Heater Maintenance

Direct fired air handlers require annual maintenance to ensure long life of the heater. At the beginning of each heating season, the air handler should be checked and cleaned to ensure optimal operation. Prior to any maintenance or service of the air handler, shut off, lockout and tagout the electrical disconnect and gas valve that supplies the unit in accordance with OSHA regulations and allow sufficient time for the air handler to cool. After maintenance is performed or direct fired air handler is serviced, the air handler shall be re-commissioned to the start-up procedures as outlined in the Installation, Operation and Service Manual. 
 

 GENERAL

 First 8 Hours of Operation

 Check belts and adjust as required. Belts were properly adjusted at factory start-up, they will stretch after the first few hours of operation. 

 First 100 Hours of Operation

 Re-check belt tension and adjust as necessary.

 Annual Fall Start-Up

 Follow entire start-up procedure at this time and check control settings and operation. 


 UNIT EXTERIOR

 Cabinet Exterior

 After installation, touch up scratches. Periodic painting (if required) should be done there after as required. Caulk around the weather enclosures and over field joints should be inspected annually. Re-apply caulk as needed to maintain integrity. Warning labels and logo labels should be legible and accurate. Contact Bananza or BANANZA® independent distributor if you need replacement warning labels or logo labels. 

 Unit Location 

 Verify that no flammable objects, liquids or vapors are present near the air handler. Do not hang anything from or place anything on the air handler. Keep the area under and around the air handler free of all objects. Maintain clearances to combustibles at all times. 


 BLOWER SECTION

 Blower Wheel

 Inspect blower wheel and clean as necessary. A small build up of dust can cause a significant decrease in blower performance. Check for excessive vibration, repair as required. Critical labels are located on or near the blower housing (proper blower rotation label). 

 Drive, Belts and Sheaves

 Check the belt ride in the groove. In multiple groove drives, belt ride should be uniform. Check groove wear area for wear. Side wall of groove should be straight, not dished out. Bottom of groove should show no signs of belt contact. 
 Sheave alignment, set screw torque and belt tension should be checked after 8, 24 and 100 hours of initial start-up. Visually inspect belts and sheaves for excessive wear. If belts has a slick, glazed look, the belts are slipping. Check drive capacity and belt tension. Never replace only one belt in a used set, as used belts will elongate. Replace the entire set if replacement is necessary. 

 Blower Bearing Lubrication

 Blowers with spider bracket bearings are pre-lubricated and do not require any re-lubrication during their entire service life. Blowers that use pillow block bearings should be re-lubricated per the chart as indicated in the Installation, Operation and Service Manual. The recommended lubricant is Shall Alvania #2 or S3 grease. To re-lubricate the blower pillow block bearings, ensure clean grease fittings on the bearing housing (or air handler cabinet if extended grease lines have been installed). Apply the recommended grease to the fitting with a low-pressure grease gun and add slowly while the shaft is spun by hand. DO NOT OVER GREASE. Over-greasing will reduce the service life of the bearings. Consult the blower manufacturer for grease capacity recommendations as capacities vary by model. Blower manufacturer varies by model, consult factory with serial number to verify blower manufacturer. 

 Motor

 Inspect motor every 3 months or 500 hours of operation, which ever occurs first. Keep the motor clean and cent openings clear. 
Motors with grease fittings must be lubricated based on table in Installation, Operation and Service Manual. A high grade ball or roller bearing grease must be used. Recommended grease for standard service is Polyrex EM (Exxon Mobil). Other compatible greases include: Texaco Polystar, Rykon Premium #2, Pennzoil Pen 2 Lube and Chevron SRI. 
*** Before greasing, be sure fittings are clean and free from dirt. Remove grease relief plug or plate and using a low-pressure grease gun, pump in the required grease. DO NOT OVER GREASE. Over-greasing will reduce the service life of the motor. Consult the motor manufacturer for grease capacity recommendations as capacities vary by motor. After re-lubrication, allow motor to run for 10 minutes before replacing relief hardware. **** DO NOT mix greases of different brand types. If alternative brand is required, grease outlets must be purged of old grease before new grease is applied. Repeat this same operation after 1 week of service. 


  BURNER

 An annual inspection of the burner and components must be made to ensure proper and safe operation. For the most part, the burner is self-cleaning. However, if the application is extremely dirty or dusty, it may become necessary to periodically clean the burner. Inspect and clean the burner in accordance with the following recommended procedures. 

 1 

 To avoid damaging the valves, disconnect the burner piping from the manifold, at the union, and cover the exposed end of the manifold. 

 2 

 Unscrew the UV (ultraviolet) scanner from the side of the burner and clean the lens with a soft cloth.

 3 

 Remove ignition cable from the igniter on the side of the burner, then remove the spark igniter. Clean the igniter contacts with a wire brush. Set the gap to 0.078"  (2.0 mm).

 4 

 Inspect each of the stainless steel mixing plates to see that all of the air holes are free of debris. Clean with a wire brush as necessary. 

 5 

 The burner orifices may need to be drilled to unplug any closed orifices. Use a pin vise with appropriate drill to clean debris from the orifices. An electric drill is not recommended because it is easy to snap drill bits off in the orifices. 

 6

 Reinstall the UV (ultraviolet) scanner and the spark igniter. The UV scanner should be installed only finger tight as over tightening can result in damaging the lens. Reconnect the burner piping to the manifold at the union. 


 MANIFOLD AND CONTROLS

 Manifold

 Periodically check gas control assembly and internal and external piping for leaks. Relief vent lines to outdoors on gas controls should be checked to ensure against blockage caused by insects or any other substance. Clean as required. 
 All gas piping to the air handler must comply with the National Fuel Gas Code - NFPA54, latest edition and local codes. Verify gas soundness of each safety shutoff valve. This test must be repeated after the first 100 hours of operation. 

 Air Flow Switch

 An annual check of the tubes attached to the air flow switch should be made to ensure against blockage caused by insects or any other substance. Clean as required.

 Electric Components

 Check for physical damage on any of the electrical components and verify all electrical connections are secure. Ensure equipment is properly grounded. 

 Temperature Sensors

 Calibrate space, outdoor air and discharge air sensors as required. 



OPTIONAL EQUIPMENT 

 Dampers 

 Check linkage when applicable and tighten set screws as required. All moving parts of damper should be cleaned and then thoroughly lubricated with a light molybdenum oil in aerosol can. Damper furnished with stainless steel side seals should also have the seals lubricated generously. Dampers should then be manually operated several times until linkages and blades operate freely. Reconnect linkages and check dampers for proper orientation. 

 Filters

 Filters should be checked for dirt restriction on a monthly basis (or as required). Replace dirty filters with filters of equal specification when they appear dirty.
NOTE: Disposable polyester filters must be inserted with the white media side facing the inlet of the filter section. Both permanent aluminum mesh or disposable polyester filters must be inserted with the arrow on the filter pointing in the direction of the airflow (towards the air handler). 


 
All installation and service of BANANZA® equipment must be performed by a contractor qualified in the installation and service of equipment sold and supplied by Bananza and conform to all requirements set forth in the BANANZA® manuals and all applicable governmental authorities pertaining to the installation, service, labeling and operation of the equipment. 
To help facilitate optimum performance and safety, Bananza recommends that a qualified contractor conduct, at a minimum, annual inspections of your BANANZA® equipment and perform service where necessary, using only replacement parts sold and supplied by Bananza.