Series 14 Installation Instructions

Transcription

1 and field service checklist Series Installation Instructions Table of Contents Page Page Page & 5 Page 6 Page 7 Page System Components Amplifiers (A0 shown) Introduction and Dimensions Specifications Installation of Components Field Service Checklist Preliminary Circuit Analysis Low Fire Start Time Adjustment Sensitivity Adjustment Wiring Diagrams Temperature Calibration Adjustments A0 (all temperature ranges) A0U (replaces A0L, suitable replacement for A0)(all temperature ranges - includes 0 or 0 second low fire start capability) Amplifier-Selectors (with integral temperature dial) (A0U Amplifier / AD0U Amplifier-Selector shown) AD0U (replaces AD0 and AD0L)(all temperature ranges - includes 0 or 0 second low fire start capability) Dual Temperature Amplifier-Selectors: (AD shown) Remote Temperature Selectors: AD (integral dual selector - any comb. of standard ranges avail.) Example - ADBC (0 to 70 F and 60 to 0 F, use w/tsbc Example - ADAD (0 to 0 F and 00 to 50 F, use w/tsad TD (55 to 90 F w/override 0 to 0 over set point) TDA (0 to 0 F) TDA- (0 to 0 F w/ override 0 to 0 F over set point) TDB (0 to 70 F) TDC (60 to 0 F) TDD (00 to 50 F) TDE (00 to 50 F) TDF (0 to 0 F w/override 0 to 0 over set point) TDG (90 to 0 F) TD- (55 to 90 F w/0 to 70 F override) * use w/ts TD- (55 to 90 F w/two outputs) TDG- (90 to 0 F w/two outputs) NOTE: Remote Selector and Discharge Temperature Sensor must have same temperature range to be compatible. Optional: ETD- enclosure, EFP- cover plate only - no enclosure Discharge Air Temperature Sensors: use with TS (55 to 90 F) TSA (0 to 0 F) TSB (0 to 70 F) TSC (60 to 0 F) TSD (00 to 50 F) TSE (00 to 50 F) TSF (0 to 0 F) TSG (90 to 0 F) TSJ (0 to 60 F) To be used w/ AD0-6 TS (dual sensor - any combination of standard ranges available) Example - TSG (55 to 90 F and 90 to 0 F, use w/td & TDG, or TDG [selector w/switch], or ADG) Example - TSAD (0 to 0 F and 00 to 50 F, use w/tda & TDD, or TDAD [selector w/ switch], or ADAD) s: (and sensor) s: MT-9 or -9 (9 length) MT- or - ( length) MT- or - ( length) MT- or - ( length) MT-57 (57 length) M (/ & / pipe size) M5 (/ & / pipe size) M6 (/ & pipe size) MRD (, -/, -/ pipe size) MRE (-/ & pipe size) MRG (-/ & pipe size) MRJ ( flanged) MR-D, E, G, J (used for -speed blower or dual fuel operation) NOTE: M (Modulator) valve requires a pressure regulator for high fire setting. MR (Modulator-Regulator) valve requires no pressure regulator up to 5 psi. OPTIONAL SYSTEM COMPONENTS: Dual Temperature Selector: DOOR HEATERS -TDHD use w/ts (door closed 55 to 90 F/open 90 to 0 F) PAINT SPRAY BOOTHS OR OTHER DUAL APPLICATIONS- TD (dual selector w/switch - any comb. of standard ranges avail.) Example - TDG (55 to 90 F [spray] and 90 to 0 F [dry], use w/tsg Example - TDAD (0 to 0 F and 00 to 50 F, use w/tsad TD X (same as TD, less enclosure) Inlet Air Temperature Sensors: use with TS0765A (: ratio) TS0765B (5: ratio) TS0765C (.5: ratio) Override Stat: (use only with TD, F,-, A-) T5 (0 to 90 F) 00 Maxitrol Company, All Rights Reserved

2 Introduction and Dimensions System Options Selectra SERIES electronic gas flame modulation systems are designed primarily for make-up air heating, as components of direct fired equipment. They may be field installed on existing equipment or specified for new equipment installation. Natural, manufactured, mixed, LP and LP gas air mixture are compatible gases. The systems utilize Modulator or Modulator-Regulator valves. Amplifiers are available with low-fire start, and with integral or remote temperature selection. A discharge air temperature sensor is mounted within a mixing tube housing. Option - a room override thermostat provides space temperature control by raising the discharge air temperature to a pre-selected point - when used in conjunction with the remote temperature selector. Option - an inlet air sensor (and mixing tube) provides inverse change in discharge air for each degree change in inlet air - when installed in a convenient duct location upstream of the burner. Option - a dual temperature selector replaces TD to provide dual control for door heaters, or other applications such as paint spray booths (TD_ or _X, or AD_). A0U, AD0U Mounting Holes 6.00 (5.).00 (50.) (5.9).69 (.9).50 (.).00 (76.) (AD models have integrated temperature dial) TD.5 T Maxitrol Company, All Rights Reserved

3 A0 ETD REF..50 Mounting Hole -Places.6 DECREASE INCREASE SENSITIVITY.5 /6.50 REF. DO NOT.5 TAMPER..0 /6 MIXING TUBES. (7.6) REF. Mounting Hole -Places LENGTH SEE PAGE ) / REF..00 DIA. /6 9 /6 #0-6 X / LG. BINDING HD. SHEET METAL SCREW (-REQ D.) #0- X / LG. BINDING HD. SH METAL SCR (-REQ D.) AD.5.7)..6 (66.5). (7.9) 5.75 (.).0 00 Maxitrol Company, All Rights Reserved

4 Specifications Power Requirements: VAC, 50/60 Hz Class II transformer NOTE: Transformer secondary must not be grounded in any portion of the circuit external to a Maxitrol amplifier. If existing transformer is grounded, a separate isolated transformer must be used. Electrical interference may effect performance and/or damage equipment. Ambient Limits: Operating o to 5 o F / -0 o to 5 o C Non-operating o to 5 o F / -6 o to 5 o C Gases: Suitable for application in natural, manufactured, mixed gases, liquefied petroleum gases and LP Gas Air Mixture piping systems. Vent: M, 5, 6...vertical vent outlet / NPT - A06 installed. MR...two vents located in upper housing, both equipped with vent limiting means Pressure Limits: Maximum Discharge Pressure: (M, 5, 6)... 7 w.c. / 7 mbar Static Pressure Rating: (M, 5, 6) psi / 5 mbar Maximum Operating Inlet Pressure: M, 5, 6... psi / 70 mbar MR psi / 5 mbar Maximum Emergency Exposure*: M, 5, psi / 0 mbar MR....5 psi / 6 mbar * May not function properly at this pressure, but will suffer no internal damage Installation of Components Control wires connected to the Override Stat, Discharge Air Sensor, or Remote Temperature Selector must not be run close to or inside conduit with power or ignition wires. Doing so may cause the unit to function erratically or may destroy the amplifier. If shielded wires are used, shield must be insulated and grounded at the amplifier location only. Wiring Run: If control wiring is inside conduit with line voltage wiring, use shielded cable up to 00 ft. For best results up to 00 ft., run control wiring in separate conduit. For longer runs see Remote Selector below. Amplifier / Amplifier-Selector: contains the wiring terminals and sensitivity adjustment - install in any convenient location that is protected from the weather and contaminated atmosphere. Typical Gas Trains Remote (or Dual) Selector: Install in control cabinet or other chosen location. NOTE: Suffix letters must match, e.g. TSA must be used with TDA. For wiring runs longer than 00 ft. substitute ES6-/ES6- for TD. The ES6s are a -piece version of the TD. ES6- is a temperature setting dial only, ES6- must be mounted at furnace location. Discharge Temperature Sensor / Assembly: sensor housed in mixing tube, install in discharge air stream. Optional: Dual Temperature Selector: see preceding Remote/Dual selector. Room Override Stat: mount in heated area not in direct path of discharge air stream. Inlet Air Sensor: install in convenient location upstream of burner, in intake air duct. Modulator (M) or Modulator-Regulator (MR) : Mount in upright position in horizontal run of pipe, downstream of other controls - a separate gas pressure regulator must be used with any modulator (M) valve. MR : Modulatorregulator valve M : Regulator upstream of modulator valve 00 Maxitrol Company, All Rights Reserved

5 Field Service Checklist SYMPTOm POSSIBLE CAUSE FIELD TEST REMEDY A. No gas flow.. Modulating valve improperly installed (or see Symptom L ).. Arrow on side of should point in direction of gas flow.. Install properly. B. Continuous Low Fire (electronics problem).. Short circuit or no voltage to the amplifier.. Open circuit in TD. Remote Temperature Selector circuit or wiring.. Short circuit in TS, Discharge Air Sensor circuit or wiring. 5. Faulty amplifier.. Check for VAC at amplifier terminals 7 and.. Inspect for loose or broken wires between amplifier terminals and, and TD terminals and, and TD terminals and.. Connect test resistor as described in Preliminary Circuit Analysis. Follow procedure outlined. 5. Check items, and.. Prove the power source.. Tighten connections or replace wiring.. If modulating voltages are obtained, Check TS circuit for shorts. Replace TS if necessary. 5. If items,, and check out and modulating voltages are still not obtained, amplifier may be assumed faulty. Replace. C. Continuous Low Fire (electronics 6. Short circuit or open circuit in Modulator Coil. 7. Plunger missing, jammed or improperly installed. 6. Measure resistance across modulator terminals with connecting wires detached. 7. Inspect. Plunger should be installed per diagrams page and operate freely in solenoid sleeve. 6. Replace modulator head if not approximately 5-55 ohms for M6 and 60-0 ohms for MR. 7. Clean or replace plunger if necessary. Install as per diagrams page. D. Correct Minimum Fire Erratic or Pulsating Flame.. Incorrect by-pass metering valve adjustment. 9. Excessive negative burner pressure.. See valve adjustments on page. 9. Close main gas supply and measure manifold pressure with blower operating. Reading should be less than.5 w.c. negative pressure.. Adjust to proper minimum fire. 9. If reading is greater than.5 negative pressure, check for clogged filters or other inlet air restrictions. Consult factory for other solutions. E. Continuous High Fire (electronics problem). 0. Short circuit in TD Remote Temperature Selector circuit or wiring.. Open circuit in TS/TS0765. Discharge or Inlet Air Sensor Circuit or wiring.. Jumper not connected across amplifier terminals and. (A0 only) 0. Inspect for shorts at or between Amplifier terminals and or TD terminals and.. Check TS/TS0765 for open internal circuit. Connect test resistor as described in Preliminary Circuit Analysis. Follow procedure outlined.. Inspect. 0. Correct wiring if shorts exist.. If modulating voltages are obtained, check TS/TS0765 for open circuits. Replace TS/TS Correct the wiring. F. Continuous High Fire (electronics. Foreign object holding valve open.. Plunger jammed.. Remove bottom plate and inspect valve and seat.. Inspect. Plunger should be smooth, clean, and operate freely in solenoid sleeve.. Clean seat. Clean valve or replace if necessary.. Clean, or if necessary, replace plunger. G. Incorrect Maximum Fire. 5. Inlet pressure too low. 6. Incorrect outlet pressure adjustment of Pressure Regulator. 5. Read pressure at inlet to modulating valve using a manometer with unit operating at full fire. Pressure should be equal to the sum of outlet pressure setting plus pressure drop of he valve (see Maxitrol Capacity Chart). 6. Read manifold pressure using manometer and compare with recommendation of equipment manufacturer. 5. Increase inlet pressure if possible. 6. See valve adjustments on page. H. Erratic or Pulsating Flame. 7. Hunting.. Erratic air patterns or improper TS location. 9. Wiring is run next to high voltage switching circuits causing induced voltages. 0. Faulty Amplifier or erratic voltage supply. 7. Adjust sensitivity control counter-clockwise.. Connect test resistor as described in Preliminary Circuit Analysis. Turn TD selector dial so heater goes through its entire modulating range. 9. Temporarily wire each of TD, TS, and MR externally and observe heater/ equipment operation. 0. With test resistor connected (per Item #) and TD locally connected (per item#9), turn TD selector dial through entire modulating range. Observe D.C. voltage across modulator terminals. 7. If flame stabilizes, adjust sensitivity control to maintain an even flame.. If the flame is steady throughout the entire modulating range, the TS must be moved. 9. If smooth operation results, isolate effected wiring from source of induced voltage. 0. If erratic or unstable D.C. voltages are obtained throughout the modulating range, the amplifier may be assumed faulty. Replace. If erratic operation is noted only over a small range of or volts, the voltage source may contain surges. Consult Maxitrol. I. Incorrect Discharge Air Temperature.. Inlet Air Sensor is used.. Incorrect Wiring.. System out of calibration.. Improper TS location. 5. Room Override Thermostat circuit closed.. Inlet Air Sensor changes 0 for each.5 0, 5 0, or 0 outside temperature change from 60 0 (predetermined turndown varies with model used).. Check wiring diagrams page 7.. Sensed temperature (thermometer next to TS) does not correspond to TD setting.. Sensed temperature (thermometer next to TS) does not represent average discharge air temperature. 5. Remove Override Thermostat lead from terminal of TD.. Sensed temperature will vary from TD dial settings. This is intentional.. Correct wiring.. See calibration procedure.. Move TS to location where average representative temperature can be sensed. 5. TD dial setting, then check thermostat setting and/or check wiring for shorts. J. Burned out Transformer. 6. Short circuit in modulator coil. 7. Short circuit between amplifier and modulator valve. 6. Measure resistance across modulator terminals with red lead wires disconnected. 7. Inspect wiring. 6. Replace modulator head if less than 0 ohms. 7. Correct wiring is short is found. K. Discharge Air Temperature too Low when T5 is operative.. Too low an Override Temperature setting. 9. Burner capacity may be insufficient.. Check Override Temperature Selector of TD. 9. Check for high fire (Maximum manifold pressure specified for heater).. Reset to correct temperature. 9. If on high fire, control can do no more. Heater unable to furnish additional heat to raise temperature. 00 Maxitrol Company, All Rights Reserved 5

6 Preliminary Circuit Analysis For ease in troubleshooting, it is advisable to wire the system as follows (this differs from the normal connection). The Discharge Air Sensor is disconnected and replaced with a 0,000 ohm, / watt test resistor (terminals and ). If inlet air sensor is being used, disconnect and replace with a jumper. On units where the Remote Temperature Selector is located a considerable distance from the heater, it may be advantageous to connect the selector at the heater location. Connect a DC volt meter (capable of reading 0- V DC) on the Modulator or Modulator-Regulator terminals. Set the temperature to the minimum dial setting. The DC voltage should read 0 volts. The DC voltage should gradually increase to at least 0 volts as you slowly rotate the dial to the maximum dial setting. If these voltages are obtained, the valve function can now be checked out. The operation of the valve with regard to voltage is as follows: from 0 volts to approximately 5 volts, the modulating valve should be on bypass flow with the heater operating on low or minimum fire. From approximately 5 volts to 5 volts DC, the valve should be performing its modulating function, and the heater should be firing at a modulated flow rate between low and high fire, depending upon the voltage. Above approximately 5 volts DC, the valve should be delivering full flow to the heater and the unit should be on full fire. If the DC voltage is obtained on the valve terminals, but the heater does not respond as described, the problem can be isolated to the valve itself or to the gas control manifold of the heater (see check list, pages and 5). In the event proper voltages are obtained, and the valve responds correctly to these DC voltages, the problem could well be in the wiring leading to the Discharge Air Sensor or the Discharge Air Sensor itself. This should be also reviewed in the check list. A0U & AD0U Low Fire Start Time Adjustment The low fire start duration can be set to approximately 0, 0 or 0 seconds, and begins timing after the amplifier has been energized. The time is set by placing the jumper over the appropriate jumper block pins. NOTE: When low fire start is desired the jumper must be removed from the J6 jumper block and placed on the J5 jumper block. The M/MR valve remains in the low fire setting position during the low fire start time period. J6 J5 J5 A0U and AD0U model amplifier-selector (cover removed) (AD0U Shown) 0 second low-fire start jumper block 0 Second 0 Second 0 Second Sensitivity adjustment If the proper voltages are not obtained when wired as instructed, the problem can be isolated to the electronics and this may once again be reviewed in the check list. After the troubleshooting test, remove the test resistor and reconnect the Discharge Air Sensor to terminals and. If Remote Temperature Selector has been moved return it to its original position. Sensitivity Adjustment The sensitivity control will allow the user to control the response of the system. Caution should be exercised in the use of this adjustment. Under normal usage the pointer should be located on the mark on the label (A0). A0 model amplifier If hunting is encountered (rapid oscillation), rotating the sensitivity adjustment (R on A0U, AD0U) counter-clockwise will dampen the oscillation - stabilizing the flame. DO NOT adjust unless necessary, because decreasing the sensitivity will increase the temperature DROOP of the system DECREASE SENSITIVITY INCREASE R J6 TIMER 0 SEC 0 SEC J5 0 or 0 second low-fire start jumper block Discharge Air Temp Set DO NOT TAMPER Sensitivity adjustment 00 Maxitrol Company, All Rights Reserved 6

7 Wiring Diagrams A0 model amplifiers AD model amplifiers WITH OPTIONAL ROOM OVERRIDE STAT TS0766 & TD Selector TS& tube t5 override TD Selector TS& tube TRANSFORMER low-fire switch TS & VAC 0va Low fire switch (not supplied by maxitrol) A # # WITH OPTIONAL INLET AIR SENSOR a0 A0U model amplifiers Transformer A0U TS & TD Selector T5 Override TS & TS0766 & TD Selector WITH OPTIONAL ROOM OVERRIDE STAT WITH OPTIONAL INLET AIR SENSOR AD0LU model amplifier-selectors AD0U TS & TS & TS0766 & Transformer WITH OPTIONAL INLET AIR SENSOR 00 Maxitrol Company, All Rights Reserved 7

8 Temperature Calibration NOTE: The components of this system are individually calibrated and are not part of a matched set. It is necessary to place an accurate temperature measuring device as near the Discharge Air Sensor as possible. Set the Remote Temperature Selector at least 0 degrees above outside air temperatures. Adjustments (See bulletin MT05 for additional M/MR valve information) NOTE: Low fire adjustment should be checked whenever the high fire adjustment is changed. MR VALVE High Fire Manifold Adjustments:. Disconnect wires from amplifier terminal # (see page 7). This cause the valve to call for continuous high fire.. Remove seal cap (A), and turn regulator pressure adjusting screw to obtain desired manifold pressure. (Clockwise rotation increases pressure.). Reconnect the wires to amplifier terminal #. NOTE: If low fire bypass is on maximum, the desired high fire outlet pressure may not be achieved. Low Fire or Bypass Adjustments:. Disconnect wire from amplifier terminal #, this causes valve to call for continuous low fire.. Remove cap (B), and loosen lock screw (C). Turn (D) to desired low fire adjustment. (Clockwise rotation reduces minimum flow rate.). Tighten set screw (C), replace cap (B) and reconnect wire to amplifier terminal #. M, 5, 6 VALVE High Fire Manifold Adjustments:. Disconnect wires from amplifier terminal # (see page 7), this causes the valve to call for continuous high fire.. Adjust the pressure regulator to obtain the desired manifold pressure (7 w.c. maximum).. Reconnect the wires to amplifier terminal #. Low Fire or Bypass Adjustments:. Disconnect wire from amplifier terminal #, this causes the valve to call for continuous low fire.. Remove cap (A), and turn adjusting screw (B) to desired low fire adjustment. (Clockwise rotation reduces minimum flow rate.). Replace cap (A), and reconnect wire to amplifier terminal #. modulator B A B D C A Maxitrol Company 555 Telegraph Rd., PO Box 0 Southfield, MI 07-0 SEL_MI_EN_ Maxitrol Company All Rights Reserved