TJERNLUND DRAFT INDUCER DJ-3 User manual

REV. A 7/00

AUTO-DRAFT®INDUCER

INSTALLATION INSTRUCTIONS

MODELS

DJ-3 IL

D-3 XL

I HD

OWNER INSTRUCTIONS, DO NOT DESTROY

Recognize this symbol as an indication of important Safety Information!

NOTE: FLUE GAS TEMPERATURES MUST NOT EXCEED

575oFAT DRAFT INDUCER INLET. DRAFT INDUCERS MUST NOT

BE USED FOR SIDEWALL VENTING APPLICATIONS.

THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED, LICENSED

SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND

OPERATION OF THIS UNIT. READ THESE INSTRUCTIONS THOROUGHLY

BEFORE ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOLLOW

THESE INSTRUCTIONS MAY RESULT IN IMPROPER INSTALLATION, ADJUST-

MENT, SERVICE OR MAINTENANCE POSSIBLY RESULTING IN FIRE, ELECTRI-

CAL SHOCK, CARBON MONOXIDE POISONING, EXPLOSION, PERSONAL

INJURY OR PROPERTY DAMAGE.

DO NOT DESTROY. PLEASE READ CAREFULLY AND

KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

TJERNLUND PRODUCTS, INC.

1601 Ninth Street • White Bear Lake, MN 55110-6794

PHONE (800) 255-4208 • (651) 426-2993 • FAX (651) 426-9547

Visit our web site • www.tjernlund.com

TABLE OF CONTENTS

PAGE(S)

DESCRIPTION............................................................................................................................................................... 1

SPECIFICATIONS.......................................................................................................................................................... 1

CAUTIONS..................................................................................................................................................................... 1

INSTALLATION RESTRICTIONS................................................................................................................................... 2

DRAFT INDUCER SELECTION TABLE ........................................................................................................................ 2

PS1505 FAN PROVER SAFETY INTERLOCK INSTALLATION ................................................................................... 3

INSTALLATION......................................................................................................................................................... 3 - 5

ELECTRICAL WIRING .............................................................................................................................................5 - 9

TYPICAL GAS DIAGRAMS........................................................................................................................ 5 - 8

TYPICAL OIL DIAGRAMS.......................................................................................................................... 8 - 9

OPERATION CIRCUIT CHECK.............................................................................................................................. 9 - 10

P/N 950-1067 POST PURGE RELAY/TIMER ADJUSTMENT ................................................................................... 10

COMBUSTION AIR & SAFETY INTERLOCK TEST.....................................................................................................10

DRAFT CONTROL........................................................................................................................................................10

MAINTENANCE .................................................................................................................................................... 10 -11

HOW TO OBTAIN SERVICE & LIMITED WARRANTY................................................................................................ 11

REPLACEMENT PARTS.............................................................................................................................................. 11

Tjernlund Products welcomes your comments and questions. Call us at (651) 426-2993, (800) 255-4208, Fax (651) 426-9547, email us

at [email protected] or write to: Customer Service, Tjernlund Products, Inc., 1601 Ninth Street, White Bear Lake, MN 55110-6794.

DESCRIPTION

TJERNLUND AUTO-DRAFT®Inducers assure positive draft when restricted boilers and furnaces, poor chimneys or slight negative pres-

sures in buildings prevent proper exhaust of combustion gas. The venturi action of Tjernlund Auto-Draft Inducers starts air moving

smoothly. These units are quick and easy to install and completely automatic in operation. Tjernlund’s unique design and durable con-

struction makes them trouble-free and reduces maintenance to a minimum. The Vari-Draft Control permits adjustments to the individual

job requirement.

SPECIFICATIONS

CAUTIONS

Disconnect the power supply when making wiring connections or when working around the fan wheel and motor. Failure to do so can

result in electrical shock, personal injury, death or property damage.

1. All wiring must comply with applicable codes and ordinances.

2. When wiring is completed, check all components by running system through its entire heating cycle. See “Operation Circuit Check”

on page 9 and “Safety Interlock / Combustion Air Test” on page 10.

3. Check vent pipe system for leakage. All vent system leaks must be sealed prior to the installation of the Draft Inducer.

4. Plan the vent system so that Code required distances are maintained from plumbing and wiring.

5. Make certain the power supply is adequate for the Draft Inducer motor requirements. Do not add the Draft Inducer to a circuit

where the total load is unknown. For Draft Inducer motor amperage see “Draft Inducer Selection Table” on page 2.

6. The Draft Inducer shall not be installed where flue gas temperatures exceed 575OF at the Draft Inducer Inlet. Ambient tempera-

tures must not exceed 104 degrees F. Item #4 under “Installation Restrictions” describes how to measure flue gas temperatures.

7. A safety inspection of an existing appliance must be performed before installation of the Draft Inducer as outlined in ANSI

Z223.1/NFPA #54, Appendix H. 1

“H” - OVERALL HEIGHT

“D” - OVERALL DEPTH

“W” - OVERALL WIDTH

“X” - PIPE SLOT WIDTH

“Y” - PIPE SLOT HEIGHT

INSTALLATION RESTRICTIONS

Failure to install, maintain and/or operate the Draft Inducer in accordance with manufacturer's instructions may result in conditions

which can produce bodily injury and property damage.

The Draft Inducer must be installed by a qualified installer in accordance with these instructions and all local codes or in their absence

in accordance with the latest editions of The National Fuel Gas Code (NFPA #54), Installation of Fuel Burning Equipment (NFPA 31),

Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances (NFPA 211), The National Electrical Code (NFPA#70) and the

Occupational Safety and Health Act (OSHA) when applicable. Improper installation can create a hazardous condition such as an

explosion, fire, electrical shock or carbon monoxide poisoning resulting in property damage, personal injury or death.

1. The Draft Inducer shall not be used on condensing heating equipment.

2. Oil burning installations and gas-fired units without a draft hood / diverter should include a barometric draft regulator.

3. The Draft Inducer motor shaft must be mounted horizontally to prevent motor bearing wear.

4. The Draft Inducer shall not be installed where flue gas temperatures exceed 575OF at the Draft Inducer Inlet. Ambient room

temperatures must not exceed 104 degrees F.

Flue gas temperature verification:

A) Consult appliance manufacturer for temperature of gases at the appliance outlet after dilution by draft hood, draft diverter or

barometric draft control.

AND

B) Measure temperature of flue gases at the Draft Inducer inlet at time of installation. Temperature should be measured after

appliance and Draft Inducer have operated for at least 10 minutes, allowing flue gas temperature to stabilize.

DRAFT INDUCER SELECTION TABLE

1. Inputs shown are believed to be

maximum capacities for inducers when

mounted on pipe sizes shown for

ordinary jobs where a moderate amount

of mechanical induced draft is required.

2. Consideration is given to typically

higher static pressure requirements for

larger installations, for the type of fuel

burned and for the type of draft control

installed.

3. Where pressure requirements are

unknown or believed to be unusually

severe, ask for complete performance

curves or consult factory.

4. All ratings have been developed in our

testing and research department and

have been approved by a nationally

known independent testing laboratory.

Certification is available upon request.

5. Heating capacities shown are for 1000

BTU per cubic foot natural gas and for

139,000 BTU per gallon No. 2 fuel oil.

Consult factory for capacities with other

fuels. Heating capacities are based on

typical combustion efficiencies and

allow for approximately 5 percent

ambient air drawn into inducer to

cool motor and drives.

6. Draft Inducers should be installed

in single wall vent pipe in order

to insure proper performance.

DJ-3

D-3

GAS FIRING

WITH

DRAFT HOOD

MODEL

GAS FIRING

WITH

BAR. DRAFT

CONTROL

OIL FIRING

WITH

BAR. DRAFT

CONTROL

HEATER

BTU

INPUT

HEATER

BTU

INPUT

HEATER

BTU

INPUT

S.P. CFM CFMS.P. CFMS.P.

FLUE GAS FLUE GAS FLUE GAS

ELECTRICAL

DATA

IN.

SIZE

PIPE

MODEL PS1505 FAN PROVING SWITCH SAFETY INTERLOCK

The Model PS1505 Fan Proving Switch works on all Tjernlund Draft Inducers to assure adequate draft is present before burner is

allowed to fire. The PS1505 complies with burner safety interlock provisions of National Mechanical Codes.

PURPOSE

The PS1505 Fan Prover has been designed to monitor the pressure within the fan housing only. A motor or wheel failure will

decrease housing pressure and deactivate the pressure switch thus preventing combustion.

The PS1505 Fan Prover is not a safety control designed to ensure proper draft or to indicate chimney failure. It is the responsibility of

the end user to properly maintain the combustion equipment and its chimney or vent. Yearly maintenance and inspection should be

conducted by qualified service personnel. Failure to follow such maintenance and inspection procedures may result in generation of

toxic carbon monoxide gas.

LOCATION

The PS1505 Fan Prover can be mounted on any vertical surface within

five (5) feet of the draft inducer. It must not be mounted on the inducer or

any other surface with a temperature in excess of 190oF. Similarly, the

temperature of the surrounding air must be less than 190oF.

RATING

15 Amps non-inductive to 277 Volts AC.

INSTALLATION

CODE REQUIREMENTS

The Draft Inducer must be installed by a qualified installer in accordance with these instructions and all local codes or in their absence

in accordance with the latest editions of The National Fuel Gas Code (NFPA #54), Installation of Fuel Burning Equipment (NFPA 31),

Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances (NFPA 211), The National Electrical Code (NFPA#70) and the

Occupational Safety and Health Act (OSHA) when applicable.

•All appliances must enter the vent system on the inlet side of the Draft Inducer.

•Provision shall be made to interlock the appliance(s) to prevent the flow of gas to the main burners when the draft system is not

performing so as to satisfy the operating requirements of the equipment for safe performance. See “Electrical Wiring” on page 5.

INSTALLER NOTES

1. Verify Draft Inducer selection using burner specifications and Draft Inducer Selection Table on page 2.

2. Make certain that the electrical requirements of the Draft Inducer shown on page 2 are fulfilled by the available power supply.

HIGH TEMPERATURE GASKET MATERIAL MOUNTING (MODELS I, IL, XL ONLY)

1. Peel tape backing off 6 inches on one end.

2. Apply peeled end to the housing flange at a corner of the unit.

3. Press thumb along the top side and peel backing as tape is applied to flange.

4. Insure a tight fit where gasket ends meet.

MOUNTING

The Draft Inducer must not be used in sidewall venting applications. Sidewall venting requires the use of a Tjernlund

Sidewall Power Venter.

1. The Draft Inducer may be mounted on vertical, horizontal or inclined smokepipe. If used on a horizontal smokepipe, mount inducer

on bottom of pipe, not on top, to avoid creating a heat trap in inducer.

2. Cut rectangular slot in pipe and fasten in place with mounting bands provided. NOTE: The models DJ-3 & D-3 do not require bands,

use mounting screws provided.

3. Select a position between draft hood, draft diverter or barometric damper and chimney, locating the inducer as near the chimney as

possible. The motor shaft must be level and horizontal to avoid excessive wear of bearings.

Do not use “bullhead” tees when connecting two smoke pipes together. When tees are necessary, connect at 45

degree angles or

less. If change in smokepipe size is required, use a tapered increaser or reducer.

NOTE: Inducer is shown tilted in above pictures to show slot. Actual installation must have shaft horizontal.

SIMPLE INSTALLATION

INSTALLATION POINTERS

SPECIAL APPLICATIONS

1. CUT SLOT IN PIPE 2. INSERT INDUCER 3. INSTALL BANDS

ONE INDUCER

FOR SEVERAL

HEATERS

BELT DRIVEN MODEL HD

ALLOWS FOR RECESSED

MOUNTING FOR USE WITH

ROUND METAL OR

MASONRY VENTS

(Model DJ-3 & D-3

fastened with screws)

ELECTRICAL WIRING

Wiring diagrams are included in these instructions for various draft inducer applications. While it would be impractical to show every

conceivable variation, the ones included will demonstrate sufficient basic techniques for the design and installation of the unusual con-

trol system.

The installer should always check the rated capacity of a burner primary control. If the amperage rating of the load contacts is not equal

to the sum of all burner components plus that of the inducer motor, an additional isolation relay must be installed as shown in some dia-

grams. Draft inducer motor amperage ratings can be found on the “Draft Inducer Selection Table” on bottom of page 2.

The diagrams included show wiring for the standard motors furnished with the inducers. If special voltage motors have been specified,

changes in wiring may be necessary.

Wiring diagrams assume all inducer motors (except Model HD) will have 115 volt service. The Model XL is furnished with 115/230 volt

motors. If 230 volt service is required for this unit, consult factory if necessary, for wiring instructions.

The amperage rating of the PS1505 Fan Prover is 15 amps non-inductive to 277 volts AC.

A Post Purge Relay/Timer (P/N 950-1067) should be installed on Draft Inducers when venting Oil Fired Equipment. This will allow the

venter to run from 1 to 10 minutes after a heating cycle to purge the vent system of any residual flue gases or oil odors. The Relay/Timer

can also be installed on gas installations with extended horizontal vent connectors.

TYPICAL INSTALLATION

GAS WIRING TO ANY APPLIANCE EQUIPPED WITH 24V CONTROLS

NO POST-PURGE RELAY/TIMER ON DRAFT INDUCER

COMPONENTS NEEDED:

(1) DRAFT INDUCER

(1) PS1505 FAN PROVER

(1) 24/115V RELAY

USE 950-1040 FOR MODELS DJ3 & D3

USE 950-1016 FOR MODELS I, IL, XL

DRAFT INDUCER CONNECTED WITH UP TO 4 24V GAS APPLIANCES WITH THE MAC-4 CONTROL

(MODEL HD REQUIRES USE OF MOTOR ISOLATION RELAY / CONTACTOR, SEE TOP OF PAGE 7)

GAS WIRING TO ANY APPLIANCE EQUIPPED WITH 24V CONTROLS

POST-PURGE RELAY/TIMER ON DRAFT INDUCER (DRAFT INDUCER MOTOR LESS THAN 4.4 AMPS)

MODELS I, IL, XL MUST USE 950-0483 ISOLATION RELAY

GAS WIRING TO ANY APPLIANCE WITH MILLIVOLT CONTROLS

REQUIRES POST-PURGE RELAY/TIMER ON DRAFT INDUCER (DRAFT INDUCER MOTOR LESS THAN 4.4 AMPS)

MODELS I, IL, XL MUST USE 950-0483 ISOLATION RELAY

COMPONENTS NEEDED:

(1) DRAFT INDUCER

(1) PS1505 FAN PROVER

(1) 950-1067 RELAY/TIMER

MAXIMUM AMP LOAD

IS 4.4 AMPS

COMPONENTS NEEDED:

(1) DRAFT INDUCER

(1) RELAY/TIMER

950-1067

MAXIMUM AMP LOAD

IS 4.4 AMPS

(1) WHK-I KIT

(1) 950-0470 THERMO-

COUPLE JUNCTION

ADAPTER (FOR

RESIDENTIAL WATER

HEATERS ONLY)

COMPONENTS NEEDED:

(1) MAC-4 APPLIANCE CONTROL

(1) DRAFT INDUCER

(1) PS1505 FAN PROVER

NOTE: The MAC-4 is used for

wiring up to 4 heating appliances

with Draft Inducers, Power Venters

or IN-FORCERs. It is suitable for

any combination of 24 VAC and 115

VAC control systems for gas and oil

burners.

IF DRAFT INDUCER MOTOR IS OVER 4.4

AMPS, WIRE 950-0483 ISOLATION RELAY

AS SHOWN IN THIS DIAGRAM.

IF DRAFT INDUCER MOTOR IS OVER 4.4

AMPS, WIRE 950-0483 ISOLATION RELAY

AS SHOWN IN THIS DIAGRAM.

DRAFT INDUCER CONNECTED WITH UP TO 4 24V GAS APPLIANCES WITH THE MAC-4 CONTROL

(DRAFT INDUCER MOTOR LOAD GREATER THAN 1 H.P.)

MULTIPLE DRAFT INDUCERS, POWER VENTERS OR IN-FORCERS CONNECTED WITH UP TO 4 24V GAS APPLIANCES

(IF INDIVIDUAL OR COMBINED MOTOR LOAD IS OVER 1 H.P. ISOLATION RELAY(S) WILL HAVE TO BE ADDED, SEE ABOVE)

COMPONENTS NEEDED:

(1) MAC-4 APPLIANCE CONTROL

(1) DRAFT INDUCER

(1) PS1505 FAN PROVER

(1) ISOLATION RELAY/CONTACTOR

NOTE: The MAC-4 is used for

wiring up to 4 heating appliances

with Draft Inducers, Power Venters

or IN-FORCERs. It is suitable for

any combination of 24 VAC and 115

VAC control systems for gas and oil

burners.

COMPONENTS NEEDED:

(1) MAC-4 APPLIANCE CONTROL

DRAFT INDUCER(S)

PS1505 FAN PROVER(S)

MOTOR ISOLATION RELAY /

CONTACTOR(S) IF OVER 1 H.P.

NOTE: The MAC-4 is used for

wiring up to 4 heating appliances

with Draft Inducers, Power Venters

or IN-FORCERs. It is suitable for

any combination of 24 VAC and 115

VAC control systems for gas and oil

burners. Wire Fan Prover(s) or

Limit(s) in Series with Prover termi-

nal block. Do not supply voltage to

Prover terminal block!

DRAFT INDUCER CONNECTED WITH UP TO 4 115V GAS APPLIANCES WITH THE MAC-4 CONTROL

(IF MOTOR LOAD IS GREATER THAN 1 H.P. AN ISOLATION RELAY WILL HAVE TO BE ADDED, SEE TOP OF PAGE 7)

DRAFT INDUCER CONNECTED TO OIL BURNER WITH R8184G CONTROLS

(DRAFT INDUCER MOTOR LESS THAN 4.4 AMPS) MODELS I, IL, XL MUST USE 950-0483 ISOLATION RELAY

DRAFT INDUCER CONNECTED TO OIL BURNER WITH R8184G CONTROLS

(DRAFT INDUCER MOTOR GREATER THAN 4.4 AMPS) INCLUDES MODELS I, IL, XL

COMPONENTS NEEDED:

(1) DRAFT INDUCER

(1) PS1505 FAN PROVER

(1) 950-1067 RELAY/TIMER

MAXIMUM AMP LOAD IS

4.4 AMPS

USE DIAGRAM BELOW IF

DRAFT INDUCER MOTOR

IS GREATER THAN 4.4 AMPS

COMPONENTS NEEDED:

(1) DRAFT INDUCER

(1) PS1505 FAN PROVER

(1) 950-1067 RELAY/TIMER

MAXIMUM AMP LOAD IS 4.4 AMPS

(1) 950-0483 115/115V RELAY

COMPONENTS NEEDED:

(1) MAC-4 APPLIANCE CONTROL

(1) DRAFT INDUCER

(1) PS1505 FAN PROVER

NOTE: The MAC-4 is used for

wiring up to 4 heating appliances

with Draft Inducers, Power Venters

or IN-FORCERs. It is suitable for

any combination of 24 VAC and 115

VAC control systems for gas and oil

burners.

DRAFT INDUCER CONNECTED WITH UP TO 4 OIL FIRED BURNERS WITH THE MAC-4 AND A 950-1067 POST-PURGE

RELAY/TIMER (VENTER MOTOR LESS THAN 4.4 AMPS) MODELS I, IL, XL MUST USE 950-0483 ISOLATION RELAY

COMPONENTS NEEDED:

(1) DRAFT INDUCER

(1) PS1505 FAN PROVER

(1) 950-1067 RELAY/TIMER

MAXIMUM AMP LOAD IS

4.4 AMPS

OPERATION CIRCUIT CHECK

1. After all appliance wiring is complete, establish 115Vpower to the appliance and Draft Inducer with the appliance thermostat /

aquastat not calling for heat. NOTE: If using a post-purge Relay/Timer, the Draft Inducer may operate when power is first estab-

lished. Wait until the Draft Inducer shuts off before continuing.

2. Adjust the appliance thermostat/aquastat to call for heat. At this point, the Draft Inducer should start. After a slight delay, (up to 4

seconds), the appliance burner should fire after the PS1505 Fan Proving Switch proves draft. The delay is caused by the PS1505

Fan Proving Switch. If you are unable to detect a slight delay, contact Tjernlund Products, Inc. at 1-800-255-4208 for assistance.

DO NOT OPERATE THE APPLIANCE WITHOUT THE PS1505 PROVING SWITCH WIRED INTO THE THE EQUIPMENT CIRCUIT!

MULTIPLE DRAFT INDUCERS, POWER VENTERS OR IN-FORCERS CONNECTED WITH UP TO 4 115V OIL FIRED BURNERS

(IF INDIVIDUAL OR COMBINED MOTOR LOAD IS OVER 1 H.P. ISOLATION RELAY(S) WILL HAVE TO BE ADDED)

IF DRAFT INDUCER MOTOR IS OVER 4.4

AMPS, WIRE 950-0483 ISOLATION RELAY

AS SHOWN IN THIS DIAGRAM.

COMPONENTS NEEDED:

(1) MAC-4 APPLIANCE CONTROL

DRAFT INDUCER(S)

PS1505 FAN PROVER(S)

MOTOR ISOLATION RELAY /

CONTACTOR(S) IF OVER 1 H.P.

NOTE: The MAC-4 is used for

wiring up to 4 heating appliances

with Draft Inducers, Power Venters

or IN-FORCERs. It is suitable for

any combination of 24 VAC and

115 VAC control systems for gas

and oil burners. Wire Fan

Prover(s) or Limit(s) in Series with

Prover terminal block. Do not sup-

ply voltage to Prover terminal

block!

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