For specific current requirements, see rating plate
located on the blower motor. Current draw may be
adjusted downward by reducing blower rotations per
minute (RPM) or by increasing external static
pressure.
41
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
16.5 Control Current Draw
The maximum current draw for an air handler’s
controls and accessories is 3A.
16.6 Safety Systems
Safety systems are required for proper performance
of the air handler. The air handler shall not be
permitted to operate with any safety system disabled.
If a fault is found in any of the safety systems, then
the system shall be repaired only by a contractor
qualified in the installation and service of gas fired
heating equipment, using only components that are
sold and supplied by Weather-Rite LLC. Refer to
Page 42, Table 10 for a brief description of each
safety device, its location and its switching voltage.
Table 10: Safety Systems
Safety Controls Location Voltage
Manual Reset High-Temp Limit (All Models) Blower Discharge 120
Pres sure Switches (All Models) Air Handler Control Enclosure 120
Flame Control (XT-115/XT-118/XT-125/XT-130) Air Handler Control Enclosure 120
Flame Control (XT-112) Air Handler Control Enclosure 24
Discharge Temperature Monitor (All Models) Blower Discharge 24
AM Resistor (AM/VAV Style) Air Handler Control Enclosure 24
16.6.1 Manual Reset High Temperature Limit Switch
If for any reason, the temperature of the air at the
discharge of the blower reaches the limit set point of
160° F (71.1° C), the high temperature limit switch will
open the circuit to the burner system and discontinue
all burner functions. Events that could result in
excessive discharge air temperatures include if the
burner modulation amplifier is defective (i.e.
temperature sensor goes open circu
it) or if a surge in
gas pressure reaches the burner. Restarting of the
burner can only be accomplished after the limit has
cooled down and the reset button on the switch has
been depressed. This switch is located on the blower
housing inside the air handler.
16.6.3 Gas Pressure Switches
Gas pressure switches are standard on certain
models (FM compliant gas trains above 2,500 MBH
and XL compliant gas trains) and are also available
as an option on the others.
The function of the gas pressure switches is to
protect against insufficient, lack of gas pressure and
excessive pressure in the system.
On the low gas pressure switch side, this switch
opens its internal switch which shuts the burner down
and prevents its operation due to insufficient gas
pressure.
On the high gas pressure switch side, its internal
16.6.2 Pressure Switches
The low airflow velocity pressure switch monitors the
airflow (differential pressure) across the burner.
When the airflow across the burner reaches the
proper velocity (volume) for combustion, the switch
closes. When the switch closes, it permits the flame
safeguard relay to begin ignition. This switch is
factory set at 0.32 in wc (0.8 mbar). The high velocity
pressure switch will open if the airflow across the
burner reaches its maximum allowable limit. This
switch is factory set at 1.40 in wc (3.5 mbar). The
pressure switch is a safety de
vice, which cannot be
field-adjusted or tampered with.
switch will open, shutting down the burner due to
excessive gas pressure passing through the gas
train.
The settings of the gas pressure switches are field
adj
ustable. The one monitoring the incoming gas
pressure is the low gas pressure switch. The low gas
pressure switch must be set to the minimum required
gas pressure as indicated on the data plate.
The high gas pressure switch must be set to 1 in w.c.
(2.5 mbar) above high fire setting established during
commissioning.
The switch will have to be reset manually, once the
condition has been corrected.
42
SECTION 16: ELECTRICAL
16.6.4 Flame Control
This device will check for both pilot flame and main
flame within the burner. When a flame signal from the
pilot flame is available, it will allow the main gas valve
to open.
All models use a flame rod to detect the flame
(between 6 to 8 Vdc).
If a pilot flame is not present, the electrical signal
cannot be sent and the pilot burner gas valve will
close. The relay is equipped with a 10-second trial for
ignition. If ignition does not occur, the flame
safeguard relay will lockout, it will reset upon power
restoration. (See the Trouble-Shooting Guide - Page
79, Section 23)
FIGURE 24: Interconect Wiring 1
16.6.5 Discharge Temperature Sensor
This device senses the discharge temperature of the
air at the blower. The discharge temperature sensor
reports the discharge temperature to the temperature
control amplifier which modulates the burner to the
temperature set on the remote panel selector. Should
this system fail, the manu
al high temperature limit
switch will turn the burner off. BMS-ready air
handlers do not come equipped with this sensor and
must be field-supplied.
16.6.6 Positive Low Fire Start
This feature forces the burner to start in low fire
rather than high fire during the air handler’s start-up
sequence of operations. The burner maintains its low
fire setting for 10 seconds (as per timer setpoint)
before it begins to modulate.
43
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
FIGURE 25: Interconect Wiring 2
44
SECTION 16: ELECTRICAL
16.7 Interlocks
16.7.1 Carbon Dioxide Interlocks
All air handlers that recirculate air from the heated
space require either a control to limit the temperature
rise in proportion to the amount of outdoor air or the
use of a room carbon dioxide sensor. The carbon
dioxide sensor is field provided and set to maintain a
CO2 concentration below 5,000 ppm.
16.7.2 Carbon Monoxide Interlocks
Carbon Monoxide Detector is a ship loose sensor
that monitors the CO levels in the space. It can either
sound an alarm and/ or force the air handler into
100% outside air if its threshold set point is
exceeded.
16.8 Control Options
16.8.1 Mild Weather Outside Air Stat
This option is designed to turn the burner off when
the incoming outside air is at or above the
temperature setpoint. The blower is allowed to run for
continued ventilation. The mild weather outside air
stat is located in the control enclosure. It has an
adjustable setting between -20° F (-29° C) and
100° F (38° C).
16.8.2 Low Temperature Limit with Override Timer
This option is designed to turn the unit off when air is
discharged below the temperature setpoint for a
period in excess of timer setpoint. The low
temperatu
re limit switch is located in the air handler’s
control enclosure. The low temperature limit switch
has an adjustable setting between -20° F (-29° C)
and 100° F (38° C). The timer by-passes the low
temperature limit switch for the first 5 minutes to allow
the burner to establish a flame when the air handler
is turned on. If the air handler’s discharge
temperature falls to the predetermined low
temperature limit setpoint, after the 5 minute
establishing period, the air handler’s blower will be
turned off. To reset the low temperature limit switch,
set the fan switch to off and then on again. The air
handler will return to the normal sequence of
operations.
16.8.3 MUA / Exhaust Failsafe Interlock
This option incorporates the low temperature limit
with override timer and an exhaust fan airflow switch
monitor. The exhaust fan airflow switch is field
provided and field w
ired as per the option sheet
supplied with the unit. When the air handler is turned
on there is a 5 minute establishing period for the low
temperature limit switch and the exhaust fan
interlock. If the air handler’s discharge temperature
falls to the predetermined low temperature limit
setpoint, after the 5 minute establishing period, the
air handler fan will be turned off. If there is a failure of
the exhaust fan to activate the field supplied airflow
switch, after the 5 minute establishing period, the air
handler fan will be turned off. To reset the
MUA/exhaust failsafe interlock, set the fan switch to
off and then on again. The air handler will return to
the normal sequence of operations.
16.8.4 Motorized Inlet Damper
The motorized inlet damper covers the outside air
inlet of the air handler. When the air handler blower is
turned on, the damper motor is energized and opens
the damper. The damper motor has an auxiliary
switch that prevents the blower from starting until that
damper has opened sufficiently to allo
w the required
air volume to pass through the air handler.
16.8.5 Motorized Discharge Damper
The motorized discharge damper is mounted in the
duct downstream from the discharge opening of the
air handler. When the air handler fan is turned on the
damper motor is energized and opens the damper.
The damper motor has an auxiliary switch that
prevents the blower from starting until that damper
has opened sufficiently to allow the required air
volume to pass through the air handler.
16.8.6 Control Enclosure Heater
The control enclosure heater is an electric heater that
keeps the temperature in the control enclosure within
the range for the control components. This option is
intended for extremely cold climates, but
recommended for installations below 15° F (-9° C).
The air handler controls are rated to perform at
temperatures as low as -30° F (-34° C). In
environments where the air handler may be exposed
to lower temperatures, a control enclosure heater
may be required.
16.8.7 Auxiliary Relay
An auxiliary relay may be added to an air handler for
either an interlock or a customer defined pu
rpose.
Refer to the option sheet supplied with the air handler
to indicate whether the relay is wired for an intended
purpose or left unwired for a future interface. Each
relay will be double pole double throw (DPDT) type.
Maximum switching capacity on the normally open
contact is 8A, and for the booth light relay, 15A.
16.8.8 Smoke Detector
A smoke detector interlock allows for the air handler
to operate (either off or on) based on signal input
from the fire alarm.
45
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
16.8.9 Single Point Connection
When a variable frequency drive or auxiliary motor
starter (both used for controlling an exhaust fan) or
an enclosure heater or ground fault interrupt (GFI)
receptacle are ordered, the installer/service
technician must bring in separate power wires and
fused disconnect (provided by others) to power these
options. The single point connection allows the
installer/service technician to bring only one set of
power wires into the air handler. Additional fusing is
also provided to protect the variable frequency drive,
enclosure heater, and/or GFI.
16.8.10 Service Receptacle Powered by Others (Wired)
This option provides a service receptacle. It includes ground-fault interrupter (GFI) receptacle mounted on the interior or exterior of the control enclosure. Power to the receptacle is supplied by the installer.
16.8
.11 Room Override Stat
For use with Standard Discharge Control remote.
This option provides additional thermostat capability
based on room temperature. The thermostat senses
room temperature, and resets the discharge air to a
higher temperature whenever the temperature falls
below settings indicated on the temperature selection
dial (located on remote panel). Override temperature
can be set 0° F to 40° F above the temperature
selection dial on the remote panel.
46
SECTION 17: SEQUENCE OF O PERATION
DANGER
Electrical Shock Hazard
Disconnect electric before service.
More than one disconnect switch may be
required to disconnect electric from
equipment.
Equipment must be properly grounded.
Failure to follow these instructions can result
in death or electrical shock.
WARNING
Carbon Monoxide Hazard
Do not recirculate air from the heated space
over burner.
Air supply to burner must be from outside.
Failure to follow these instructions can result
in death or injury.
SECTION 17: SEQUENCE OF OPERATION
17.1 Air Handler Configuration
Based on the air handler application, the air handler
may be configured in any of the four styles described
in the upcoming sections. These configurations are
available on all air handlers, except the XT-112 which
is only available in the MUA style. For a comparison
of these configurations, See Page 48, Table 11 and
Page 48, Figure 26.
17.1.1 Make-Up Air (MUA) Style
The MUA style air handler has a constant speed
blower that is designed to deliver a constant volume
of air to the heated space. This style air handler
supplies 100% outside air to the heated space and is
not capable of supplying return air.
17.1.2 Fixed Recirculation (FR) Style
The FR style air handler has a constant speed
blower that is designed to deliver a constant volume
of air to the heated space. In all cases, however, the
air being delivered directly over the burner for
combustion must always be 100% outside air. The air
handler delivers 20% outside air and 80% of return
air. The outside air is heated then mixed with the
return air prior to being deliv
space.
17.1.3 Air Management (AM) Style
The AM style air handler has a constant speed
blower that is designed to deliver a constant volume
of air to the heated space. A building pressure sensor
is used to detect the differential pressure between
the outside and the heated space. The total volume
of air delivered by the air handler may at times
consist of 0% to 80% return air. An automatic control
is provided for the outdoor air and return air dampers.
A null pressure switch is used to sense a positive
space pressure (room or duct). This null pressure
switch is mounted in the control enclosure. More or
less outdoor air is brought into the space to satisfy
the pressure setpoint. Most installations require a
setpoint of 0.02 in wc to 0.03 in wc to achieve
adequate pressure control in the building space. 5/
16" diameter tubing connected to the positive
pressure port of the switch must run to the inside of
the building. 5/16" diameter tubing connected to the
negative pressure port of the switch must run to the
outside of the building.
17.1.4 Variable Air Volume (VAV) Style
The VAV style air handler uses a building pressure
sensor to detect differential pressure between the
outside and the heated space. The air handler will
deliver 100% outside air and will not deliver return air.
The air handler will ensure proper air velocity over
the burner by using a photohelic air sensor to
measure the pressure drop across the burner and by
using a damper to modify the airflow when a
pressure change is required. A second photohelic air
pressure sensor is used to measu
pressure between the outside and the heated space.
Most installations require a setpoint of 0.02 in wc to
0.03 in wc to achieve adequate pressure control in
the building. The second pressure sensor is used to
provide a control signal to the variable frequency
drive that, in turn, controls the blower speed. 5/16"
diameter tubing connected to the positive pressure
port of the pressure sensor must run to the inside of
the building. 5/16" diameter tubing connected to the
negative pressure port of the pressure sensor must
run to the outside of the building.
ered to the heated
re the differential
47
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
Table 11: Configuration Chart
Air Handler
Configuration
Make Up Air (MUA) 100% Outside Air Constant -
Fixed Recirculation (FR)
Air Management (AM)
Var iabl e Ai r Vo lume (VAV) 100% Outside Air
Air Flow Air Volume Control
Non-adjustable ratio of
20% outside air and
80% return air
Adjustable ratio of 20%
outside air and 80%
return air to 100% out-
side air and 0% return
air
Constant -
Constant
Var iab le
50% -
100%
FIGURE 26: Air Handler Styles
MUA - MAKE UP AIR (All Models) FR - FIXED RETURN (All Models)
Building Pressure
Controls Outside/
Return Air Ratio
Building Pressure
Controls Air
Vol ume
Requirement
VAV - VARIABLE AIR VOLUME (All Models)AM - AIR MANAGEMENT (All Models)
Floating Damper Floating Damper
48
SECTION 17: SEQUENCE OF O PERATION
17.2 HVAC Remote Panels and Panel Options
The remote panel should be mounted in the conditioned space in a convenient location for controlling the air
handler. Do not locate a remote panel that contains temperature sensing equipment in an area directly
affected by the air handler or another heat source as it may interfere with the operation of the air handler.
17.2.1 Standard Discharge Control (SDC) Remote
ON/SUMMER Mode:
Only the blower operates continuously to provide
unheated air. The burner remains off regardless of
temperatures on the temperature selection dial and
thermostat.
FAN ON indi cator :
Indicates that the air handler is supplying power to
the blower motor via the M1 motor starter.
BURNER ON indicator:
Indicates that the air handler has supplied power to
open the main gas safety shut off valve.
BURNER LOCKOUT indicator:
The burner control module has experienced a fault
and will need to be reset. The burner control module
must be reset at the air handler. Refer to Page 69,
Section 21 and Page 79, Section 23 to determine the
cause of the fault.
This control is typically used for air handlers
providing space heating. The burner flame
modulates to maintain a constant discharge air
temperature as selected on the temperature
selection dial. While in "auto" mode, a space
temperature thermostat controls the operation of the
air handler to maintain the desired space
temperature.
AUTO/WINTER Mode:
The air handler (blower and burner) cycle on and off
to maintain space temperature as selected on the
room thermostat. When the air handler is operating,
air is being discharged at the setpoint on the
discharge temperature selection dial. The burner
flame modulates to maintain a constant discharge air
temperature as selected on the temperature
selection dial. The discharge air temperature setting
must be higher than the thermostat setting.
ON/WINTER Mode:
The air handler (blower and burner) operate
continuously to provide heated air. When the air
handler is operating, air is being discharged at the
setpoint on the discharge temperature selection dial.
The burner flame modulates to maintain a constant
discharge air temperature as selected on the
temperat
ure selection dial. The unit disregards the
thermostat setpoint while in this mode.
CHECK FILTER indicator:
The airflow in the unit is insufficient to activate the low
pressure switch. This is most commonly caused by
dirty filters, but cou
ld also indicate other obstructions
in the air stream.
17.2.2 Deluxe Temperature Control (DTC) Remote
This control is typically used for providing automatic
day/night space heating. The burner flame
modulates and varies the discharge air temperature
to maintain the space temperature set on the
49
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
Selectrastat dial. The 7-day programmable
touchscreen thermostat provides nighttime setback
for unoccupied space heating.
AUTO/WINTER Mode:
Occupied time: Blower and burner cycle operate
continuously to maintain a constant space
temperature as selected on the Selectrastat dial. The
burner flame fully modulates and varies the
discharge air temperature to maintain the space
temperature.
Unoccupied time: Blower and burner cycle on and off
to maintain space temperature as selected on the
touchscreen thermostat (night setback).
ON/WINTER Mode:
Blower and burner operate continuously to maintain
a constant space temperature as selected on the
Selectrastat dial. The burner flame modulates and
varies the discharge air temperature to maintain the
space temperature.
ON/SUMMER Mode:
Only the blower operates continuously to provide
unheated air. The burner remains off regardless of
temperatures on the temperature selection dial and
thermostat.
FAN ON indicator:
Indicates that the air handler is supplying power to
the blower motor via the M1 motor starter.
BURNER ON indicator:
Indicates that the air handler has supplied power to
open the main gas safety shut off valve.
BURNER LOCKOUT indicator:
The burner control module has experienced a fault
and will need to be reset. The burner control module
must be reset at the air handler. Refer to Page 69,
Section 21 and Page 79, Section 23 to determine the
cause of the fault.
CHECK FILTER indicator:
The airflow in the air handler is insufficient to activate
the low pressure switch. This is most commonly
caused by dirty filters but could also indicate other
obstructions in the air stream.
50
Table 12: Factory Preset Schedule on TH8110 Thermostat
Monday - Friday Saturday - Sunday
Time Temperature Fan Setting Time Temperature Fan Setting
6:00 AM 68° F Fan On 6:00 AM 62° F Fan Auto
Wake
Leave Unused Unused
Return Unused Unused
Sleep
The air handler will run when the thermostat calls for heat. The air handler will run when the thermostat calls for heat.
The air handler will run continuously.
Temperature controlled by Maxitrol stat.
5:00 PM 62° F Fan Auto 5:00 PM 62° F Fan Auto
The air handler will run when the thermostat calls for heat.
SECTION 17: SEQUENCE OF O PERATION
17.2.3 BMS-Ready Control Option
The BMS-ready option provides inputs to receive
control signals from a customer determined control
system. Each BMS input is capable of receiving a
4-20mA or 0 - 10VDC from the control system. On all
air handlers, the burner modulation will be controlled
by the control system. For AM/VAV style air handlers,
the control system can also control the modulating
damper.
On DDC/BMS-ready systems, no temperature control
amplifier is installed. Discharge temperature
monitoring and modulation valve adjustment are
completed by the customer supplied control system.
For optimum efficiency, Weather-Rite LLC suggests
to limit the discharge temperature to 160 °F.
17.3 Basic Air Handler Sequence of Operation
While the control transformer is energized, the
secondary side supplies 115 VAC to the control
circuit. When the fan switch is in the "on" position, the
M1 motor starter is energized and starts the blower
motor. The M1 motor starter auxiliary contact
supplies voltage to the burner switch and "Fan On"
light. When the burner switch is in the "on"/"winter"
position, power is supplied to the flame control
modu
le and the burner control circuit. The burner
control circuit includes the high temperature limit
switch and the low and high airflow pressure
switches. Once the burner control circuit is satisfied,
then the flame control module will execute the burner
ignition sequence. Once the pilot flame is ignited and
sensed by the UV scanner, the flame control module
will open the safety shutoff valve to ignite the main
flame. When the safety shutoff is opened, 115 VAC is
applied to the "Burner On" light and T3 transformer,
the secondary side supplies 24 VAC to the
temperature control amplifier. The temperature
control amplifier controls the modulating valve based
on the discharge temperature monitor (and also the
room temperature monitor, in the case of a DTC
remote panel).
17.3.1 Flame Control
The flame control is a safety device and not
serviceable. See Pages 51 through 53 for detailed
sequence of operation.
17.3.2 Fireye
®
M4RT1 Flame Safeguard
This control is located in the center of the main
control panel. To reset this flame relay, power to it
must be shut off and turned back on.
FIGURE 27: Fireye M4RT1
This is an exposed circuit board one piece control. It
contains a fuse to protect itself from external shorts
or overloads and on its exterior it has five lights which
indicate the operating status of the control.
The functions of the indicator lights, which are
located on the programmer module, are as follows.
They are listed in the order you will find them on the
flame safeguard and is also the order in which they
will occur in the sequence. The indicators are
actually a red colored light emitting diode or LED, this
is how they will be referred to from now on.
1. Operating Control - This indicator is on when
power is present at terminals #1 and #7 of the
flame safeguard.
51
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
2. Air Flow - This indicator comes on at the same
time as the one above. This is because the
actual circuit is not used and is jumped out. It
can be used as a troubleshooting guide, that
power is present to terminals #6 and #8 in the
flame safeguard.
3. PTFI - This acronym stands for Pilot Trial For
Ignition. This indicator is on only during the trial
for ignition period. It indicates that terminal #3
(pilot valve) and terminal #4 (ignition module),
in the flame safeguard, have been turned on.
4. Flame On - This indicator comes on after the
flame safeguard has proven out the flame sig-
nal. It also shows that the main valves have
been activated in the equipment. On the safeguard control, terminal #5 is powered up.
5. Alarm - This indicates that a safety lockout has
occurred, whether by loss of flame signal or
failure to ignite.
17.3.2.1 Fireye
®
M4RT1 Flame Safeguard Opera-
tion (ANSI, FM < 2.5MBH and XL < 1MBH)
The following will describe the internal operation of a
flame safeguard and the external functions that will
take place. We will just trace the electromechanical
steps and not the electronic network.
• All interlocks, control relays and safety limits are
closed. Power is supplied to terminal #7 of the
flame safeguard.
• The Operating Control LED illuminates.
• The electronic network is now powered up which
illuminates the Air Flow LED.
NOTE: The airflow circuit of the safeguard control is
not used and is jumped. This is why the Air Flow LED
illuminates with the Operating Control LED.
• Following a short time delay period (purge cycle)
determined by the jumpers,
and Page 53, Table 13
28
See Page 53, Figure
. The electronic network
closes a contact that powers up terminal #3 and
terminal #4 in the safeguard control.
• Terminal #3 powers up the equipment's pilot gas
solenoid valve which opens allowing gas to flow.
• Terminal #4 powers up the ignition module
creating the spark at the burner.
• This lasts for 10 seconds. This cycle is called trial
for ignition. During this time period, the PTFI LED
is illuminated.
• When the flame sensor detects a pilot flame, the
signal is sent back to the safeguard control. The
electronic network illuminates the FLAME LED.
• It closes a contact, which powers up terminal #5
in the control. This terminal powers up the main
gas valves allowing the main burner to come on.
• At the same time the electronic network opens a
contact which removes power from terminal #4.
This shuts off the power to the ignition module,
which stops the spark at the burner. The
safeguard control at this point monitors the flame.
NOTE: If a pilot flame is not detected during the 10
second trial for ignition, the pilot gas solenoid valve
and the ignition module are turned off. A safety
lockout occurs which shuts down the electronic
network. The only LED that will be illuminated at this
time will be the OPERATING CONTROL. 30 seconds
after the lockout occurs, the alarm circuit is powered
up, illuminating the ALARM LED. Manual reset is
now required. Wait 10 seconds before resetting the
control to allow the lockout switch to cool down.
NOTE: If the flame signal is lost while the burner is
on, the ignition module will be turned back on. A 10second re-light trial for ignition is started. The PTFI
LED will illuminate during this time.If a flame signal is
detected, the main gas valves will turn back on and
the ignition module will turn off. If a flame is not
detected during this re-light trial, the pilot gas
solenoid valve and ignition module will shut off. A
safety lockout occurs which shuts down the
electronic network. The only LED that will be
illuminated at this time will be the OPERATING
CONTROL. Thirty seconds after the alarm lockout
happens the alarm circuit is powered up, illuminating
the ALARM LED. Manual reset is now required. Wait
10 seconds before resetting the control to allow the
lockout switch to cool down.
17.3.2.2 Fireye® M4RT1 Flame Safeguard (FM ≥
2.5MBH and XL ≥ 1MBH)
If the equipment is ordered with a FM compliant
Manifold equal or over 2.5M BTU or XL compliant
equal to or over 1M BTU, certain sequences must be
provided in the flame safeguard control. There is a
specified time for pre-purge, trial for ignition, and non
recycle.
1. Timed pre-purge
This m
ust be a separate purge from the rest of
52
SECTION 17: SEQUENCE OF O PERATION
Jumpers
the system. The trial for ignition must be
delayed by 7 seconds while the blower in the
unit is running. This is to guarantee that there
are no combustible gases or vapors present in
the air stream during burner ignition and light
off.
2. Trial for ignition
The length of time must be fixed at 10 seconds.
This is to prevent the ignition module from con-
tinuing activating the spark electrode if a hazardous malfunction takes place.
3. Non recycle
This feature prevents the flame safeguard control from trying to re-light the burner if it should
fail during the ignition cycle or firing cycle.
Instead it goes directly to a lockout condition
and the flame safeguard will need to be manu-
ally reset.
The M4RT1 has a series of 8 jumpers that are used
to configure the Purge timing, Pilot Trial for Ignition
FIGURE 28: Jumper Locations
(PTFI) timing, and recycle or non-recycle operation.
See Page 53, Figure 28.
Purge Timing
•Jumpers JP1 through JP5 are used to select the
purge timing for the M4RT1. The available purge
timing selections are 5, 7, 30, 60, and 240
seconds and any additive combination of those
times. Selecting two or more purge timing
jumpers will result in a purge time period equal to
the sum of the jumpers selected. Selection of a
purge time is accomplished by cutting or not
installing the associated jumper. The factory set,
default purge time of 5 seconds (JP1 not installed)
is always selected.
See Page 53, Table 13
lists all
available purge times and how to select those by
cutting jumpers JP2 through JP5.
Table 13: Jumper Settings
Purge Time (seconds) JP2 JPS JP4 JP5
5 Installed Installed Installed Installed
12 Cut Installed Installed Installed
35 Installed Cut Installed Installed
42 CutCut Installed Installed
65 Installed Installed Cut Installed
53
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
Pilot Trial for Ignition
•Jumpers JP6 and JP7 are used by the factory
only to select the PTFI for the M4RT1. The factory
set, default PTFI time is 10 seconds (JP6
installed, JP7 not installed). The PTFI time may
only be set by the factory.
Recycle/Non-recycle Operation
•Jumper JP8 is used to select either Recycle or
Non-Recycle operation of the M4RT1. The factory
set, default is Recycle operation (JP8 installed).
To select Non-Recycle operation, cut jumper JP8.
17.3.2.3 Fireye® M4RT1 Flame Safeguard Operation (FM ≥ 2.5MBH and XL ≥ 1MBH)
The following will describe the internal operation of a
flame safeguard control (that has had its jumpers
changed to comply with the agency requirements)
and the external functions that will take place. Refer
to the drawing below to follow the steps. We will just
trace the electromechanical steps and not the
electronic network.
• At the same time that the contact in step b closes,
the electronic network opens a contact, which
powers terminal #4. This shuts off the power to
the ignition module, which stops the spark at the
burner. The safeguard control at this point
monitors the flame.
NOTE: If a pilot flame is not detected during the 10
second trial for ignition, the pilot gas solenoid valve
and the ignition module are turned off. A safety
lockout occurs which shuts down the electronic
network. The only LED that will be illuminated at this
time will be the OPERATING CONTROL. 30 seconds
after the lockout has activated, the alarm circuit is
powered up, illuminating the ALARM LED. Manual
reset is now required. Wait 10 seconds before
resetting the control to allow the lockout switch to
cool down.
• All interlocks, control relays and safety limits are
closed. Power is supplied to terminal #7 of the
flame safeguard.
• The Operating Control LED illuminates.
• The electronic network is now powered up which
illuminates the Air Flow LED.
• Following a time delay period (purge cycle) 7
seconds. The electronic network closes a contact
that powers up terminal #3 and terminal #4 in the
safeguard control.
• Terminal #3 powers up the equipment's pilot gas
solenoid valve which opens allowing gas to flow.
• Terminal #4 powers up the ignition module
creating the spark at the burner.
• This lasts for 10 seconds. This cycle is called trial
for ignition. During this time period, the PTFI LED
is illuminated.
• When the flame sensor detects a pilot flame, the
signal is sent back to the safeguard control. The
electronic network illuminates the FLAME LED.
• It closes an internal contact, which powers up
terminal #5 in the control. This terminal powers up
the main gas
valves allowing the main burner to
come on.
54
SECTION 18: DIRECT FIRED BURNER
WARNING
Failure to follow these instructions can result in death, electric shock, injury or property damage.
Burn Hazard
Allow heater to cool
before service.
Tubing may still be
hot after operation.
Explosion Hazard
Leak test all components of gas piping
before operation.
Gas can leak if piping
is not installed
properly.
Do not high pressure
test gas piping with
equipment connected.
DANGER
Electrical Shock Hazard
Disconnect electric
before service.
More than one
disconnect switch may
be required to
disconnect electric from
heater.
Heater must be
connected to a properly
grounded electrical
source.
Carbon Monoxide Hazard
Heaters installed
unvented must be
interlocked with sufficient
building exhaust.
Heaters must be installed
according to the
installation manual.
SECTION 18: DIRECT FIRED B URNER
®
Manufactured by Midco International
burner combines the two main ingredients needed for proper combustion air (oxygen) and fuel (gas whether
natural or manufactured). In this burner raw gas is delivered to the burner ports at low pressure. The air
passing across the burner is maintained between 2,500 and 3,200 feet per minute. The arrangement and
shape of the air holes in the baffles that surround the burner provide the proper amount of air for proper
combustion for all of the firing rates.
, Inc., the HMA-2A is used for natural gas and propane (LP). The
55
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
WARNING: the ignition system on the air handler generates between 6,000 to 10,000 volts.
ABCDE
in 2.940 0.125 0.125 1.881 0.633
cm 7.468 0.318 0.318 4.778 1.608
FIGURE 29: Midco HMA-2A Burner
18.1 Direct Fired Burner Ignition
The burner that is used in the Weather-Rite LLC unit
is equipped with a pilot assembly. The pilot assembly
consists of a pilot gas tube, spark electrode or rod
and a flame rod with grounding assembly. For proper
ignition the spark rod must be adjusted correctly. A
FIGURE 30: Spark Rod Dimensions
A
B
C
E
high voltage arc is generated between the spark rod
and the pilot gas tube. The gas flowing out the ports
in the pilot gas tube is ignited by this arc. The arc will
be a brilliant electric blue in color. See Page 56,
Figure 29.
D
The gas supplied to the pilot gas tube should be 3 1/
2" wc for natural gas and between 9 to 11" wc for
propane or LP. The difference between the two fuels
is that a restricting orifice is installed in the propane
tube. The pilot flame will be mostly blue in color with
streaks of yellow. The flame size will be roughly 2" in
diameter. The flame must be steady and consistent
in size.
or LP pilot gas tube. The pilot assembly can be used
on propane or LP without an orifice, if this is the case
then the pressure for LP is 2.0"w.c. Ignition will take
place with the introdu
56
ction of gas to the pilot gas
18.2 Direct Fired Burner Flame Proving (Flame Rod)
The flame rod in the burner is constructed of a
material that produces a signal when heated. This
signal is measured as a direct current micro amp.
The path of the signal is from the flame rod to the
burner. From the burner, which is mechanically
grounded to the unit casing, the signal continues to
the grounded side of the flame rectification module in
the flame safeguard control. The signal continues out
of the module to the flame rod where it completes the
loop. The length the flame rod extends into the
burner is determined by, the insulator surrounding
the rod. This insulator must not be exposed more
than 1/8" into the burner and not recessed more than
1/8". At this setting the flame rod will be enveloped by
the pilot or main flame. It will be glowing bright red
along at least 50% of its length. See Page 56, Figure
30.
NOTE: For the flame rod to produce this signal its
position in relation to the grounding rod, pilot and
main flame is critical.
The flame rectification module of the flame safeguard
control converts this signal to a D.C. v
oltage. This
voltage is the value that is used to monitor the pilot
and the main flame of the burner. For the flame
safeguard control to recognize this signal the value of
the voltage must be between 6 to 18 volts D.C. and it
must be steady. This signal is measured at the flame
relay, on the rectification module's test jacks; S1
(colored red) and S2 (colored black). Upon receiving
the correct signal, the flame relay will accept this as
proof that the burner is functioning correctly and will
proceed with its functions.
SECTION 18: DIRECT FIRED B URNER
57
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
Electrical Shock Hazard
Disconnect electric before service.
More than one disconnect switch may be
required to disconnect electric from
equipment.
Equipment must be properly grounded.
Severe Injury Hazard
Do not enter equipment while in operation.
Equipment may start automatically.
Do not operate with door open.
Installation, operation and service must be
done by a trained technician only.
DANGER
Failure to follow these instructions can result in death, electrical shock or injury.
Explosion Hazard
Leak test all components of equipment
gas piping before
operation.
Gas can leak if
piping is not
installed properly.
Do not high pressure
test gas piping with
equipment
connected.
Carbon Monoxide
Hazard
Do not recirculate air
from the heated
space over burner.
Air supply to burner
must be from outside.
Falling Hazard
Use proper safety
equipment and
practices to avoid
falling.
Do not use any part
of equipment as
support.
Burn Hazard
Allow equipment to
cool before service.
Internal components
of equipment may
still be hot after
operation.
WARNING
Failure to follow these instructions can result in death, injury or property damage.
SECTION 19: DIRECT FIRED PROCESS AIR HEATERS
This section applies to direct gas-fired process air
heaters of the recirculating or non-recirculating type.
During the process heating cycle (bake or cure)
excess Carbon Monoxide is produced and all entry
into the controlled space is prohibited. Exhaust
systems must be provided for proper operation and
no entry is allowed into the space during the high
58
temperature or baking cycle. This equipment is to
provide process heating to non-occupied spaces and
may also include operation as a non-recirculating
ventilation air heater. This heater may or may not be
used in a paint booth application.
The intent of this section is to supply the required
information concerning installation and operation of
SECTION 19: DIRECT FIRED PROCESS AIR HEATERS
the process air heater in compliance with:
United States: Refer to NFPA 86 - latest revision,
Ovens and Furnaces /ANSI Z83.25 - latest revision,
Direct Gas-Fired Process Air Heaters.
Canada: Refer to CSA 3.19 - latest revision, Direct
Gas-Fired Process Air Heaters.
19.1 Direct Fired Process Air Heater Models
•100% Outside Air - Ventilating and Bake Cycle
Mode
•100% Outside Air - Ventilating with Reduced
Airflow for Bake Cycle Mode
•100% Outside Air - Ventilating with Recirculation
for Baking Cycle Model (80% Recirculated Air
after the burner and 20% Outside Air)
•100% Outside Air - Ventilating with Recirculation
for Baking Cycle Model (90% Recirculated Air
across the burner and 10% Outside Air)
Other terms may be used to describe the bake cycle
mode such as; Cure or Cure Time Cycle, Dry or
Drying Cycle, and Flash Kick Cycle. Ventilation air
and the term outside air are also used
interchangeably.
All process heaters come equipped with two High
Limit discharge controllers, one for the ventilation
cycle - maximum 160 °F (71 °C) (automatic reset)
and one for the bake cycle mode - maximum 300 °F
(149 °C) (manual reset). The discharge temperature
controller limits the temperature to a maximum
250 °F (121 °C).
4. Instructions must be provided to require periodic inspection and cleaning of the recircula-
tion air duct. The installer must supply this
information.
5. The gas piping installer must locate a manual emergency gas shutoff valve in an appropriate location that allows access to shut off the flow of gas to the Process Heater in case of an emergency.
6. If a post purge (cool-down) cycle is not sup-
plied with the Process Heater, then the installer
must supply a timing circuit that allows 100%
ventilation air of the space to cool the products
down and purge any airborne contaminants.
7. It is also suggested that the following Burn
Hazard Warning be installed at all access
opening(s) to the heated space, served by the
Process Heater that can be used by personnel
to enter the space.
See Page 60, Figure 31.
19.2 Installer's Responsibilities
1. All access opening(s) to the heated space, served by the Process Heater that can be used by personnel to enter the space, must have door interlock switch or switches to shut down the Process Heater if in the bake cycle.
2. On recirculation Process Heaters, the return air
duct from the served space must have filters
installed to prevent particulate matter from
entering the heater. If not supplied by the Process Heater, then the installer must supply
them. These filters must be approved by the
a
uthority having jurisdiction of the installation.
3. The return air duct system must be installed with doors, panels or other means for access to facilitate inspection, maintenance, cleaning and access to fire protection devices.
59
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
WARNING
Burn Hazard
Allow equipment to cool before service.
Internal components of equipment may still
be hot after operation.
Failure to follow these instructions can result
in injury.
FIGURE 31: Burn Hazard
8. The space serviced by the Process Heater,
during the bake cycle mode must have its lighting turned off. If not supplied by the process
heater, then the installer must electrically interlock the facility lights with the bake cycle.
9. Process Heaters in the baking cycle mode
require a minimum of 200 CFM of ventilation
air per 1000 CFH of fuel gas for proper com-
bustion. If the Process Heater does not come
equipped with the features to meet this require-
ment, then the installer must provide the
method to accomplish it.
19.3 Installer's Responsibility for Process Heaters Connected to Paint Booths
1. If the exhaust control system is not supplied by the Process Heater, then the installer must electrically interlock the exhaust system with the heater.
2. If a purge cycle between ventilation cycle mode
and the bake cycle mode is not supplied with
the Process Heater, then the installer must
supply a purge timer that delays the bake cycle
from operating for a minimum of 3 minutes or
at least 4 air changes of the space.
3. The space serviced by the Process Heater,
during the purging cycle and bake cycle mode
must have all spray equipment turned off. If not
supplied by the Process Heater, then the
installer must electrically interlock the spray
equipment with the Process Heater.
NOTE: Process Heaters supplied by Rapid
Engineering LLC are available with the options
required to satisfy this requirement.
A. Reduced Airflow Process Heaters
• Variable Frequency Drive control of the Process
Heater's airflow.
B. 90/10 Recirculation Process Heaters
• The installer must ensure that the Outside Air
Damper, when supplied by Rapid Engineering
LLC, is set to provide proper airflow for
combustion and to make sure the recirculation air
is properly diluted during the bake cycle mode.
This is accomplished by ensuring the bypass
feature of the ventilating air damper is not blocked
by the installation or that the minimum position
control of the ventilating air damper is functioning
properly.
60
SECTION 20: START-UP PROCEDURES
Explosion Hazard
Leak test all components of equipment
gas piping before
operation.
Gas can leak if
piping is not
installed properly.
Do not high pressure
test gas piping with
equipment
connected.
Carbon Monoxide
Hazard
Do not recirculate air
from the heated
space over burner.
Air supply to burner
must be from outside.
Falling Hazard
Use proper safety
equipment and
practices to avoid
falling.
Do not use any part
of equipment as
support.
Burn Hazard
Allow equipment to
cool before service.
Internal components
of equipment may
still be hot after
operation.
WARNING
Failure to follow these instructions can result in death, injury or property damage.
SECTION 20: START-UP P ROCEDURES
DANGER
Electrical Shock Hazard
Disconnect electric before service.
More than one disconnect switch may be
required to disconnect electric from
equipment.
Equipment must be properly grounded.
Failure to follow these instructions can result in death, electrical shock or injury.
Do not enter equipment while in operation.
Equipment may start automatically.
Do not operate with door open.
Installation, operation and service must be
done by a trained technician only.
Severe Injury Hazard
61
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
Correct Alignment
Incorrect Alignment
Installation Code and Annual Inspections:
All installation and service of WEATHER-RITE
™
equipment must be performed by a contractor
qualified in the installation and service of equipment
sold and supplied by Weather-Rite LLC and conform
to all requirements set forth in the WEATHER-RITE
™
manuals and all applicable governmental authorities
pertaining to the installation, service, labeling and
operation of the equipment.
To help facilitate optimum performance and safety,
Weather-Rite LLC recommends that a qualified
contractor conduct, at a minimum, annual
inspections of your WEATHER-RITE
™
equipment
and perform service where necessary, using only
replacement parts sold and supplied by Weather-Rite
LLC.
Check installation site to ensure all codes and
engineering specifications are correct. This section of
the manual is intended to be used as an instructional
guide to the commissioning of the direct fired air
handler. Fill out the start up sheet located at the back
of the manual as each step of the procedure is
performed. This procedure must be completed by the
commissioning contractor and returned to WeatherRite LLC. If the document is not returned, the
manufacturing date will be used as the warranty start
date.
All components have been checked at initial factory
startup. During transit components may have
loosened/shifted, check all wiring before initial
startup.
20.1 Installation of Recirculating Air Handler
Every direct-fired air handler which recirculates room
air (i.e., AM and FR styles) must utilize either a
control system which limits temperature rise in
proportion to the amou
nt of outdoor air, or a room
carbon dioxide sensor, installed per the
manufacturer’s recommendations. The normallyclosed contacts of this sensor must be wired in as
per the CO
concentration of CO
interlock diagram based on air handler
CO
2
interlock diagram, maintaining the room
2
below 5,000 ppm. Select the
2
configuration and model. See Page 43, Figure 24.
With the AM and VAV package, a temperature rise
limiting resistor comes prewired. When the air
handler goes into full recirculation, the resistor is
activated, lowering the maximum temperature rise to
comply with government standards. For the FR
package, the gas valve is preset to the proper
temperature rise. See Page 66, Table 18.
20.2 Mechanical
This piece of equipment requires at least 4 CFM
3
(6.8m
/h) of outside air per 1,000 Btu/h (0.293 kW).
Before installation, check that the local distribution
condition, nature of gas and pressure, and the
current state of adjustment of the equipment are
compatible.
If filters are not installed (via inlet hood or filter
section), an air strainer must be installed on the inlet
of the air handler with openings less than or equal to
5/8" (16 mm) in diameter.
Air inlets must be installed with the lowest edge 19"
(500 mm) above any surface. This applies to roof
curbs, upright stands and suspended air handlers.
20.2.1 Sheave Alignment
Sheaves are factory aligned. On all air handlers,
check sheave alignment as follows.
1. Attach a string to the vertical surface next to
the blower shaft bearing. (See Page 62, Figure
32)
2. Wrap the string around the blower sheave and across both sheave surfaces as shown.
3. Adjust until all four contact points (triangle)
touch the sheave su
rfaces. "IN" or "OUT"
adjustment of the motor sheave and/or motor
adjustment may be required.
4. Pull the string away from the motor sheave and then move it slowly back towards the sheave, making sure the string remains straight while touching all contact points.
5. Remove string before turning air handler on.
FIGURE 32: Sheave Alignment
62
SECTION 20: START-UP P ROCEDURES
Span Length
Deflection 1/64” per inch of span
T
20.2.2 Belt Tension
• Belt tension should be checked with a belt-tension
gauge when one is available. Follow the belt
tension gauge instructions.
• When a tension gauge is not available, measure
the belt span of the belts (
).
33
See Page 63, Figure
• Allow for 1/64" (0.40 cm) of deflection for each
inch of center distance length for the charted
pounds of force. Check
Page 63, Table 14
for
proper deflection force.
• EXAMPLE: A 40" (101.6 cm) shaft center
distance would dictate 40"/64" or 5/8" (1.59
cm) of deflection. With a standard B-belt and
a motor sheave measuring between 5.8"
(14.7 cm) and 8.6" (21.84 cm), the belt will
have proper tension if a 5/8" deflection can be
achieved with a minimum of 6-3/8 lbs. and a
maximum of 8-3/4 lbs. of pressure as
measured with a belt tensioning gauge.
FIGURE 33: Belt Tension
20.3 Electrical
1. Check motor starter for proper overload set-
tings. The overload setting should meet full
load amps (FLA) of motor.
2. Measure the supply voltage with the air handler off and then on. For a system that is powered with three phase power, measure the voltage of each phase.
3. Verify correct blower rotation.
4. While the blower is running and the burner is off, measure the total system current draw with an ammeter. Measure the system current draw again after the burner adjustments are made and with the burner and blower both on.
5. If applicable, compare all variable frequency drive (VFD) programming parameters with specifications provided on electrical drawing.
20.4 Airflow
The air flow switches are factory calibrated safety
devices for burner air flow. If an air flow switch does
not close, the problem may not be the air flow switch.
It could be an indication of an air flow problem
(incorrect blower rotation, duct restrictions, etc.).
20.4.1 Differential Pressure
Table 14: Deflection Force B and BX Belts (in lbs)
Belt
Cross-
Section
B
NOTE: If drive belts squeal during start-up, increase belt tension
to the highest allowed value. Re-check tension during each
inspection. See Page 69, Section 21 for additional information.
20.2.3 Air Temperature Sensing
The sensing probe is factory mounted in the blower
Motor Sheave
Dimension Range
in - cm
3.4-4.2 4 5 1/2 5 3/4 8
4.4-5.6 5 1/8 7 1/8 6 1/2 9 1/8
5.8-8.6 6 3/8 8 3/4 7 3/8 10 1/8
TYPE B
Min. Max. Min. Max.
TYPE B-X
(High HP)
housing (Not included if customer orders BMSready).
In order to verify proper airflow across the burner, the
differential pressure across the profile plate needs to
be measured. Attach a manometer to the pressure
test ports where the pressure switch is attached and
measure the differential pressure with a manometer.
This reading must be 0.9 in wc +/- 0.1 in wc.
(2.24 mbar +/- 0.25 mbar)
To a d j ust the differential pressure that was measured
in the step above, use the adjustable sheave. To
decrease the speed of the blower and the differential
pressure, turn the adjustable half of the sheave
o
utward (decrease diameter). To increase the speed
of the blower and the differential pressure measured
at the burner, rotate the adjustable half of the sheave
inward (increase diameter). Both sides of the sheave
must be turned equal, multiple grooves must be
adjusted equal.
After any adjustment, it is necessary to re-check the
alignment, belt tensions and verify that all sheave set
screws are tightened to the specified torque value
before engaging the blower. See Page 64, Table 15
and Ta b l e 1 6 . Typically, all sheaves have two set
screws to secure the sheave to the motor shaft.
Some sheaves may be press fit onto the motor shaft.
On the two belt sheaves, there are four setscrews
that hold the size adjustment. On the single belt
sheaves, there are two set screw
s to hold the size
63
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
Connect
Test Leads
Here
adjustment.
Table 15: Motor Sheave Drive Torque Specifications
Setscrew Size Allen Wrench
1/4" 1/8" 87 7.3
5/16" 5/32" 120 10.0
3/8" 3/16" 290 24.2
Tor que Settings
•Lbs ft•Lbs
in
Table 16: Motor and Blower Bushing Torque Specifications
Bolt Size (on Bushing)
#10 60 5
1/4" 108 9
5/16" 192 16
3/8" 360 30
1/2" 720 60
Tor que Settings
in
•Lbs ft•Lbs
20.4.2 Burner Pressure
1. A pressure tap is used to measure differential
at the burner and to set high fire gas pressure.
On air handlers equipped with a M611 modu-
lating valve (Model XT-112), the pressure tap is
located on a tee between the M611 valve and
the burner. See Page 39, Figure 22 and Page
68, Figure 37. On air handlers equipped with
the MR212 modulating valve (Models XT-115 -
XT-130), the pressure tap could be located on
the downstream side of the MR212 valve, on a
T-fitting coming off the outlet pressure tap on
the MR212 valve or between the MR212 valve
and the burner. See Page 39, Figure 23 and
Page 67, Figure 35.
2. Measure the burner pressure with the inlet
manual gas valve off.
- Open the manual shut off located between
the modulating valve and the burner.
- Turn the blower on and record the negative
pressure on a u-tube manometer or gas
pressure gauge. This reading is used for high
fire burner pressure adjustment.
3. After taking the burner pressure reading, temporarily leave the manometer attached to the
1/8" tap. It will be used later to check high fire
gas pressure.
20.5 Gas Piping and Initial Pressure Settings
1. Perform a pressure test on all gas supply lines
to the air handler per applicable codes.
Make sure to isolate all gas controls before
pressure testing the system.
2. Verify supply pressure does not exceed maximum rated gas pressure as stated on the rating
plate.
3. Set the supply gas pressure at the step down regulator (normally outside of the enclosure if one is installed) according to the nameplate rating inlet gas pressure specifications.
4. Only after performing steps 1-3 (above), verify pilot pressure.
•Place a u-tube manometer or gas pressure
gauge on the tee at the downstream side of
the pilot pressure regulator.
• Open the main gas valve and close the gas
valve downstream of the MR valve.
•Set the burner switch to "on" and adjust the
pilot pressure regulator to 1.0 in wc for
natural gas or 0.5 in wc for LPG.
• Verify that the burner flame control has a
flame signal of 6-8 Vdc.
Figure 34
.
See Page 64,
FIGURE 34: Fireye Flame Module
64
SECTION 20: START-UP P ROCEDURES
5. Adjust air handler high fire gas pressure.
• Determine the high fire gas pressure by
adding the manifold pressure for maximu m
input (from the rating plate) and the burner
negative pressure (from the measurement
made in the burner pressure section of this
procedure). Record this value for use in
adjustment step.
For example:
Differential pressure= -1.0 in wc
Maximum manifold pressure (from rating plate)= 2.0
in wc
High fire gas pressure= 2.0 + (-1.0) in wc
High fire gas pressure= 1.0 in wc
• Force the burner into high fire. Refer to the
burner mode setting chart
Ta b l e 1 7
, for the specific amplifier and action
on Page 65,
• Set the pressure at the burner side of the
modulating valve to the calculated value
(from the begining of this step), by removing
high fire adjustment cap and rotating the
regulator adjustment screw. A clockwise
rotation increases manifold pressure.
Temperature rise should not exceed
maximum as listed
on Page 66, Table 18
.
For under a million BTU input, the high fire
gas pressure is set by adjusting the
regulator upstream of the M611 valve.
Page 68, Figure 37
.
See
• Reconnect any wires that were used for
adjustment.
6. Adjust recirculating mode or reduced air vol-
ume high fire gas pressure
• This adjustment is required for and only
applies to AM and VAV style units.
• Force the unit into high fire and maximum
recirculation for AM style or minimum air
volume for VAV style. Refer to the burner
mode setting chart
on Page 65, Table 17
for
specific amplifier and action required to
place it into high fire.
• Measure the recirculation temperature rise
and compare it to
Page 66, Table 18
.
• The resistor on the reduced flow switch
(mounted inside the control enclosure) may
need adjustment until recirculation
temperature rise is obtained.
• Return unit to normal operating conditions.
• Reconnect any wires that were removed for
adjustment.
7. M a x i m um discharge temperature is 160° F (71° C) for models approved to Z83.4 and Z83.18 (see ETL Standard). For models approved Z83.25 (see ETL Standard), the maximum discharge temperature is 200° F (93° C).
8. Low fire adjustment
•
NOTE:
High fire gas pressure must be set
BEFORE adjusting low fire. There are three
critical items to consider before adjusting
low fire:
A. Low fire adjustment does not regulate
gas pressure.
B. If the low fire adjustment screw is set to
maximum, high fire regulation problems
will occur.
C. The burner control system must be
forced into low fire per the "Burner Mode
by Amplifier Type" table. See Page 65,
Ta b l e 1 7 .
•Low fire is set at the MR212 valve using the
adjustment screw under the low fire
adjustment cap screw (loosen locking screw
before adjustment),
See Page 67, Figure 35
or on the M611 valve using the brass
adjusting screw on the front side,
68, Figure 36
. The burner must be forced
See Page
into low fire first. Then rotate the adjustment
screw until there is a continuous blue ribbon
across the entire burner. A counter
clockwise rotation increases the flame size.
Low fire temperature rise must not exceed
12° F (7° C). Tighten locking screw when
finished.
• Reconnect any wires that were removed for
adjustment.
9. Once gas pressure and high/low fire adjust-
ments are made, the gas setup is completed.
All taps and instruments must be removed and
all caps and plugs must be replaced.
Table 17: Burner Mode by Amplifier Type
Amplifier Type High Fire Mode Low Fire Mode
Series 14
Series 44
Remove wire from terminal
#4 on the amplifier
Remove wires from termi-
nals #2 and #4 on the
amplifier
Remove wire from terminal #8 on the ampli-
fier
Remove from terminal
#9 on the amplifier
,
65
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
Set BMS to max fire or
SC11 Signal
Conditioner
Series 94
Series MP2
remove input wires from
terminals #6 and #5 and
connect a 9VDC battery to
the signal conditioner
Disconnect selector ribbon
cable from the amplifier.
Set system to maximum
temperature
Remove from terminal
#1 on the
signal conditioner
Remove wire from terminal #2 on the ampli-
fier
Remove wire from ter-
minal #2 on the amplifer
20.6 Safety Shut Off Valve Check
After the initial start up and gas pressure adjustment,
verify gas soundness of each SSOV (Safety Shut Off
Valve). This check must be repeated after the first
100 hours of operation.
20.7 Temperature Control System Calibration
The temperature control system components are
factory calibrated to a base resistance so that
component replacement will not upset the system
calibration. If the temperature control system should
require field calibration, refer to the provided
temperature control amplifier product information
sheet.
Table 18: Maximum Temperature Rise
Model
XT-112 90 50 80 44.5
XT-115 - XT-130 110 61.1 90 50
Natural Gas LPG
°F °C °F °C
66
FIGURE 35: MR 212 Valve
T
N
E
V
R
2A0
4
1
12A06
R
Low Fire Adjustment
(loosen locking screw
before adjustment)
High Fire Adjustment Cap
Modulator
TOP VIEW (cover removed)
NOTE: For high fire adjustment, turn clockwise to
increase manifold pressure; turn counter clockwise to
decrease manifold pressure.
SECTION 20: START-UP P ROCEDURES
SIDE VIEW
Outlet Pressure
Ta p
(Burner Pressure)
Inlet Pressure
Ta p
67
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
Low Fire Adjustment
(under cap)
Gas Inlet
Gas Outlet
NOTE: Modulating only.
IN
PSI
2
OFF
ON
Outlet Pressure
Tap-1/8 NPT
Inlet Pressure
Tap-1/8 NPT
Regulator
Adjustment Below
(High Fire Adjustment Cap)
Gas FlowGas Flow
FIGURE 36: M611 Valve
FIGURE 37: Regulator (XT-112)
68
SECTION 21: MAINTENANCE
SECTION 21: MAINTENANCE
DANGER
Electrical Shock Hazard
Disconnect electric before service.
More than one disconnect switch may be
required to disconnect electric from
equipment.
Equipment must be properly grounded.
Failure to follow these instructions can result in death, injury or property damage.
Do not enter equipment while in operation.
Equipment may start automatically.
Do not operate with door open.
Installation, operation and service must be
done by a trained technician only.
Severe Injury Hazard
WARNING
Explosion Hazard
Leak test all components of
equipment gas piping
before operation.
Gas can leak if piping is not
installed properly.
Falling Hazard
Use proper safety
equipment and practices to
avoid falling.
Do not use any part of
equipment as support.
Allow equipment to cool
before service.
Internal components of
equipment may still be hot
after operation.
Burn Hazard
Do not high pressure test
gas piping with equipment
connected.
Failure to follow these instructions can result in death, injury or property damage.
69
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
Prior to any maintenance or service of the air
handler, shut off, lockout and tagout the electrical
disconnect and gas valve that supplies the unit in
accordance with OSHA regulations and allow ample
time for the air handler to cool. After maintenance is
performed or air handler is serviced, the air handler
shall be re-commissioned to the start-up procedure
as outlined on Page 61, Section 20.
Installation Code and Annual Inspections:
All installation and service of WEATHER-RITE
™
equipment must be performed by a contractor
qualified in the installation and service of equipment
sold and supplied by Weather-Rite LLC and conform
to all requirements set forth in the WEATHER-RITE
manuals and all applicable governmental authorities
pertaining to the installation, service and operation
and labeling of the equipment.
To help facilitate optimum performance and safety,
Weather-Rite LLC recommends that a qualified
contractor conduct, at a minimum, annual
inspections of your WEATHER-RITE
™
equipment
and perform service where necessary, using only
replacement parts sold and supplied by Weather-Rite
LLC.
21.1 General First 8 Hours of Operation Check belts and adjust as required (See Page 63, Section 20.2.2). Though
belts were properly adjusted at the factory, they will stretch after the first few
hours of operation.
First 100 Hours of
Operation
Re-check belt tension and adjust if necessary.
Annual Fall Start-Up Follow entire start-up procedure at this time and check control settings and
operation. See Page 61, Section 20.
™
21.2 Unit Exterior Cabinet Exterior After installation, touch up scratches. Periodic painting should be done there-
after as required. The caulk around weather enclosures and over field joints
should be inspected annually. Re-apply caulk as needed to maintain integrity.
Warning labels and logo labels should be legible and accurate. Please contact Weather-Rite LLC or WEATHER-RITE
™
independent distributor if you
need replacement warning labels or logo labels.
Unit Location Verify that no flammable objects, liquids or vapors are present near the air
handler.
Do not hang anything from or place anything on the air handler.
Keep the area under and around the air handler free of all objects.
See Page 5, Section 3 for Clearances to Combustibles.
21.3 Blower Section Blower Wheel Inspect blower wheel and clean as necessary. A small build up of dust can
cause a significant decrease in blower performance. Check for excessive
vibration, repair as required. Critical labels are located on or near the blower
housing. Contact Weather-Rite LLC or WEATHER-RITE
™
independent dis-
tributor if you need replacement labels.
70
SECTION 21: MAINTENANCE
251 to 500
RPM
501 to 750
RPM
751 to 1000
RPM
812 10 7
16754
Suggested Lubrication Pe riod i n W ee ks
Hours Run
Per Day
Lubrication Schedul e
Use a No.2 Lithium complex base grease or equivalent
Drive Belts and Sheaves Check for belt ride in the groove. In multiple groove drives, belt ride should be
uniform. Check groove wear area for wear. Side wall of groove should be
straight, not dished out. Bottom of groove should show no signs of belt
contact.
Sheave alignment, set screw torque and belt tension should be checked after
8, 24, and 100 hours of initial start-up. Visually inspect belts and sheaves for
excessive wear. If belts have a slick, glazed look, the belts are slipping. Check
drive capacity and belt tension. Never replace only one belt in a used set, as
used belts will elongate. Replace the entire set if replacement is necessary.
See Page 62, Section 20.2.1 and Page 63, Section 20.2.2.
Blower Bearing
Lubrication
Blowers with spider bracket bearings are pre-lubricated and do not require
any re-lubrication during their entire service life. Blowers that u
se pillow block
bearings; should be re-lubricated per the chart below. The recommended
lubricant is Shell Alvania #2 or S3 grease. To re-lubricate the blower pillow
block bearings, be sure that the grease fittings on the bearing housing (or air
handler cabinet wall in the case of extended grease lines) are clean. Apply
the recommended grease to the fitting with a low-pressure grease gun and
add slowly while the shaft is spun by hand. Do not over-grease. Over-greasing
will reduce the service life of the bearings. Consult the blower manufacturer
for grease capacity recommendations as capacities vary by model.
71
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
Table 19: Motor Lubrication Intervals
NOTE: These intervals are based on severe duty. Over
lubricating bearings could result in reduced motor life
.
NEMA Frame Size (Motor HP) Rated at 1800 RPM
Up to 210 incl. (3 - 5 HP) 6,000 hrs
Over 210 to 280 incl. (7.5 - 20 HP) 4,750 hrs
Over 280 to 360 incl. (25 - 30 HP) 3,700 hrs
Motors Inspection:
1. Inspect motor every 3 months or 500 hours of operation, which ever occurs first. Keep the motor clean and vent openings clear.
Lubrication:
1. M o t o r s with grease fittings must be lubricated based on the table below.
2. A high grade ball or roller bearing grease must be used. Recommended
grease for standard service is Polyrex EM (Exxon Mobil). Other compatible greases include; Texaco Polystar, Rykon Premium #2, Pennzoil
Pen 2 Lube and Chevron SRI.
3. Motors without grease fittings are sealed for life and do not require re- lubrication.
Instructions for Lubricating
Before greasing, be sure fittings are clean and free from dirt. Remove grease
relief plug or plate and, using a low-pressure grease gun, pump in the
required grease. Do not over-grease. Overgreasing will reduce the service life
of the motor. Consult the motor manufacturer for grease capacity recommen-
dations as capacities vary by motor. Relubrication intervals are specified in
the table above. After relubricating, allow motor to run for 10 minutes before
replacing relief hardware.
NOTE: In general it is not recommended to mix greases of different brands.
The mixing of different types of thickeners may destroy the composition and
physical properties of the grease. In the event that a different grease is
required by the end user, the following steps can be taken. Using the instruc-
tions for lubrication, open grease outlet and purge the system as much as
possible of the old or unwanted grease. Repeat this same operation after 1
week of service. Consult Weather-Rite LLC or the motor manufacturer for fur-
ther recommendations on grease compatibility.
72
SECTION 21: MAINTENANCE
21.4 Manifold and Controls
Manifold Periodically check gas control assembly and internal and external piping for
leaks. Relief vent lines to outdoors on gas controls should be checked to
ensure against blockage caused by insects or any other substance. Clean as
required.
All gas piping to the air handler must comply with the National Fuel Gas Code
- NFPA54, latest edition and all local codes. Verify gas soundness of each
SSOV (Safety Shut Off Valve). This test must be repeated after the first 100
hours of operation.
See Page 37, Figure 18 through Page 38, Figure 21.
Air Flow Switch An annual check of the tubes attached to the air flow switch should be made
to ensure against blockage caused by insects or any other substance. Clean
as required.
See Page 63, Section 20.4.
Electric Components Check for physical damage on any of the electric components and verify all
electrical connections are secure. Ensure equipment is properly grounded.
Temperature Sensors Calibrate space, outdoor air, and discharge air sensors as required.
See Page 63, Section 20.2.3.
21.5 Burner
An annual inspection of the burner and components must be made to ensure
proper and safe operation. For the most part, the bu
However, if the application is extremely dirty or dusty, it may become neces-
sary to periodically clean the burner. Inspect and clean the burner in accordance with the following recommended procedures:
1. To avoid damaging the valves, disconnect the burner piping from the manifold, at the union, and cover the exposed end of the manifold. See Page 37, Figure 18 through Page 38, Figure 21.
2. Remove the pilot assembly. See Page 43, Section 16.6.4.
3. Remove the ignition cable from the igniter on the side of the burner, and then remove the spark igniter. Clean the igniter contacts with a wire brush. Set the gap to 0.125" (3.17 mm).
4. Inspect each of the stainless steel mixing plates to see that all of the air holes are free of debris. Clean with a wire brush as necessary.
5. The burner orifices may need to be drilled to unplug any closed orifices. Use a pin vise with the appropriate drill to clean debris from the orifices. An electric drill is not suggested because it is easy to snap drill bits off in the orifices.
6. Reinstall the pilot assembly. Reconnect the burner piping to the mani-
fold at the union.
rner is self cleaning.
73
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
21.6 Optional Equipment
Dampers Check linkage when applicable and tighten set screws as required. All moving
parts of dampers should be cleaned and then thoroughly lubricated with a
light molybdenum oil in aerosol can. Dampers furnished with stainless steel
side seals should also have the seals lubricated generously. Dampers should
then be manually operated several times until linkages and blades operate
freely. Reconnect linkages and check dampers for proper operation.
See Page 30, Section 12.
Filters Filters should be checked for dirt restriction on a monthly basis (or as
required). Replace filters with filters of equal specification when they appear
dirty.
NOTE: When using Weather-Rite LLC supplied disposable polyester filters,
they must be inserted with the white media side facing the inlet of filter section. When using Weather-Rite LLC supplied permanent aluminum mesh or
disposable filters, they must be inserted with the arrow on the filter pointing in
the direction of airflow (toward the air handler).
See inlet hood or filter section for filters. See Page 21, Section 10.1
Page 23, Section 11
and See
74
SECTION 22: REPLACEMENT PARTS
WARNING
Severe Injury Hazard
Use proper lifting practices and equipment.
Equipment and accessories are heavy.
Failure to follow these instructions can result
in death, injury or property damage.
Carbon Monoxide Hazard
WARNING
Use only genuine WEATHER-RITE™ replacement parts per this installation, operation and service
manual.
Failure to follow these instructions can result in death, electric shock, injury or property damage.
Explosion Hazard
DANGER
Electrical Shock Hazard
Fire Hazard
SECTION 22: REPLACEMENT PARTS
WARNING
Cut/Pinch Hazard
Wear protective gear during installation,
operation and service.
Edges are sharp.
Failure to follow these instructions can result
in injury.
Replacement parts list is for general direct fired applications and MAY NOT BE APPLICABLE for your
specific unit configuration. Before ordering replacement parts, please contact factory to make sure that the
replacement parts are the direct replacement for your specific unit.
75
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
Table 20: Control Panel Spare Parts
Description Models Part Number
Pressure Switch Low Airflow All models 28892
Pressure Switch High Airflow All models
Maxitrol 1014U (Temp Control Amp) 07432
Maxitrol 1044 (Temp Control Amp) 07431
Mixing Tube All models 07380
Discharge Air Sensor 1014 07337
Discharge Air Sensor 1044 07433
24 V Transformer 40 VA All models 07037
Ignition Transformer All models 18244
Direct-drive mod motor, two position, 35 in-lb All models 01692
Direct-drive mod motor, two position, 35 in-lb XT-125, XT-130 27095
Direct-drive mod motor, floating point, 90 in-lb XT-112,XT-115,XT-125,XT-130 22993
Direct-drive mod motor, 2-10VDC, 180 in-lb XT-112,XT-115,XT-125,XT-130 28430
Ignition Control Module 07617
Flame Rod All models 07590
High Temperature Limit Switch 17071
Igniter All models 07640
Relay 15Amp 07165
Relay 8Amp 28560
Relay Socket 28561
DDC Controller All models 10244
Table 21: Manifold Spare Parts
Model XT-112 XT-115 XT-118 XT-125 XT-130
Manifold size 0.75" 1.0" 1.25" 1.5" 2.0"
Safety shut off valve 36009 36010 36011 36012 36013
Modulating Valve 07440 07485.3 07490.3 07500.3 07505.3
Pilot Regulator 28311 28311 28311 28311 28311
Pilot Solenoid 07522 07522 07522 07522 07522
Manual ball val
Manual ball valve (pilot) 30000 30000 30000 30000 30000
Visual Position Indicator 36001 36001 36001 36001 36001
High pressure switch 08602 08602 08602 08602 08602
Low pressure switch 08604 08604 08604 08604 08604
Vent valve 07225 07225 07225 07225 07225
ve (main) 72108 30002 30003 30004 30005
76
Table 22: Blower Spare Parts
SECTION 22: REPLACEMENT PARTS
Model XT-112
1000-2000 CFM 2000-4000 CFM
Blower 62924 62923 P-000315 P-000316 P-000317 P-000318
Bearing - - P-000627 P-000630 P-000633 P-000636
Shaft - - P-000628 P-000631 P-000634 P-000637
Wheel - - P-000629 P-000632 P-000635 P-000638
XT-115 XT-118 XT-125 XT-130
Table 23: Remote Spare Parts
Description Remote Panel Part Number
Rocker Switch Center Off SDC & DTC 19899
Rocker Switch DPST All 19898
Remote Temperature Selector DTC 07390
Thermostat with Timer DTC 28688
Amber Status Light All 22550
Temperature Selector Basic Remote & SDC 07345
Thermostat SDC 07837
40VA Transformer DTC 07037
Terminal Block All 28057
Table 24: Motor Control Spare Parts
460/3/60
1 1.52 3 57.510152025304050
Overload 28706 28710 28710 28709 28708 28711 28712 28713 28714 28715 28716 28717 28718
Starter 33810 33810 33810 33810 33810 33811 33812 33813 33814 33815 33816 33817 33818
Fuse 25128 25091 25092 25093 25094 25095 25096 25097 25099 25100 25101 25103 25106
Fuse
Block
25130 25130 25130 25130 25130 25130 25130 25130 25131 25131 25131 25132 25132
230/3/60
1 1.5 2 3 5 7.510152025304050
Overload 28709 2878 28708 28711 28712 28713 28714 28716 28717 28718 28719 28720 28720
Starter 33810 33810 33810 33811 33812 33813 33814 33816 33817 33818 33819 33819 33820
Fuse 25093 25114 25094 25115 25096 25116 25099 25101 25103 25106 25108 25109 25117
Fuse
Block
Overload 28705 28706 28710 28710 28708 28707 28711 28712 28713 28714 28714 28716 28717
Starter 33810 33810 33810 33810 33810 33810 33811 33812 33813 33814 33814 33816 33817
Fuse 18605 18609 18614 28610 18594 18598 18599 18607 18608 18622 18616 18619
Fuse
Block
25130 25130 25130 25130 25130 25130 25131 25131 25132 25132 25906 25906 25906
575/3/60
1 1.5 2 3 5 7.510152025304050
18505 18505 18505 18505 18505 18505 18505 18505 18504 18504 18504 22648
77
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
208/3/60
1 1.5 2 3 5 7.510152025304050
Overload 28709 28708 28708 28711 28712 28713 28714 28716 28717 28718 28719 28720 28720
Starter 33810 33810 33810 33811 33812 33813 33814 33816 33817 33818 33819 33819 33820
Fuse 25120 25094 25094 25095 25096 25116 25100 25121 25122 25106 25108 25110 25117
Fuse
Block
Overload 28708 28711 28712 28713 28714 28716 28717
Starter 33810 33811 33811 33812 33814 33815 33816
Fuse 25115 25095 25126 25097 25127 25101 25103
Fuse
Block
Overload 28712 28713 28713 28715 28717 28718 28719
Starter 33812 33813 33813 33815 33817 33818 33819
Fuse 25096 25097 25099 25100 25103 25108 25109
Fuse
Block
25130 25130 25130 25130 25130 25130 25131 25132 25132 25132 25906 25906 25906
230/1/60
11.52357.510
25130 25130 25130 25130 25131 25131 25132
120/1/60
11.52357.510
25130 25130 25131 25131 25132 25906 25906
Table 25: V-Belts Spare Parts
Description Part Number Description Part Number
V-BELT, BX49 02557 V-BELT, BX126 04597
V-BELT, BX51 04448 V-BELT, BX128 04452
V-BELT, BX50 4XT-130 V-BELT, BX154 21290
V-BELT, BX53 42026 V-BELT, BX150 04471
V-BELT, BX89 04836 V-BELT, BX162 04472
V-BELT, BX93 22371 V-BELT, BX52 42036
V-BELT, BX103 22370 V-BELT, BX54 42028
V-BELT, BX100 04465 V-BELT, BX92 12707
V-BELT, 5VX1030 21225 V-BELT, BX96 22372
V-BELT, BX115 P-000377 V-BELT, 5VX1060 05896
V-BELT, BX113 05468 V-BELT, 5VX1250 04522
V-BELT, 5VX1150 21229 V-BELT, BX144 04453
V-BELT, BX120 04469 V-BELT, BX140 30817
V-BELT, 5VX1180 04538 V-BELT, 5VX1600 04518
V-BELT, BX136 04470
V-BELT, 5VX1400 04539
V-BELT, BX133 04400
V-BELT, 5VX1500 04523
V-BELT, BX58 P-000376
V-BELT, BX59 22348
V-BELT, BX61 22350
V-BELT, BX99 22378
V-BELT, BX105 04466
V-BELT, BX112 04467
78
SECTION 23: TROUBLESHOOTING
Falling Hazard
Use proper safety
equipment and
practices to avoid
falling.
Do not use any
part of equipment
as support.
WARNING
Failure to follow these instructions can result in death, injury or property damage.
Burn Hazard
Allow equipment
to cool before
service.
Internal components of
equipment may
still be hot after
operation.
Explosion Hazard
Turn off gas
supply to
equipment before
service.
Fire Hazard
Keep all
flammable
objects, liquids
and vapors the
minimum required
clearances to
combustibles
away from
equipment.
Some objects will
catch fire or
explode when
placed close to
equipment.
Cut/Pinch Hazard
Wear protective
gear during
installation,
operation and
service.
Edges are sharp.
SECTION 23: TROUBLESHOOTING
DANGER
Electrical Shock Hazard
Disconnect electric before service.
More than one disconnect switch may be
required to disconnect electric from
equipment.
Equipment must be properly grounded.
Failure to follow these instructions can result in death, electrical shock or injury.
Do not enter equipment while in operation.
Equipment may start automatically.
Do not operate with door open.
Installation, operation and service must be
done by a trained technician only.
Severe Injury Hazard
79
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
23.1 Initial Checks
When encountering any abnormal operation or fault conditions of the equipment, all troubleshooting should
start with the following initial checks. If a problem is discovered in these initial checks it must be corrected
before moving on in the trouble shooting.
1. Compare voltage and phase of supply power on site with rating plate information.
2. Review wiring between remote panel and control panel. Do the electrical connections match the sup-
plied wiring diagram?
3. Compare gas type and supply pressure on site with rating plate information.
4. Check for proper blower rotation on air handler and any exhaust blowers.
•Blowers powered with a three phase motor can be reversed by swapping any two incoming power
legs. For blowers powered by a single phase motor refer to the motor rating plate for reversing
instructions.
23.2 Motor and Blower PROBLEM POSSIBLE CAUSE SOLUTION
Motor does not operate Main disconnect switch is OFF Turn disconnect to ON
Blown fuse(s) in disconnect Replace fuse(s)
Blown fuse(s)/breaker tripped in control transformer Replace fuse(s)/reset breaker (with
disconnect off)
Fan switch on Check wiring between remote panel
and air handler. Replace switch.
Optional: Damper does not open Check that damper is not obstructed
Check that linkage is tight and
secure
Replace damper actuator
Motor starter (contactor) does not operate. Replace starter
Tripped motor overload. Power out to MUA motor
when motor starter is energized?
Optional: Low limit switch set to high Re-adjust low limit switch setting
Blower does not operate Belts broken or loose? Replace/tighten belts
Loose motor or blower sheaves (pulleys) Reinstall and properly torque set-
Blower bearings, do they turn freely? Replace bearing(s)
Reset
Check for proper FLA setting
Replace overload
If applicable: Tighten screws on
heater packs or overload.
screws
80
23.3 Burner PROBLEM POSSIBLE CAUSE SOLUTION
Flame control
does not try for
ignition
Burner Lockout
No PILOT flame
Pilot flame does
not stay lit
Auxiliary contact not closed. Properly mount contact or replace
Burner/winter switch closed? Replace switch
High temp limit switch tripped? Manually reset or replace
Check blower operation
Low airflow pressure switch contacts not made.
High airflow pressure switch contacts not made.
Optional: Mild weather stat, dial set to low
Optional: High gas pressure switch
Optional: Low gas pressure switch
Flame control defect Replace
Failure to ignite pilot or main flame
Flame control failure
No spark
No gas
Improper pilot gas pressure Adjust pilot gas pressure.
Flame rod does not detect flame, Is there 5VDC
on Flame signal at flame safeguard?
Flame rod dirty Clean flame rod
Reconnect tubes to pressure switch
Clean pressure test tubes
Check filters/duct work for restrictions
Check blower FLA and compare to data plate.
Cabinet pressure too high check system setup
and for restrictions down stream of blower.
Set dial higher
Replace stat
Manual reset
Verify gas pressure
Manual reset
Verify gas pressure
Reset the flame control module at the unit and
proceed to the next step, observing the unit to
indicate at which step lockout condition occurs.
Check wiring from burner control to ignition
transformer.
Check high tension wire to spark plug.
Replace ignition transformer.
Open manual gas shut off valves.
Check wiring from burner control to pilot gas
valve.
Verify inlet gas pressure.
Adjust pilot gas pressure.
Replace pilot gas valve.
Check burner pilot opening for obstruction.
Replace flame rod
Replace flame rod
SECTION 23: TROUBLESHOOTING
81
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
Burner (continued)
PROBLEM POSSIBLE CAUSE SOLUTION
Manual shut off valve closed Open manual shut off valve
Check wiring from burner control to SSOV
Verify inlet gas pressure
Replace SSOV
Veri fy minimum gas supply pressure as per data
plate is available
Remove obstruction
Clean burner orifices holes
Adjust low fire as per the relevant Maxitrol tempera-
ture control instructions
No main flame
Safety Shut Off Valve not operating. Is there
positive gas pressure downstream of SSOV?
Minimum gas supply pressure
Burner openings obstructed
Improper burner lower fire adjustment on
modulating valve
23.4 Temperature Controls
If temperature control problems occur and are not remidied in the troubleshooting procedure, refer to the
trouble shooting table for the unit specific temperature control amplifier.
For units with the Maxitrol
®
series 14 temperature control amplifier, refer to the Field Service Check List for
Series A1014 Amplifiers. Series 14 Amplifiers are supplied on units equipped with Basic and SDC style
remote panels.
For units with the Maxitrol
®
series 44 temperature control amplifier, refer to the Field Service Check List for
Series A 1044 Amplifiers. Series 44 Amplifiers are supplied on units equipped with DTC remote panels.
If problems persist after performing the troubleshooting procedure and the temperature control amplifier
troubleshooting procedure contract the factory.
82
23.5 A1014 Amplifier - Field Checklist
SYMPTOM POSSIBLE CAUSE
A. No Gas Flow 1. Modulating valve improperly installed.
B. Continuous Low Fire (electronics problem). 2. Short circuit or no voltage to the ampli er.
3. Open circuit in TD114. Remote Temperature Selector circuit or wiring.
4. Short circuit in TS114, Discharge Air Sensor circuit or wiring.
5. Faulty ampli er.
C. Continuous Low Fire (electronics ok) 6. Short circuit or open circuit in Modulator Coil.
7. Plunger missing, jammed or improperly installed.
D. Incorrect Minimum Fire Erratic or Pulsating Flame. 8. Incorrect by-pass metering valve adjustment.
9. Excessive negative burner pressure.
E. Continuous High Fire (electronics problem). 10. Short circuit in TD114 Remote Temperature Selector circuit or wiring.
11. Open circuit in TS114/TS10765. Discharge or Inlet Air Sensor Circuit or wirin
12. Jumper not connected across ampli er terminals 2 and 3.
F. Continuous High Fire (electronics ok). 13. Foreign object holding valve open.
14. Plunger jammed.
G. Incorrect Maximum Fire. 15. Inlet pressure too low.
16. Incorrect outlet pressure adjustment of Pressure Regulator.
H. Erratic or Pulsating Flame. 17. Hunting
18. Erratic air patterns or improper TS114 location.
19. Wiring is run next to high voltage switching circuits causing induced voltages
20. Faulty Ampli er or erratic voltage supply.
I. Incorrect Discharge Air Temperature 21. Inlet Air Sensor is used.
22. Incorrect Wiring.
23. System out of calibration.
24. Improper TS114 location.
25. Room Override Thermostat circuit closed.
J. Burned out Transformer. 26. Short circuit in modulator coil.
27. Short circuit between ampli er and modulator valve.
K. Discharge Air Temperature too Low when T115 is Opera-
tive
28. Too low an Override Temperature setting.
29. Burner capacity may be insufficient.
SECTION 23: TROUBLESHOOTING
83
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
FIELD TEST REMEDY
1. Arrow on side of Valve should point in direction of gas ow. 1. Install properly.
2. Check for 24VAC at ampli er terminals 7 & 8.
3. Inspect for loose or broken wires between ampli er terminals 1 & 2, and
TD114 terminals 1 & 2, and TD114 terminals 1 & 3.
4. Connect test resistor as described in Preliminary Circuit Analysis, in Maxitrol product information sheet. Follow procedure outlined.
5. Check items 2, 3, and 4.
2. Prove the power source.
3. Tighten connections or replace wiring.
4. If modulating voltages are obtained, Check TS114 circuit for sho
Replace TS114 if necessary.
5. If items 2, 3, and 4 check out and modulating voltages are still no
obtained, ampli er may be assumed faulty. Replace.
6. Measure resistance across modulator terminals with connecting wires
detached.
7. Inspect. Plunger should be installed per diagrams in Maxitrol information
sheet and operate freely in solenoid sleeve.
6. Replace modulator head if not approximately 45-55 ohms for M6
Valve and 60-80 ohms for MR212 Valve.
7. Clean or replace plunger if necessary. Install per Maxitrol produc
information sheet.
8. See valve adjustments in Section 19.5.
9. Measure manifold pressure as outlined in Section 19.4.
8. Adjust to proper minimum re.
9. If reading is greater than 1.0 in wc negative pressure, check for
clogged lters or other inlet air restrictions. Consult factory for othe
solutions.
10. Inspect for shorts at or between Ampli er terminals 1 & 2 or TD114 terminals 1 & 3.
11. Check TS114/TS10765 for open internal circuit. Connect test resistor as
described in Preliminary Circuit Analysis, in Maxitrol product information sheet.
Follow procedure outlined.
12. Inspect
10. Correct wiring if shorts exist.
11. If modulating voltages are obtained, check TS114/TS10765 for o
circuits. Replace TS114/TS10765.
12. Correct the wiring.
13. Remove button plate and inspect valve and seat.
14. Inspect. Plunger should be smooth, clean, and operate freely in solenoid
sleeve.
13. Clean seat. Clean valve or replace if necessary.
14. Clean, or if necessary, replace plunger.
15. Read pressure at inlet to modulating valve using a manometer with unit
operating at full re. Pressure should be equal to the sum of outlet pressure
setting plus pressure drop of the valve (see Maxitrol capacity chart).
16. Read manifold pressure using manometer and compare with recommendation of equipment manufacturer.
15. Increase inlet pressure if possible.
16. See valve adjustments in Section 19.5.
17. Adjust sensitivity control counter-clockwise.
18. Connect test resistor as described in Preliminary Circuit Analysis, in
Maxitrol product information sheet. Turn TD114 selector dial so heater goes
through its entire modulating range.
19. Temporarily wire each of TD114, TS114, and MR212 externally and observe heater/equipment operation.
20. With test resistor connected (per item #18) and TD114 locally connected
(per item #19), turn TD114 selector dial through entire modulating range. Observe D.C. voltage across modulator terminals.
17. If ame stabilizes, adjust sensitivity control to maintain an even
ame.
18. If the ame is steady throughout the entire modulating range, th
TS114 must be moved.
19. If smooth operation results, isolate effected wiring from source
induced voltage.
20. If erratic or unstable DC voltages are obtained throughout the
modulating range, the ampli er may be assumed faulty. Replace. I
erratic operation is noted only over a small range of 2 or 3 volts, the
age source may contain surges. Consult factory.
21. Inlet Air Sensor changes 1°, for each 3.5°, 5°, or 8° outside temperature
change from 60° (pre-determined - turndown varies with model used).
22. Check wiring diagrams per maxitrol product.*
23. Sensed temperature (thermometer next to TS114) does not correspond to
TD114 setting.
24. Sensed temperature (thermometer next to TS114) does not represent
average discharge air temperature.
25. Remove Override Thermostat lead from terminal 2 of TD114.
*information sheet
21. Sensed temperature will vary from TD114 dial settings. This is
intentional.
22. Correct wiring.
23. See calibration procedure.
24. Move TS114 to location where average representative temperat
can be sensed.
25. TD114 dial setting, then check thermostat setting and/or check
ing for shorts.
26. Measure resistance across modulator terminals with red lead wires
disconnected.
27. Inspect wiring.
26. Replace modulator head if less than 40 ohms.
27. Correct wiring if short is found.
28. Check “Override Temperature Selector” of TD114.
29. Check for high re (Maximum manifold pressure speci ed for heater).
28. Reset to correct temperature.
29. If on high re, control can do no more. Heater unable to furnish
ditional heat to raise temperature.
84
23.6 A44 Amplifier - Field Service Checklist
SYMPTOM POSSIBLE CAUSE
A. No gas ow. 1. Valve improperly installed.
B. Continuous low re (electronics ok). 2. Open circuit in modulator coil.
3. Plunger missing, jammed or improperly installed.
4. Ruptured main or balancing diaphragm.
C. Continuous Low Fire (electronics problem) 5. No voltage to the ampli er.
6. Short in modulator coil circuit.
7. Short in TS144 circuit.
8. Faulty ampli er.
D. Incorrect Low Fire 9. Incorrect by-pass metering valve adjustment.
10. Excessive negative burner pressure.
E. Continuous Minimum Discharge Air Temperature 11. Faulty ampli er.
12. Short in T244 or TS244/TD244 circuit
13. Incorrect space temperature calibration.
F. Incorrect Max. or Min. Discharge Air Temperature. 14. Improper TS144 location.
15. Incorrect discharge air temperature calibrations
G. Continuous High Fire (electronics ok) 16. Foreign material holding valve open.
17. Plunger jammed.
H. Continuous High Fire. (electronics problem) 18. Open circuit in TS144
I. Incorrect High Fire 19. Inlet pressure too low.
20. Incorrect outlet pressure adjustment.
J. Continuous Maximum Discharge Air Temperature 21. Faulty ampli er.
22. Open circuit in T244 to TS244/TD244
23. Incorrect space temperature calibration.
K. Burned out Transformer. No Voltage to Ampli er 24. Short in modulator coil circuit.
L. Incorrect Space Temperature. 25. Incorrect maximum discharge air temperature
setting (A1044).
26. Incorrect minimum discharge air temperature
setting (A1044).
27. Insufficient burner capacity.
28. Incorrect space temperature calibration.
*Control circuits external to the Series 44 can cause burner malfunction. Always check manual valve to be certain gas is on, and check limit contro
for normal operation.
FIELD TEST REMEDY
1. Arrow on side of valve should point in direction of gas ow. 1. Install properly.
2. Remove wires connected to ampli er terminals 6 & 7 and measure resistance. MR212 (60-80 ohms), M611 (45-55 ohms).
3. Inspect - plunger should be installed per Maxitrol product information sheet and operate freely in solenoid sleeve.
4. Disassemble valve for inspection of internal parts.
2. If proper resistance values are not observed, replace modulator head or
repair wiring.
3. Clean or replace plunger if necessary and install per Maxitrol product information sheet.
4. Replace diaphragm if ruptured.
5. Check for 24VAC at ampli er terminals 8 & 9.
6. Measure resistance per item 2.
7. Remove wires connected to ampli er terminals 1, 2, & 3. Measure resistance across wires 1 & 3, then 2 & 3. Meter should read
greater than 2500 ohms.
8. Follow procedures outlined in “PRELIMINARY CIRCUIT ANALYSIS” (Sections I & II) in Maxitrol product information sheet.
5. Provide 24VAC to ampli er. Refer to item 24.
6. If proper resistance values are not observed, replace modulator head or
repair wiring.
7. If readings are incorrect, replace the TS144 or repair wiring.
8. If power source and modulator coil check out (items 5 & 6) but proper mod
lating voltages cannot be obtained, then ampli er may be assumed at fault.
Install replacement ampli er.
9. See Valve Adjustments - Section 19.5.
10. Measure manifold pressure as outlined in Section 19.4.
9. Adjust to proper low re.
10. If greater than 1.0 in wc negative pressure, check equipment for clogged
lters & other inlet air restrictions. For other solutions, consult factory.
11. Follow procedures outlined in “PRELIMINARY CIRCUIT ANALYSIS” (sections I & II), in Maxitrol product information sheet.
12. Remove wires connected to ampli er terminals 4 & 5. Set T244
or TD244 to maximum setting. Measure resistance across wires.
Meter should read 6000 ohms +/- 1000 (T244). If TS244/TD244 are
used, meter should read 4500 ohms +/- 1000 (TS244) and 2100
ohms +/- 150 (TD244).
13. Follow procedures outlined in “PRELIMINARY CIRCUIT ANALYSIS” (Sections IV), in Maxitrol product information sheet.
11. If ampli er is proven at fault, install replacement ampli er.
12. If reading is incorrect, replace the T244, TS244/TD244 or repair wiring.
13. If proper action is obtained, rst check item 12. Recalibrate if necessary
See section 19.7.
14. Compare sensed temperature reading at TS144 with average
discharge air temperature.
15. Follow procedures outlined in “PRELIMINARY CIRCUIT ANALYSIS” (Sections IV), in Maxitrol product information sheet.
14. Move TS144 to location where average temperature can be sensed.
15. If proper temperatures are not observed, refer to temperature calibration
procedures, in Maxitrol product information sheet.
16. Remove button Plate and inspect valve and seat
17. Inspect - plunger should be smooth and clean and operate
freely in solenoid sleeve.
16. Clean, replace valve and/or seat if necessary.
17. Clean, or if necessary, replace plunger.
18. Measure resistance per item 7. 18. If readings are incorrect, replace the TS144 or repair wiring.
19. Read inlet pressure at valve, using a manometer with heater
operating at full re. Pressure should be at least equal to the sum
of: outlet pressure setting and pressure drop of the valve (See Maxitrol Capacity Chart Bulletin) plus 1.0 in wc.
20. Read outlet pressure using manometer and compare with
recommendation of equipment manufacturer.
19. Increase inlet pressure if possible or change to larger valve. Consult facto
about possibility of using special spring to reduce pressure drop on selected
installations.
20. See valve adjustments in section 19.5.
21. Follow procedure outlined in “PRELIMINARY CIRCUIT ANALYSIS” (Sections I & II), in Maxitrol product information sheet.
22. Measure resistance per item 12.
23. Follow procedures outlined in “PRELIMINARY CIRCUIT
ANALYSIS: (Section IV), in Maxitrol product information sheet.
21. If ampli er is proven at fault, install replacement ampli er.
22. If reading is incorrect, replace the T244, TS244/TD244 or repair wiring.
23. If proper action is obtained, rst check item 22. Recalibrate if necessary.
Refer to Temperature Calibration Proceedures in Maxitrol product information
sheet
24. Measure resistance per item 2. 24. If proper resistances are not observed, replace modulator head or repair
wiring.
25. Check to see if heater is delivering air at maximum discharge
air setting.
26. Check to see if heater is delivering air at maximum discharge
air setting.
27. Check to see if heater is operating at high re.
28. Place thermometer next to T244 or TS244. Compare space
temperature reading with T244 or TD244 dial setting.
25. If desired temperature is not reached, increase maximum discharge air
temperature setting.
26. If desired space temperature is not reached, decrease minimum discharg
air temperature setting.
27. If desired space temperature is not reached with heater at high re, it may
be undersized. Consult manufacturer.
28. If temperature reading is incorrect, check items 25, 26, & 27, then recalibr
if necessary.
SECTION 24: WEATHER-RITE™ XT-SERIES START-UP P ROCEDURES
Explosion Hazard
Leak test all components of equipment
gas piping before
operation.
Gas can leak if
piping is not
installed properly.
Do not high pressure
test gas piping with
equipment
connected.
Carbon Monoxide
Hazard
Do not recirculate air
from the heated
space over burner.
Air supply to burner
must be from outside.
Falling Hazard
Use proper safety
equipment and
practices to avoid
falling.
Do not use any part
of equipment as
support.
Burn Hazard
Allow equipment to
cool before service.
Internal components
of equipment may
still be hot after
operation.
WARNING
Failure to follow these instructions can result in death, injury or property damage.
DANGER
Electrical Shock Hazard
Disconnect electric before service.
More than one disconnect switch may be
required to disconnect electric from
equipment.
Equipment must be properly grounded.
Failure to follow these instructions can result
in death or electrical shock.
SECTION 24: WEATHER-RITE
Date of Installation _____________ Model # ____________ Serial # _______________
™
XT-SERIES START-UP PROCEDURES
XT-Series Start Up Form
Installed at:
Name: __________________________________
Address: ________________________________
Phone: __________________________________
Fax: ____________________________________
Notice: Please return a completed copy to Weather-Rite™ LLC. If this document is not returned, the manufacturing date will be used as the warranty
start date.
Service Company
Name: __________________________________
Address: ________________________________
Phone: __________________________________
Fax: ____________________________________
Receiving Inspection
Check installation site to ensure all codes and engineering
specifications are correct. Place a check next to line items
completed or enter data.
1. Inspect air handler and all accessories for possible shipping damage. No Damage___ Damaged ___. (Specify on separate sheet.)
2. Check packing list against items receive d . OK ___ Missing items ____ (Call factory.)
3. Check all nuts, bolts and fasteners to ensure they are tight. OK ____ Loose____ (Specify.)
4. Check sheaves, set screws and bearing collars. Make sure they are tight. OK ____ Loose ____ (Specify.)
5. Compare voltage on unit rating plate to job site voltage. Job Site Voltage ______/____/_____.
6. Compare gas type and supply pressure on unit rating plate to job site gas supply. Job Site Gas Type____ Supply Pressure_______
87
SERIES XT INSTALLATION, OPERATION AND SERVICE MANUAL
7. Check lifting brackets to make sure they are tight and secure before lifting heater. OK __.
8. For FR, AM models: CO2 sensor installed? OK ____
The following procedures reference pages and tables from the
2000-Series Installation, Operation and Service Manual
™
(P/N RP121100NA). Contact the local WEATHER-RITE
independent distributor or Weather-Rite LLC for a manual.
At Start-up:
Verify proper belt tension and sheave alignment per instructions
on Page 62, Section 20.2.1.
OK _____.
Verify proper torque on all sheaves per table on Page 63, Section
20.2.2.
OK _____.
Air Temperature Sensing:
1. The sensing probe is factory mounted in the blower hous-
ing. (Advance to next section.)
Electrical (
Page 40, Section 16)
1. Check all motor starters for proper overload settings. The overload should not exceed Full Load Amps for the motor. ___________ A.
2. What is the supply voltage to the air handler?
Air Hander Off ____ #1____#2 ____ #3 ____
Air Hander On ____ #1____#2 ____ #3 ____
3. Verify correct fan rotation. OK ______.
4. What is total system current draw?
Motor current draw (Burner Off)? _________.
Burner and motor current draw? _________.
5. Compare all variable frequency drive (VFD) programming parameters with specifications provided on electrical drawing. OK _____.
6. For VFD systems, make sure to set programming parameters for proper overload protection.
(See VFD Instruction Manual). OK _____.
7. If more than one exhaust motor is used with one VFD, each motor must have its own overload protection. OK _____.
Differential Pressure: (
Page 39, Section 15.5.1)
1. In order to verify proper airflow across the burner, the dif-
ferential pressure across the profile plate needs to be
measured. Attach a manometer to the pressure test ports
where the pressure switch is attached and measure the
differential pressure with a manometer. This reading must
be 0.9 in wc +-0.1 in wc (2.24 +/- 0.25 mbar)
Record differential box pressure _______ in. wc/mbar
Burner Pressure: (
Page 39, Section 15.5.2)
1. A pressure tap between the Maxitrol modulating valve and
the burner is used to measure negative airflow at the
burner and to set high fire gas pressure. This tap could
also be located on the Maxitrol valve itself, manual shut off
valve or “T” fitting. See unit data plate on control enclosure
door for high fire setting.
2. Record burner pressure with inlet manual gas valve off and blowers on ______________ in wc/mbar
(Page 39, Section 15.4)
1. Perform a pressure test on all gas supply lines to air han-
dler per local codes. OK _____.
2. Verify supply pressure does not exceed maximum rated gas pressure as stated on the rating plate. OK_____.
3. Set the supply gas pressure at the step down regulator
(normally outside of the enclosure if one is installed),
according to the rating plate inlet gas pressure specifications.
Fuel Type: _______ Pressure: ___________.
4. Only after performing steps 1-3, open the main gas valve and close the manual gas valve downstream of the MR valve. Set the burner switch to on. Verify pilot pressure, and flame signal of 5.0 VDC. OK ______.
(To adjust pilot flame, set pilot regulator to 1.0 in wc (2.5 mbar)
natural gas or 0.5 in wc (1.25 mbar) L.P. gauge pressure.
5. Open both manual gas valves at air handler. Force the
burner into high fire. See Page 65, Table 17, “Bu
rner
Mode By Amplifier Type”. Read the gas pressure at the
MR valve and set according to the determined high fire
gas pressure in Table. The small cap screw is for high fire
on MR212 valve only. Take a reading of the temperature
rise. Temperature rise must be in accordance with Page
66, Table 18.
High Fire Discharge Temperature ______°F/°C
_______Manifold Pressure for Maximum Input
(from rating plate)
_______Burner Pressure
_______High Fire Gas Pressure Setting
There are three critical items to consider before adjusting low fire:
A. Low fire adjustment does not regulate gas pressure.
B. If the low fire adjustment screw is set to maximum, high fire
regulation problems will occur.
C. The burner control system must be forced into low fire per
Maxitrol's instruction for the given amplifier/temperature control
system. See Page 65, Table 17, “Burner Mode By Amplifier Type”.
*
6. Low fire is set at the MR212 valve using the adjustment
screw under the large cap screw, or on the M611 valve
using the brass adjusting screw on the side. The burner
must be forced into low fire first. The low fire ribbon across
the burner must be adjusted. OK________.
Once gas pressure and high/low fire adjustments are made,
the gas setup is completed. All taps and instruments must be
removed and all caps and plu gs must be replaced.
Please leave all manuals and
a copy of this sheet with the air handler!
Technician's Name:_________________________
Signature:_________________________________
Date:_____________________________________
Gas Piping and Initial Pressure Setting:
88
SECTION 25: THE WEATHER-RITE™ XT-SERIES WARRANTY
WEATHER-RITE LLC WILL PAY FOR:
Within 24 months from date of purchase by buyer or 27
months from date of shipment by Weather-Rite LLC
(whichever occurs first), replacement parts will be provided
free of charge for any part of the product which fails due to
a manufacturing or material defect.
Weather-Rite LLC will require the part in question to be
returned to the factory. Weather-Rite LLC will, at its sole
discretion, repair or replace after determining the nature of
the defect and disposition of part in question.
WEATHER-RITE
period of 12 months from date of shipment from WeatherRite LLC or the remaining WEATHER-RITE
™
Replacement Parts are warranted for a
™
XT-Series
warranty.
WEATHER-RITE LLC WILL NOT PAY FOR:
Service trips, service calls and labor charges.
Shipment of replacement parts.
Claims where the total price of the goods have not
been paid.
Damage due to:
• Improper installation, operation or maintenance.
• Misuse, abuse, neglect, or modification of the
WEATHER-RITE
• Use of the WEATHER-RITE
™
XT-Series in any way.
™
XT-Series for other
than its intended purpose.
• Incorrect gas or electrical supply, accident, fire,
floods, acts of God, war, terrorism, or other casualty.
• Improper service, use of replacement parts or
accessories not specified by
Weather-Rite LLC.
• Failure to install or maintain the
WEATHER-RITE
™
XT-Series as directed in the
Installation, Operation and Service Manual.
™
• Relocation of the WEATHER-RITE
XT-Series after
initial installation
™
• Use of the WEATHER-RITE
XT-Series in a
corrosive atmosphere containing contaminants.
™
• Use of the WEATHER-RITE
XT-Series in the
vicinity of a combustible or explosive material.
™
• Any defect in the WEATHER-RITE
XT-Series
arising from a drawing, design, or specification
supplied by or on behalf of the consumer.
• Damage incurred during shipment. Claim must be
filed with carrier.
WARRANTY IS VOID IF:
The WEATHER-RITE™ XT-Series is not installed by an
contractor qualified in the installation and service of gas
fired heating equipment.
Yo u cannot prove original purchase date and required
annual maintenance history.
The data plate and/or serial number are removed,
defaced, modified or altered in any way.
The ownership of the WEATHER-RITE
™
XT-Series is
moved or transferred. This warranty is non-transferable.
Weather-Rite LLC is not permitted to inspect the damaged
equipment and/or component parts.
READ YOUR INSTALLATION, OPERATION AND
SERVICE MANUAL.
If you have questions about your equipment, contact your
installing professional. Should you need Replacement
Parts or have additional questions, call or write:
Weather-Rite LLC
110 0 S e ven Mile Road NW
Comstock Park, MI 49321
Telephone: +1.616.338.1401
Fax: +1.616.784.0435
Toll Free: 800.589.3691
www.rapidengineering.com
Weather-Rite LLC's liability, and your exclusive
remedy, under this warranty or any implied warranty
(including the implied warranties of merchantability
and fitness for a particular purpose) is limited to
providing replacement parts during the term of this
warranty. Some jurisdictions do not allow limitations on
how long an implied warranty lasts, so this limitation may
not apply to you. There are no rights, warranties or
conditions, expressed or implied, statutory or otherwise,
other than those contained in this warranty.
Weather-Rite LLC shall in no event be responsible for
incidental or consequential damages or incur liability
for damages in excess of the amount paid by you for
the WEATHER-RITE
™
XT-Series. Some jurisdictions do
not allow the exclusion or limitation of incidental or
consequential damages, so this limitation or exclusion
may not apply to you. This warranty gives you specific
legal rights, and you may also have other rights which vary
from jurisdiction to jurisdiction.
Weather-Rite LLC shall not be responsible for failure to
perform under the terms of this warranty if caused by
circumstances out of its control, including but not limited to
war, fire, flood, strike, government or court orders, acts of
God, terrorism, unavailability of supplies, parts or power.
No person is authorized to assume for Weather-Rite LLC
any other warranty, obligation or liability.
LIMITATIONS ON AUTHORITY OF
REPRESENTATIVES:
No representative of Weather-Rite LLC, other than an
Executive Officer, has authority to change or extend these
provisions. Changes or extensions shall be binding only if
confirmed in writing by Weather-Rite LLC's duly authorized
Executive Officer.
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