User Operation Manual: Sales Offices Across Canada and Usa
User Operation Manual: Sales Offices Across Canada and Usa
User Operation Manual: Sales Offices Across Canada and Usa
MANUAL
FOR
DJM3
DJM3
The DJM3 has been certified by Intertek (ETL) for use with Engineered Air appliances only. It has been
evaluated to CSA C22.2 No. 24 Temperature‐Indicating and Regulating Equipment and UL 873 UL
Standard for Safety Temperature‐Indicating and Regulating Equipment. This is a User Operation
Manual and therefore not subject to evaluation.
If any errors or omissions are noted please contact the nearest Engineered Air Technical Service
Department.
To ensure warranty is honored, only qualified personnel should be employed for service and
troubleshooting. If further information is required please contact the nearest Engineered Air office.
There are two sets of electrical drawings and unit function sheets provided with the appliance. One set
is in an envelope which also contains the Operation, Installation and Maintenance manual(s). This
package is for copying, then should either be returned to the appliance or stored in a safe place. The
other set is attached to the control panel door and should never be removed.
Please report any omissions to the national service manager.
Warning: Improper installation, adjustment, alteration, service or maintenance can cause
property damage, injury or death. Read the installation, operating and
maintenance instructions thoroughly before installing or servicing this equipment.
Warning: This unit is connected to high voltages. Electrical shock or death could occur if
instructions are not followed. This equipment contains moving parts that can start
unexpectedly. Injury or death could occur if instructions are not followed. All
work should be performed by a qualified technician. Always disconnect and lock
out power before servicing. DO NOT bypass any interlock or safety switches under
any circumstances.
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TABLE OF CONTENTS
INTRODUCTION ............................................................................................................................................................... 5
CONTROLLER RATINGS ..................................................................................................................................................... 5
CONTROLLER DESCRIPTION .............................................................................................................................................. 6
TERMINALS .................................................................................................................................................................................. 6
DIP SWITCHES .............................................................................................................................................................................. 7
INDICATION AND DIAGNOSTIC LIGHTS ........................................................................................................................................ 7
ADJUSTMENT POTS ...................................................................................................................................................................... 8
MULTIMETER TEST POINTS .......................................................................................................................................................... 9
SYSTEM TIMINGS ......................................................................................................................................................................... 9
TEMPERATURE CONTROL ................................................................................................................................................. 9
CALCULATED SETPOINT (SPC) ...................................................................................................................................................... 9
DISCHARGE TEMPERATURE SENSOR (D TEMP) .......................................................................................................................... 10
MODULATING ROOM RESET ...................................................................................................................................................... 10
Multiple Room Sensors .................................................................................................................................................... 11
ROOM RESET AUTHORITY TABLE ............................................................................................................................................... 11
BMS RESET ................................................................................................................................................................................. 12
AMBIENT RESET (CONTINUOUS BLOWER OPERATION ONLY)................................................................................................................. 12
MAKE/BREAK RESET AND OVERRIDE ........................................................................................................................................... 13
“OR” and “V” Override (Day Operation only) .................................................................................................................. 13
“X” and “Z” Override (Day and Night Operation) ............................................................................................................. 13
OPERATION ................................................................................................................................................................... 14
DAY / NIGHT OPERATION ........................................................................................................................................................... 14
FAN CONTROL ............................................................................................................................................................................ 14
DAMPER CONTROL .................................................................................................................................................................... 14
BURNER CONTROL ..................................................................................................................................................................... 14
LOW LIMIT .................................................................................................................................................................................. 15
Resetting Low Limit .......................................................................................................................................................... 15
SERVICE ......................................................................................................................................................................... 15
SERVICE MODE ........................................................................................................................................................................... 15
BURNER SET UP .......................................................................................................................................................................... 15
TEMPERATURE CONTROL .......................................................................................................................................................... 22
AIR BALANCING .......................................................................................................................................................................... 22
PRE‐PURGE PROBLEM ................................................................................................................................................................ 22
INDUCED VOLTAGE ON REMOTE CONTROL WIRING .................................................................................................................. 23
CALIBRATION ................................................................................................................................................................. 23
DISCHARGE SENSOR ........................................................................................................................................................................ 23
DISCHARGE SETPOINT CALIBRATION ................................................................................................................................................... 23
ROOM SENSOR CALIBRATION ............................................................................................................................................................ 23
BMS SIGNAL CALIBRATION ............................................................................................................................................................... 24
SENSOR TABLE ........................................................................................................................................................................... 24
FAN OPERATION FLOWCHART........................................................................................................................................ 25
HEAT OPERATION FLOWCHART ...................................................................................................................................... 26
UPGRADING DJM3.2 OR 3.3 TO DJM3.4 ......................................................................................................................... 26
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A DJM3
INTRODUCTION
The DJM3 is an independent controller for Engineered Air DJ style gas fired heating equipment
designed to provide the majority of control requirements. The DJM3 modulates a variable speed
combustion blower in conjunction with an modulating gas valve. The combustion blower speed and
the gas valve flow rate are both modulated to maintain the required discharge air temperature.
The information used in this manual should be used in conjunction with the unit function sheet(s) and
the DJ(E,S) & DG or DJX series Installation, Operation, and Maintenance manuals.
The DJM3 is designed to control only Engineered Air equipment. Various upgrades and improvements
have been made over time. Always include any suffix letters and numbers for troubleshooting and/or
replacement.
Note: It is necessary that all of the remote wiring and controls be complete and operational before
starting the appliance.
CONTROLLER RATINGS
Power requirements: 24 Vac, 40 VA.
Contact Rating: 120V 5A inductive
0‐10 Vdc input impedance: 2 k
Environment: ‐40 to 120°F (‐40 to 50°C) non‐condensing.
Fuse Rating: 1.5 GDC slow‐blow
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CONTROLLER DESCRIPTION
TERMINALS
TABLE 1
Terminal Description
T1 Board power supply. (HOT) 24 Vac isolated.
T2 Board power supply. (NEUTRAL) 24 Vac isolated.
FS Fan switch (or Day mode) enable input (24 Vac).
K Night (unoccupied) mode enable input (24 Vac).
HS Heat enable input (24 Vac).
N Grounded 24 Vac neutral (reference to FS, K, HS).
DM1, DM2 Damper motor output contacts (dry).
FR, CFR Flame relay output contacts (dry).
AL Alarm output.
C Contact common input power (to AL and SA).
SA Supply air fan enable output.
CB1 Combustion blower motor input.
CB2 Combustion blower motor speed control output.
PV1, PV2 Pilot valve disable contact (dry).
VFB120 Main gas valve feedback (SSOV) hot input for 120V valves.
VFB24 Main gas valve feedback (SSOV) hot input for 24V valves.
VN Main gas valve feedback (SSOV) neutral input.
MX1, MX2 Modulating valve output. (DC volts)
VS Legacy input. Not used.
OS, GS, YS Combustion blower speed sensor input.
Q, U Discharge air temperature sensor input.
S SP M Internal (jumpered) or external discharge setpoint inputs.
V X Y Z Modulating (resistive) room / return air thermostat inputs.
OR Single stage heat thermostat input.
+ / ‐ 0‐10 Vdc (4‐20 mA) temperature reset input.
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DIP SWITCHES
The DJM3 options are configured by DIP switch selection and/or wiring connections.
TABLE 2
DIP SW Description
1 Enable Vdc or mA temperature reset if ON.
2 Enable ambient reset if ON.
3 Enable room/return temperature reset if ON.
4 Not used.
5 Service mode (must be left OFF for normal operation).
6 Not used.
7 Constant combustion air purge mode if ON.
8 Enable low limit discharge temperature sensing if ON
Note: The DJM3 will only accept one type temperature reset signal.
INDICATION AND DIAGNOSTIC LIGHTS
There are 4 status lights on the DJM3 labeled 1 to 4. They operate in 4 patterns: constant on, 2 second
flash (on for 1 second, off for 1 second), 1 second flash (on for ½ second, off for ½ second) and an
irregular flash (flashes twice, then off, repeat).
TABLE 3
LIGHT LED ON 2 SEC FLASH 1 SEC FLASH INT FLASH
1 LL LOCKOUT LL BYPASS D SEN OPEN ‐‐‐‐‐‐‐‐‐‐
2 PRE PURGE PP PROBLEM ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐
3 HEAT CALL HT SW OPEN ‐‐‐‐‐‐‐‐‐‐ SERVICE MODE
4 IGN ENABLE ‐‐‐‐‐‐‐‐‐‐ FLAME FAIL ‐‐‐‐‐‐‐‐‐‐
The appliance has been shut down due to low limit failure and lockout.
1 ON (discharge temperature below 4°C (40°F)) Reset with the service switch.
Normal operating status: OFF.
Unit has low discharge temperature and is timing out. If the temperature does
not recover to above 4°C (40°F) it will shut down and lockout.
1 2 SEC
Normal operating status: OFF, or waiting for the discharge temperature to rise
above 4°C (40°F).
The discharge sensor circuit is open (sensor range must be between 880 and
1 1 SEC 4000Ω).
Normal operating status: OFF.
The combustion blower is purging the exchanger as a preliminary to ignition.
2 ON Normal operating status: EITHER ON or OFF.
Pre Purge problem. The DJM3 is not receiving a correct signal from the hall
2 2 SEC effect tachometer sensor, into terminals YS, OS, GS.
Normal operating status: OFF.
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The discharge sensor is below calculated setpoint (SPC) and the DJM3 has
3 ON initiated the heating sequence.
Normal operating status: ON for heating.
There is a call for heating, however the heating has been disabled from no
3 2 SEC input into terminal HS (24Vac).
Normal operating status: OFF.
Unit is in service mode, allowing the technician to manually set the heating
INT
3 from low to high fire with the service pot.
FLASH
Normal operating status: OFF.
FR and CFR contacts have closed, enabling the ignition control to fire the
4 ON burner.
Normal operating status: ON for heating.
Burner ignition was unsuccessful. The DJM3 did not receive a main gas valve
4 1 SEC (SSOV) feedback signal into terminals VFB24 or VFB120.
Normal operating status: OFF.
ADJUSTMENT POTS
There are a number of setting and calibration potentiometers (POT’s) located on the front of the
DJM3. Modifications to these should only be done by experienced and qualified personnel.
TABLE 4
POT Description
D SEN CAL Discharge sensor calibration.
DIS SP CAL Discharge setpoint calibration.
BMS CAL BMS (0‐10Vdc or 4‐20 mA) reset calibration.
ROOM CAL Room sensor calibration.
SERVICE Service mode pot.
RESET RATIO Temperature reset range adjustment.
LOW FIRE* Low fire speed RPM adjustment pot (near terminal PV1).
CURVE MATCHING* Valve curve matching RPM adjustment pot (near terminal CS).
SETPOINT If used, the on‐board discharge setpoint dial.
* These pots should only be adjusted when used with a combustion analyzer.
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The DJM3 is designed to use either of the following as a setpoint:
The setpoint mounted on the face of the DJM3 (range of 50‐95°F (10‐35°C)). If the DJM3 face
mounted set‐point is used, terminals “SP and S” must be jumpered; or
The Johnson Controls TE 6100‐960 set‐point (range of 50‐85°F (10‐29°C)). If the TE 6100‐960 is used
as a set‐point, “S to SP” is not jumpered and the TE 6100 must be wired:
TABLE 7
TE 6100 Wires DJM3 Terminals
Violet (not used) ‐
Red (not used) ‐
Grey Wired to terminal U
Blue Wired to terminal M
Orange Wired to terminal S
DISCHARGE TEMPERATURE SENSOR (D TEMP)
The DJM3 uses the discharge sensor for both temperature control and low limit. Because of this, the
DJM3 will not operate with a faulty discharge sensor. If the discharge sensor resistance is greater than
4000‐ohms or less than 880‐ohms, the unit will lock out either on low limit or bad temperature sensor.
MODULATING ROOM RESET (continuous blower operation only)
DIP switch 3 must be "on". This option also requires a TE 6100 wired:
TABLE 8
TE 6100 Wires DJM3 Terminals
Red (not used) ‐
GREY Wired to terminal V
VIOLET Wired to terminal X
ORANGE Wired to terminal Y
BLUE Wired to terminal Z
If DIP switch 3 is on and the TE 6100 is not wired to the correct DJM3 terminals, the DJM3 will reset the
discharge temperature down as it thinks that the room sensor is very warm. The room temperature
requirements can increase or decrease (reset) the calculated discharge air set‐point.
Note: If room reset calling, the “calculated” discharge temperature setpoint will vary from the setting
of “master” setpoint.
The room‐reset feature is activated by DIP switch 3.
Room sensor calibration pot is Room Cal Pot.
Room reset band is 3°F (fixed).
The “room reset band” means a room temperature error of just 3°F will result in a maximum reset of
the discharge air set point. The actual amount reset (in degrees) varies as per both the setting of Pot
Reset Ratio and the discharge set point. The calculated discharge air set point (dial setting + reset) is
limited between 48 and 120°F.
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To determine the amount of reset available refer to Table 9.
EXAMPLE: DJM3 setpoint 70°F; pot #5 set at 3; room thermostat set 75°F.
If room thermostat sensor is at 75°F ‐ no reset, discharge at 70°F.
If room sensor is 3°F cold (72°F), discharge is reset up full amount of its authority (+20) to 90°F.
If room thermostat was at 73°F then of the reset would be used ( * 20 is approx. 14°F),
added on to the set‐point of 70°F giving discharge of 84°F.
If room sensor is 3°F hot (78°F) full reset down will lower the discharge 13° (57°F discharge).
Multiple Room Sensors
Four sensors can be wired to give an average reading of room temperatures to the DJM3 control. They
must be wired in a series/parallel arrangement. Refer to main or field electrical diagram for
appropriate wiring.
ROOM RESET AUTHORITY TABLE
TABLE 9
Reset Reset
Reset
Discharge Maximum Minimum Band Maximum Minimum Band
Ratio
Set‐Point Temp. °C Temp. °C Width Temp. °F Temp. °F Width
Pot
°C °F
1 25 (+9.5) 12 (‐3.5) 13 77 (+17) 54 (‐6) 23
15.5°C 2 26 (+10.5) 11.5 (‐4) 14.5 79 (+19) 53 (‐7) 26
3 28 (+12.5) 10.5 (‐5) 17.5 82 (+22) 51 (‐9) 31
60°F 4 33 (+17.5) 9 (‐6.5) 24 91 (+31) 48 (‐12) 43
5 38 (+22.5) 9 (‐6.5) 29 100 (+40) 48 (‐12) 52
1 29 (+8) 16 (‐5) 13 84 (+14) 61 (‐9) 23
21°C 2 30 (+9) 15 (‐6) 15 86 (+16) 59 (‐11) 27
3 32 (+11) 14 (‐7) 18 90 (+20) 57 (‐13) 33
70°F 4 37 (+16) 11 (‐10) 26 99 (+29) 52 (‐18) 47
5 40.5 (+19) 9 (‐12) 31.5 105 (+35) 48 (‐22) 57
1 33 (+6) 21 (‐6) 12 91 (+11) 70 (‐10) 21
27°C 2 34 (+7) 19 (‐8) 15 93 (+13) 66 (‐14) 27
3 35.5 (+8) 18 (‐9) 17.5 96 (+16) 64 (‐16) 32
80°F 4 39 (+12) 15 (‐12) 24 103 (+23) 59 (‐21) 44
5 44 (+17) 11 (‐16) 33 111 (+31) 52 (‐28) 59
1 38 (+6) 25 (‐7) 13 100 (+10) 77 (‐13) 23
32°C 2 38 (+6) 23 (‐9) 15 101 (+11) 74 (‐16) 27
3 40 (+8) 22 (‐10) 18 104 (+14) 72 (‐18) 32
90°F 4 44 (+12) 18 (‐14) 26 111 (+21) 64 (‐26) 47
5 47 (+15) 13 (‐19) 34 116 (+26) 56 (‐34) 60
NOTE: The above table is not linear and reset up and down is equal at a set‐point of about 82°F
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It is possible to obtain an extended temperature range by placing a 120‐ohm resistor in series with the
ambient temperature sensor.
Note: With this resistor the discharge temperature will be at its maximum when ambient is at ‐15°F.
With this resistor, the calculated discharge air set‐point equals the dial set‐point at 35°F
(different from above). Above 40°F the calculated discharge air temperature will be below the
dial set‐point.
TABLE 11
Reset Ratio Pot Reset Amount °F Reset Amount °F
Setting (no resistor) (with a 120 ohm resistor in series)
1 10 18
2 11 20
3 13 24
4 16 30
5 21 37
MAKE/BREAK RESET and OVERRIDE
“OR” and “V” Override (Day Operation only)
To activate this feature DIP switch 3 must be off. If a thermostat or contact is closed across terminals
“OR” and “V”, the discharge temperature is set at 120°F (49°C). When thermostat or contact is open,
the discharge temperature is set at the dial setpoint plus any other resets being used.
“X” and “Z” Override (Day and Night Operation)
To activate this feature DIP switch 3 must be on. During day operation, if a thermostat or contact is
closed across terminals “X” and “Z”, the discharge temperature is set at the dial setpoint plus the
maximum amount of reset upwards. When the thermostat or contact is open across terminals “X” and
“Z”, the discharge temperature is set at the dial setpoint less the maximum amount of reset
downwards.
During Night operation, if a thermostat or contact is closed across terminals “X” and “Z”, the discharge
temperature is set at 120°F (49°C). When the thermostat or contact is open across terminals “X” and
“Z”, heat is off.
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OPERATION
DAY / NIGHT OPERATION
The DJM3 supports a variety of fan, damper, and temperature control operating schemes. The exact
operation depends on the status of terminals “FS, HS”, and “K”. Night operation is not suitable for
100% make‐up air applications, due to the equipment having to open outside air dampers and heat
outside air. To operate in Night mode, a room thermostat or make/break reset must be used.
TABLE 12
Terminal Status Blower Damper Control
Control Source
HS FS K Operation Operation Mode
XXX Off Off Off Off N/A Off
XXX On Off Constant Powered Discharge/Room/BMS Day
N/A
Off XXX On Off Off Off
Room
On Off On Intermittent Off Night
Discharge w/Room
On On On Constant Off Night
Reset
XXX = Switch (SW.) can be "ON" or "OFF"
FAN CONTROL
In day mode, the supply air fan should run continuously (unless just starting the morning warm‐up or
tripped on low limit.). For supply fan operation, the discharge sensor must be operating correctly as it
is also used as the low limit sensor. If the discharge sensor resistance is too high (or open circuit), the
DJM3 perceives a low limit fault and locks off DJM3.
DAMPER CONTROL
The inlet damper actuator(s) is enabled through output terminal DM2. The DJM3 has a delayed supply
blower start to allow time for the dampers to open.
BURNER CONTROL
Burner is enabled when a valid heat call is made and terminal “HS” is powered. The DJM3 will enter a
heat exchanger purge cycle. When the purge cycle is complete, the DJM3 will run combustion blower
at light‐off speed and enable the ignition control to start the pilot. When the ignition control proves
pilot light‐off it will enable the main gas valve. Once the main flame is established and the DJM3
receives a feedback signal to terminals VFB24 or VFB120 and VN the control will modulate the gas
valve and combustion blower to satisfy the heat call. If the DJM3 does not receive the feedback signal
the alarm contact, terminal “AL”, will be activated.
When heat call is satisfied the DJM3 will cycle off the burner. The combustion blower will continue to
run for several minutes after heat call is open to maintain purge and cool off the burner and heat
exchanger.
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LOW LIMIT
The low limit set point is fixed at 40°F. There are two low limit bypass timers, start‐up and anti‐noise.
The start‐up auto bypass low limit timer is started every time terminal “K”, “SA” or “FS” energized
status changes (on/off). The start‐up timer will bypass the low limit for 5 minutes. After the 5 minute
start up bypass, a 30‐second anti‐noise low limit bypass timer is started every time a low limit
condition is detected. This timer is designed to prevent nuisance trips caused by any electrical noise
picked up by the discharge sensor. If the low limit condition exists for more than 30 seconds, a low
limit lockout will occur. This will activate the alarm contact on the DJM3, terminal “AL”.
Resetting Low Limit
To reset the low limit, cycle power to the DJM3 control terminals "T1" and/or "T2"; or interrupt power
to terminals "FS, HS, and K" all at the same time.
SERVICE
SERVICE MODE
Placing the DJM3 into service mode allows for direct control of the burner firing rate. DIP switch 5 will
activate service mode and enable the heat immediately. The service POT, located to the right of the
setpoint dial, will manually set the burner to any firing rate. When in service mode, the supply air fan
may need to be activated manually.
Note: DO NOT leave DJM3 in service mode, burner will not cycle off. Service mode should only be used
for combustion set‐up and operational checks.
BURNER SET UP
Service Pot
This pot is designed to allow a service technician to manually set the burner to any firing rate he
chooses. If the service switch (dipswitch 5) is on and the blower switch (terminal FS) is powered, the
burner firing rate is controlled by the Service Pot. The Service Pot is located close to the “+" terminal
and above the dipswitches. Rotating this pot will allow the firing rate to be set at any rate between low
and high fire.
Low Fire Pot
The low fire pot is located below the PV1 terminal. The low fire pot is used to adjust the combustion air
at low fire. The low fire speed is adjustable from 1150 to 1400 RPM (high turndown) or 1800 to 2000
(standard burner). The low fire pot is to be adjusted by a qualified service technician only.
Curve Matching Pot
The curve matching pot is located below the CS terminal. The DJM3 can be used with several different
Maxitrol valves. Each of these valves has a slightly different opening curve. The Curve Matching Pot is
to be adjusted by a qualified service technician only.
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Burner Selection
The DJM3 is designed to operate with both the standard (round burner plate) and high turndown
(rectangular) burners. The selection is made by cutting a jumper wire R100 which is located on the
small board. (The DJM3 must be turned over to access the jumper wire.)
NOTE: Jumper wire R100 is cut only for the high turndown burner operation. Caution – do not cut
resistor R100 on the large board.
NOTE: Do not adjust any other pots located on the small board, which are not accessible from the
front of the DJM3
Combustion Set Up
When measuring combustion gases, ensure probe of analyser inserts fully into the flue connection to
the heat exchanger. Measuring at the flue outlet may be a diluted reading due to air mixing into the
flue.
NOTE: If combustion is not set correctly it can result improper burning which may produce
products of combustion that smell, carbon and or an excessive amount of water in the flue.
Care should be taken to set burners up properly. Note that temperature of the air and fuel
may have a great affect on the set up selected. If both the combustion air and the fuel are
at a constant temperature throughout the heating season, once combustion is set it should
remain similar through the season.
High Turndown (Rectangular) Burner
Most high turndown DJ units will employ on of the following Maxitrol modulating DC volt gas valves.
Series 20 420, M520, M620. These valves do not have high fire regulators. High fire pressure is
set up at the appliance regulator.
Series 50 550, M650, ES350. These valves do not have high fire regulators. High fire pressure is
set up at the appliance regulator
ES345D‐L This valve has a built in high fire regulator. Typically used on DJ140 models.
The above valves differ from each other in size, configuration, BTU capacity, physical layout, and low
fire set up.
Check the equipment to verify what type of modulating gas valve you have to ensure the correct
combustion set up method is used.
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5. Curve Matching Procedure
Turn Service Pot to high fire (approximately 3450 RPM or 57.5 Hz) for 1 minute. Adjust the
Service Pot down very slowly until the combustion motor speed is about 3060 RPM (51 Hz).
If the pot is adjusted below 51Hz return to high fire and attempt to lower without passing
51Hz. Let the burner stabilize for 2 minutes, then re‐check O2 reading. If O2 has dropped to
less than the original high fire O2 reading, adjust the Curve Matching pot. Adjusting CCW
increases the O2 reading by reducing the voltage to the Maxitrol modulating gas valve. The
Curve Matching pot only changes the voltage to the gas valve; it does not affect fan speed.
If the curve matching pot is adjusted to the fully CCW position and the O2 reading is still not
within 10% of the original high fire O2 reading, add a 180‐ohm 2 watt resistor across the
modulating gas valve terminals; repeat above test until proper curve matching is achieved.
(A 150‐ohm, 2‐watt resistor may have to be used if O2 level still does not rise to within 10%
of original high fire O2 reading.)
Switch burner to low fire again and re‐check low fire, both at 0 VDC and 2.25 VDC. (An
addition of a resistor above may have changed the low fire setting, if it was needed.)
Lock the locking ring on the spring activated low fire adjustment screw (from step 1). Failure
to lock it may cause the screw to vibrate loose allowing low fire gas pressure to increase.
This can create sooting of burner parts and the heat exchanger. If the locking ring is missing,
drop one drop of Loctite thread locker onto the brass screw threads.
Series 50/M550, M650 AND ES350 (High Turndown Burner)
These valves have only 1 low fire adjustment (spring activated low fire).
1. The combustion set up is similar to the above except there is no low fire bypass adjustment
on the bottom of these valves. Therefore simply set up low fire by turning the manual firing
Pot Reset Ratio to the low fire position ‐ 1250 RPM 10 RPM 20.8 Hz. (15:1 turndown set at
1195 RPM, 19.91 Hz.) Voltage to the series 50 valve should be near 0 volts DC. Adjust the
spring activated low fire adjustment at the top of the modulating gas valve (small screw)
until an O2 reading of 16.8% to 17.5% is achieved.
2. Lock the low fire adjustment screw as described in point 7 above and then adjust the curve
matching pot as in point 5 above.
Type ES345D‐L (High Turndown Burner)
As this valve has 2 low fire adjustments the following procedure should be applied.
1. Bring the unit to low fire using the service firing pot fully CCW. Adjust Pot Low Fire until the
combustion fan is turning 1250 RPM 10 RPM (20.8 Hz). (15:1 turndown is 1195 RPM, 19.91
Hz.) Voltage to the ES valve should be near 0 volts DC. The low fire bypass adjustment on
this valve is under the top cover on the large port and the adjustment inside it is marked:
Increase Decrease
After removing the cover, loosen the locking screw first before making adjustment. This
should be done at 0 VDC to the modulating gas valve terminals and the spring activated low
fire brass screw turned fully CCW and the locking ring loosened off.
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Propane Gas
Combustion set up for propane fuels for either the high turndown or the standard burner are similar to
the above. The only modification suggested is it may be desirable to increase the oxygen settings by 1%
to 1.5% above those for natural gas.
Due to the quantity of fuel that can be drawn off a propane tank, it is often necessary to equip a
propane fuel system with a vaporizer. The usual sign that a vaporizer is required is that the equipment
fuel supply falls off as the line “freezes”. The following could be observed:
Lack of temperature rise,
Rumbling or shaking burner due to air/fuel mix,
After turning the unit off for a period of time the fuel line thaws and restarting it, all appears
to be normal.
High turndown burners operating on propane fuel will generally exhibit the following:
High Fire At 3.5% O2 will appear yellow from behind the burner. However, if you could
view it from the other side of the burner you would see blue as the flame
lengthens out.
Low Fire At 16% O2 the flame will likely be yellow. At 17% O2 the flame will likely be blue
and yellow.
Inlet/Manifold Pressure Settings
Manifold pressure settings that the unit was tested and clocked at in the factory are recorded on the
unit rating plate. Any attempt to clock a unit in the field should be done with care as corrections for
density (altitude and station pressure), temperature, and for the meter are often overlooked, thus
leading to an incorrect conclusion.
Inlet gas pressures are recorded on the unit label. At high fire inlet gas pressure to the unit should not
fall below 6.25" on units designed for 7" inlet pressure. If design is for 14" pressures should not fall
below 12".
If design is for 11" propane gas, then inlet pressures should not fall below 10". Note that with propane
fired units it may be necessary to equip the propane system with a properly sized vaporizer.
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TEMPERATURE CONTROL
Modulation of the firing rate is gradually made until the discharge air temperature is within 1.5°F of
the “calculated” set‐point. When the heat load is light and the burner is cycling between low fire and
off there will be small temperature swings.
AIR BALANCING
Installation and air balancing is often done during warmer weather than that experienced in the cold of
winter. If the air balancer did not allow for the changes that will occur in air volume in cold weather
then the unit will appear to be short of temperature rise. As the fan is a constant volume device and as
it is located before the heat exchanger, air will expand as it is heated. The amount of change will be
about 20% increase in air volume from ‐30°F to +70°F.
PRE‐PURGE PROBLEM
If a Pre‐Purge problem is found, typically the DJM3 is receiving a signal from the tachometer sensor
(Hall Effect sensor) that is not consistent with the combustion blower status. If there is a call for heat
and the combustion blower is not running the DJM3 has likely detected a false or grounded
tachometer signal. Remove all three wires to terminals O, YS, and G. If the combustion blower fails to
start, check the combustion motor and or motor wiring.
Magnet
Magnet Retainer Ring
Blower Shaft
Hall Effect
Sensor
1/8” Gap
If the combustion blower is running and the tachometer signal is absent, weak, or grounded. With a
digital AC voltmeter, measure the AC volts present on terminals “YS to G”. When the combustion
blower is running there should be 4 to 6 Vac present. If the AC voltage is not present, check the
tachometer sensor to magnet gap. It should be 1/16 to 1/8 inch. If the gap is satisfactory, attempt to
repair by flipping the magnet over, then flipping the tachometer sensor over, before replacing the
tachometer sensor to correct the problem.
Note: No part of the speed sensor’s sensing element should be located over the end of blower motor
shaft.
IOM-17 22 of 27 Mar 99 R3
A DJM3
IOM-17 23 of 27 Mar 99 R3
A DJM3
IOM-17 24 of 27 Mar 99 R3
A DJM3
Main Supply power ‘ON’
Service Switch ‘ON’
Fire alarm contact ‘CLOSED’
24Vac on terminals T1, T2
24Vac on terminals FS,HS
YES Equipment in
NO NO 24 Vac on
Heat call Fan Starts Night mode,
light ’ON’? after 30s? terminal fan operation
‘K’? is intermittent.
YES NO
YES
NO
Fan Starts YES Normal 24 Vac on Restore power
after 30s? Operation terminal to terminal
‘FS’? ‘FS’.
YES
NO
YES
If burner fires for
30s but fan does Fan Starts
not start after 30s?
NO
Problem External to NO
DJM3, check other
YES 24 Vac on
terminal Faulty DJM3
interrupting
‘SA’
contacts
IOM-17 25 of 27 Mar 99 R3
A DJM3
HEAT OPERATION FLOWCHART
Main Supply power ‘ON’
Service Switch ‘ON’ Heat call NO
Fire alarm contact ‘CLOSED’ Any lights
light ’2 SEC Flashing?
24Vac on T1,T2 FLASH’?
24Vac on FS,HS
YES
YES
NO
Heat call Restore 24Vac Indicates
No heat call to ‘HS’ possible
light ’ON’?
lockout
YES NO
NO
NO Faulty combustion fan
PP light Combustion
No output from terminal
’ON’? fan started?
’CB’
YES
YES YES
Pre‐Purge 10 Vdc on
Speed Sensor
light ‘2 SEC terminals
Problem
FLASH’? ‘O’ or ‘G’?
NO
Ignition
NO
Enable light DJM3 fuse YES
‘ON’? failure or faulty
Faulty DJM3 DJM3
Power goes to Ignition Unit stuck in NO
Control, burner will Pre‐Purge
light. Once DJM3
If 0 or 10 Vdc across ‘YS’ and ‘G’
receives feedback signal,
with Combustion fan running,
firing rate will modulate.
replace speed sensor
Normal operation
IOM-17 26 of 27 Mar 99 R3
A DJM3
UPGRADING DJM3.2 OR 3.3 to DJM3.4
IOM-17 27 of 27 Mar 99 R3