Installation & Service Instructions for Jackson & Church Flexaire Packaged Furnaces SDF-125 thru SDF-400 Gas Firing

Transcription

1 Installation & Service Instructions for Jackson & Church Flexaire Packaged Furnaces SDF-125 thru SDF-400 Gas Firing Important: To protect the unit and avoid damage to the heat exchanger, the blower speed must be set to give not more than an 85 o temperature rise. Use a thermometer to record temperature of return and discharge air and adjust blower motor pulley to provide 85 o temperature difference. Proper operation of the burner depends on draft in firebox of not less than 0.02 inches of water. Important Notice: This equipment is not intended for use in furnishing temporary heat to the structure in which it is installed, prior to the completion and acceptance of such structure and installation by the owner or other person for whom the entire project is being constructed. Therefore, the warranty and warranty service normally issued in respect to this equipment will not apply during periods of temporary heat, nor to any defect in material and workmanship in the equipment becoming apparent after such use and during the warranty period. AESYS Technologies, LLC 693 North Hills Road York, PA Phone: Fax: Website: JC-97-S125/300G r1 02/07

2 NOTE: The following instructions were specifically prepared for use with the floor mounted, up-flow model (FU); but generally apply to all available models, such as Suspended Horizontal (SH), Floor Horizontal (FH), Floor Inverted (FI), and Weather-Proof (WP). LOCATION The unit must be installed on a smooth level floor according to the following clearances from unprotected combustible material; not less than 18 in. at top, sides, and rear; 48 in. at front; 18 in. from flue pipe; when suspended, 18 in. below. Floor beneath up-flow unit may be combustible; floor shall be noncombustible for down-flow or horizontal units. Helpful NBFU Standard include the following: Standards for the Installation of Air Conditioning, Warm Air Heating and Ventilation Systems, Pamphlet No.90. In direct space heating applications, set unit and air nozzles to cover area to be heated. Use type unit that allows return air to be closest to floor of heated space. There should be no obstructions for air returning to the heater return opening. This will result in maximum personal comfort and reduce the possibility of losing heat to unused overhead space. Generally speaking, heaters are most effective when installed in center of the space, with warm air directed at the cold wall. In the case of units used with duct work, the duct should be carefully sized with the allowable external static pressure and CFM listed in the appropriate specification sheet. All heaters should be so located that a short and direct-as-possible flue connection can be made to the induced draft fan outlet. Consideration should also be given to the location of the fuel supply to make the fuel lines as short and direct as possible. When a unit is located in a closed room, provide at least one square inch per 1000 BTU per hour input of free area intake, and a like amount of relief area for ventilation. Intake should be within six inches of floor and relief within six inches of ceiling. Be sure return ductwork is tight so that the fan suction does not reduce ventilation air. All Jackson & Church Flexaire Packaged Furnaces and equipment must be installed in accordance with the standards of the National Board of Fire Underwriters for the class. Local and state authorities having jurisdiction on warm air installations should be consulted before unit installations are made. INSTALLATION The unit should be placed in its pre-selected location on a solid foundation and leveled. Rooftop models should be placed on structural steel or roof-curb in level position. Various sections such as Mixing Box, Filters, Dampers, and Plenums will require attachment using self-drilling screws, bolts, nuts, and hardware provided. Joints must be air tight. Outdoor units are supplied with foam rubber gasketing for each joint, these joints must be water tight. Use a high quality silicon sealer after assembly to assure leak-free performance. The wooden framing and protective paper around the burner and controls should only be removed after the unit is located permanently. Unmounted items are shipped in separate containers and are to be mounted as described herein. If the unit is to use standard air discharge nozzles, they are boxed separately as is the nozzle transition plenum. They should be removed from their packaging and installed on the outlet rings of the transition after it has been secured to the flanged top of the heater. If the unit is intended for duct connection, the discharge nozzles are not provided, and all holes for attachment of ducts must be drilled at the installation site. 1

3 INSTALLATION (cont.) Filter cabinets may be provided if required and must be installed in the return air duct at the installation site. Adhere to all installation clearances. See UNIT DATA PLATE for specific clearance requirements. CONNECTIONS Since the unit is a "Packaged" type of unit, the field connections are few and simple. They are electrical power supply, exhaust stack connection, fuel connection, and controlling thermostat. 1. Electrical Connection - Run proper power line in approved conduit from source of supply to a main disconnect switch located adjacent to the unit. This switch should be so located so that it cannot be tampered with yet should be convenient for authorized personnel to cut off power to the unit for servicing etc. Run line from the disconnect switch to the terminals on the control panel as indicated in the wiring diagram supplied with this manual. Complete wiring of the furnace in accordance with wiring diagram. In all cases, the power leads must be brought to the panel board on the unit and connection made in the panel as per the specific diagram. The other wiring to complete is from the thermostat to the thermostat terminals of the panel board. All wiring, other than that mentioned, such as to the fan limit switch, the blower motor, combustion safety control, is pre-wired at the factory. Where separate accessories such as Mixing Boxes are provided, there are pre-wired harnesses with wires tagged to match terminal numbers in the control panel. All wiring must conform to the National Electrical Code. Local authorities and codes must be consulted where applicable. In all cases consult the instructions packed with the controls, or burner furnished with the furnace. 2. Exhaust Stack Connection - Connect exhaust opening on the induced draft fan to a 12" dia. stack on SDF-125 to 200,14" dia. stack on SDF-225 to 400 of minimum 25 ga. galvanized, extending at least 3 feet above the roof provided with a weather cap. This connection may be made with standard flue pipe sections and must be the same size as shown in the following table. The flue pipe should be run as direct as possible and should contain the minimum number of elbows possible (Maximum - Two 90 o elbows and 30 feet of total run). IN NO INSTANCE SHALL THIS STACK BE CONNECTED TO ANY OTHER STACK COMING FROM ANOTHER HEATING APPLIANCE. Jackson & Church recommends a drip leg in all stacks to prevent condensate from draining into the furnace or induced draft fan. CHECK LOCAL CODES FOR SPECIFIC VENTING REQUIREMENTS. Outdoor models include a Flue Outlet Assembly which requires only simple attachment at the job site. The outlet of the Induced Draft Fan Assembly is 8-1/2" x 12" on SDF-125 to 200 & 9-1/2" x 13-1/2" on SDF-225 to 400. The inducer is typically assembled for vertical-up discharge. If a 45 o up or horizontal discharge is required during installation, proceed as follows: a. Disconnect inducer motor, motor mounting plate, and air switch from housing by removing eight (8) screws. b. Remove fan housing collar and mounting plate by removing eight (B) nuts. c. Turn inducer housing to desired position and re-assemble. d. Attach motor mounting plate to inducer housing so that motor and air safety switch are in the original position. 2

4 CONNECTIONS (continued) Model No Flue Pipe Size Diameter 12" 12" 12" 12" 14" 14" 14" 14" 14" 3. Fuel Connection - All gas pipes must be run directly from the gas meter to the burner. The local gas company should be consulted concerning any local requirement concerning the gas line. The pipe should be sized so that adequate gas pressure is available at the burner manifold. The manual shutoff cock must installed upstream from the regulator, and the pilot tapping must be upstream from this shutoff valve. A drip leg should be installed before manifold controls. All gas piping should be installed in accordance with local codes and American Standard Installation of Gas Piping & Gas Appliances in Buildings, Z21, Controlling Thermostat - Locate and install thermostat by following instructions of the thermostat manufacturer supplied with this manual. Some models use duct-mounted sensors which require field-mounting. PRECAUTIONS BEFORE STARTING UNIT 1. Place main disconnect switch in off position. 2. Check all electrical connections and tighten if required. 3. Oil the motor where oil cups are provided. 4. To prevent excessive wear on blower bearings it is necessary to have the "V" belt adjusted correctly. The proper adjustment is attained when the "V" belt can be depressed an inch, with moderate hand pressure. (Consult Lau Blower sheet in this manual). 5. Check main fans and bearings by rotating fan shaft by hand. Check all bearing, pulley, and main blower/fan set-screws for tightness before starting. 6. Check setting of fan and limit controls as follows (Refer to unit spec sheet & wiring diagram): a. For applicable controls, set limit control at 180 o F. (This refers to the auto reset safety limit.) b. Set fan control at 140 o F. (This is an optional control) c. Set manual reset safety limit at 250 o F. 7. Check all fuses. 8. Reset safety control. 9. Check fuel supply to the unit. 3

5 CHECK, TEST, AND START A. REVIEW BURNER & HEATER MANUALS, INCLUDING WIRING, PIPING, AND ARRANGEMENT DRAWINGS BEFORE ATTEMPTING TO START THIS UNIT. DO NOT START THIS UNIT UNTIL ALL NECESSARY DUCT WORK IS COMPLETED. B. Check fuel line components, motors, fans, belts, controls, electrical terminals, fuses, and electrical/service lines for visible damage and for mechanical tightness. Loosening can occur during shipping, handling, and installation. Tighten and repair as needed. Gas tightness of shut off valves shall be checked annually. C. Use a water tube manometer to check gas pressure at inlet to burner gas trains. Pressures should typically be between 6" w.c. and 14" w.c. Higher pressures require regulators selected for available fuel supply. DO NOT APPLY GAS PRESSURE ABOVE 13 INCH. WATER COLUMN before verifying that proper regulators have been installed. (Refer to unit spec sheet and fuel piping diagram.) D. Check electrical supply to verify proper voltage to unit. Close main disconnect switch. "Jog" motors to determine proper direction of rotation. (Fans must always rotate toward the discharge opening.) "Manual" switch on Fan-Limit Control can be used for this check. E. For initial start-up, close main manual shut-off valve closest to burner. Pilot burner operation will be checked first. Before starting burner, be certain that main blowers are operating and delivering air over the heat exchanger. Open Induced Draft Fan (I.D.) damper to position marked, or approximately 50%. Open pilot manual shut-off valves. Turn on Electrical Power supply - Flame Safeguard Control "POWER" light should be ON. Close operating limit controls and thermostats to start burner ignition sequences. (See Wiring Diagrams for these controls.) Both Forced Draft and Induced Draft fans should start and both Air Proving Switches should close, allowing purge to continue. After pre-purge period (typically 30 or 90 seconds) Flame Safeguard Control will signal "PILOT", Ignition Transformer will energize spark, and Pilot Solenoid Valve will open. If gas lines have been purged, pilot should light and "FLAME" indicator will come 'ON" to indicate that pilot signal has been detected. Pilot flame will be visible through the burner peep-site. If lines have not been purged, this step may require several "Resets" and re-cycles to get gas to the pilot. NOTE: On Two-Stage or Modulated PowerFlame and Eclipse Burners, the air shutter must be in the Low fire position for light-off of main flame. This is especially critical on Eclipse Burners, since the shutter must be totally closed for pilot signal to be detected. When "FLAME" is indicated, open main manual gas valves to allow main burner to fire. The electrical (Safety Shutoff) valves are opened under control of the "Flame Safeguard" when pilot flame has been "proved". With low fire main flame on, energize modulation signal to allow burner to modulate up and down through the full range of capacities. 4

6 CHECK, TEST, AND START (continued) F. When basic burner operation has been verified, recheck test data; adjust if needed: Draft-Over-Fire 0.05 inches water column to 0.10" w.c. after five minutes at High fire operation. (D.O.F. reading at Flame Observation Port.) Stack (Flue) temperature at entrance to I.D. fan must not exceed 575 o F. Fuel input rate must be reduced if flue temp exceeds 575 o F. Burner pressure should match the test report shipped with each heater. Efficiency at high fire may be checked by flue gas analysis at the entrance to the I.D. fan. High fire C0 2 should be between 7-1/2 and 9-1/2%; 0 2 should be between 7-1/2 and 4%. In these ranges, efficiency is 80% plus or minus 2%. Adjustment is made by reducing burner air and draft to increase C0 2 or to reduce 0 2 ; increasing burner air and draft will lower C0 2 and increase 0 2. Draft must be readjusted any time burner air settings are changed. Check operating amps of all motors; verify overload selection. Record motor nameplate amps and operating amps. G. Using the standard operating controls, cycle the burner several times to assure proper sequencing of startup, firing, and capacity modulation, plus operation of all safety and monitoring controls. It must be remembered that the burner is designed to retain the flame at its combustion head at the end of the blast tube of the burner. The general shape of the flame will be somewhat bushy and be retained on the burner head. If too much draft is supplied by the draft inducer, it will tend to pull the flame away from the burner head and will cause a floating pulsating condition. The balancing of the primary and secondary air damper can be set to give a quiet smooth fire. After the draft has been set, a combustion product sample should be taken at the point of intake to the draft inducer. The best place to observe the flame is through the peep sight over the burner mounting. The flame can also be observed through the optional observation glass on the opposite end of the unit. This rear observation port, affords a very good point for observing after shut down, the condition of the air nose, burner head, and safety control. H. Check operation of all Dampers, Mixing Boxes, Economizer Controls, Remote Control Panel, Smoke Detectors, and Accessories. A Sequence of Operation is included elsewhere in this manual. If, after checking all items above, a question remains, contact Jackson & Church at or Fax In any situation, it is essential that the Service Department is contacted by the Service Technician directly involved in the start-up, and not by someone with only indirect knowledge of the facts. SHUT DOWN OF UNIT 1. Set thermostat setting so the unit will not call for heat. 2. Close main manual gas valve and pilot valve. 3. Allow main circulating air fan to run for several minutes. 5

7 4. Place main disconnect switch in off position. FINAL CHECK-UP Upon completion of the installation, the following points should be checked before placing the unit into operation. 1. Check all gas piping for leaks. Have a gas utility representative check the installation. 2. Check all sheet metal joints on duct work so that no excessive leakage will take place. 3. Check belt tension on blower motor drive. Check rotation of blower by momentarily shorting the fan switch. 4. Set limit control at 180 o F and fan switch at 140 o on 100 o off (where applicable). 5. Start burner and check its operation. Check the input rate by clocking the gas meter. Flame appearance should have dark base with orange tips extending the length of the firing tube. The C02 should be between 8.0 and 9.0 per cent. 6. Check air temperature rise through the unit. Use thermometer rise should be approximately 80 o F, plus or minus 10 per cent. Adequate air quantities are of vital importance to satisfactory performance and long life of the unit. 7. Allow unit to cycle a number of times on controls to be sure that they are operating correctly. Interrupt fuel supply to the burner to be sure that the safety control functions correctly. 8. Keep the equipment room clean. Do not allow rubbish, boxes, or trash to be left around the equipment, especially at or near the air inlet. 9. Conduct the follow-up examination of the unit approximately two or three weeks after the installation is completed. Repeat all checks noted above. CLEANOUT, INSPECTION. & LUBRICATION The unit should be cleaned and inspected at least every heating season. Under normal operating conditions, it is not necessary to clean the firebox. The secondary portion, or tubes, of the heat exchanger may be cleaned by first removing the induced draft fan, then the access panel, and finally the cleanout cover and gasket. All of this is accomplished at the burner end of the unit and without requiring the removal of the burner. This procedure will expose the tubes and tube collector box, so as to provide a sufficient space for cleaning. At the time of cleaning, oil all motor bearings with a light oil containing no detergent, and grease blower bearings through appropriate fittings. CHECKING THE CONTROLS Before leaving the installation - Inspect the complete job and re-check the control system; that is, be sure the thermostat is operating properly; that the electronic relay is functioning properly; that it will stop the burner in the required length of time upon ignition or other abnormal failure. Check limit control; be sure it is in control circuit, that it will stop burner when setting is reached, and that it is operating satisfactorily. Check all other controls that may be in the circuit to be sure that they are operating correctly. Be sure electrode is adjusted properly and has not carboned up. Check flame and see that it does not burn back into the air cone. Check C0 2 draft and stack temperature. Check gas lines and fittings for leaks. 6