Replacement Parts   |  Troubleshooting  |  MaintenanceAnnual Inspection

 

Replacement Parts for Paint Booth Make-Up Air & Direct-Fired Air Handlers

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Direct fired air handlers provide heat, pressurization and/or ventilation to the space. Over the life of the heater, parts will need to be replaced. The customer service team at Bananza will be able to assist with part identification. BANANZA® Replacement Parts are warranted for a period of 12 months from date of shipment from Bananza or the remaining BANANZA® B-Series warranty. Before ordering replacement parts, please contact the factory to make sure that replacement parts are the direct replacement for your specific unit. Common part descriptions are included below for reference.
 

Ignition Module (7800-Series) - Functioning as the brain of the air handler, Ignition Modules are standard on every air handler, located in the unit control enclosure.
 

Flame Amplifier (7800-Series) - Flame Amplifier transmits a 5V signal, indicating the presence or lack of presence of flame from the ultraviolet scanner. This amplifier locks into the bottom of the standard ignition module.
 

Ultraviolet Scanner - Ultraviolet Scanner (UV) detects radiation emitted from the burner flame. A signal is sent back to the flame amplifier on the ignition module.

 

Purge Card (7800-Series) - Purge Card provides pre-purge timing for the flame module. Once dust cover has been removed, purge card can be inserted.
 

Amplifiers (1014, 1044, 1494) - Amplifiers supply output voltage to the modulating regulating valve based on incoming information from the temperature sensor and Selectrastat (temperature selector). With the addition of positive low fire start, allows for the burner to start in low fire rather than high fire during air handler start-up.

 

Selectra® Modulating Valves (M/MR-Series) - Modulating / Modulating/Regulating Valves (MRV) perform dual function of gas modulation and pressure regulation. Valves are standard on every air handler.

 

Safety Shutoff Valves (SSOV) - Safety Shutoff valves are available in 2psi or 5psi version on ANSI-Compliant, FM-Compliant and XL-Compliant manifolds. Visual indicators are included on safety shutoff valves for vehicle finishing applications. 

 

Pilot Regulator / Solenoid - Pilot Regulator/Solenoid allows for use of on/off control of gas flow to the pilot burner. Combination CV100 valve allows for maximum inlet gas pressure of 14" wc and two valve system allows for maximum inlet gas pressure of 5psi.

 

High & Low Gas Pressure Switches -  gas pressure switches monitor gas pressure against the gas pressure setpoint. Burner will turn off if actual pressure exceeds setpoint. 

 

Airflow Switches - Airflow switches ensure proper airflow across the burner by measuring pressure differential. Each air handler features two non-adjustable switches monitoring low limit at 0.32" wc and high limit at 1.4" wc. 

 

Ignition Transformer - Ignition Transformer provides power to the spark plug for proper burner ignition. Ignition transformers are standard on every air handler.

 

Micron Control Transformer - Micron Control Transformer reduces incoming voltage from 208V/230V/460V/575V to 120V for control components. 

 

Fused Rotary Disconnect (ABB) - A fused rotary disconnect disconnects the electrical supply from the air handler. The main component located within the control enclosure has protruding shaft to exterior red handle. Red handle on exterior cabinet door must be in OFF position to allow door to open. 

 

High Temperature Limit Switch - High Temperature Limit Switch monitors the temperature of the discharge air and shuts off the burner is above pre-determined setpoint. The burner can be re-started after the switch has cooled down and the manual reset button has been depressed. 

 

Discharge Temperature Sensor - Discharge Temperature Sensor senses and transmits the temperature of the discharge air back to the amplifier. Standard on every air handler for use with standard remote panel. 

 

Mixing Tube - Mixing tube houses the discharge air temperature sensor. Air is drawn into the tube through exterior holes and allows accurate temperature reading. Standard on every air handler for use with standard remote panel. 

 

Maxon Burner - Maxon NP-II LE burners deliver for 30:1 turndown ratio. Burner section lengths vary by model size but each six inch section produces a maximum of 400,000 btu/h. The burner features stainless steel mixing plates attached to a cast iron manifold. 

 

Variable Frequency Drive (VFD) - Variable Frequency Drives available in various voltages (208/230/450/575) and up to 30HP motors. For variable air volume units, based on the information received from the photohelic, the blower speeds up or slows down by modulating the frequency of the electrical power supplied to the motor. For vehicle finishing applications, exhaust fan speeds can be adjusted.

 

Dwyer Photohelic - For variable air volume units, Dwyer Photohelic located in the control enclosure compares actual indoor vs. outdoor pressure differential to pressure differential setpoint. The high low limits are field adjustable.

 

Dwyer Null Pressure Switch - For air management units, Dwyer Null Pressure Switch compares actual indoor vs. outdoor pressure differential to pressure differential setpoints. The switch is field adjustable. 

 

Signal Conditioner - Signal Conditioner controls burner modulation through the regulation of the modulating/regulating valve. The regulation is based on incoming 0-10vDC or 4-40mA singal from the building management system. The signal conditioner is used alternatively to a standard remote panel. 

 

Air Handler Discharge Air Blower - A double width, double inlet (DWDI), forward curved (FC), v-belt driven blower, located within the air handler housing supplies fresh, heated discharge air into the space. Structural steel framework supports the main blower housing. 

 

Motors - The single speed motor installed within the cabinet of the air handler is sized for appropriate voltage (208/230/460/575) and available as ODP (open drip proof) or TEFC (totally-enclosed, fan cooled). 

 

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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. 


Troubleshooting for Paint Booth Make-Up Air & Direct-Fired Air Handlers

In the event of the air handler not working properly, there are several areas in and around the heater to check for problems. Before resolving any issues, the following initial checks should be corrected:

  1. Compare voltage and phase of supply power on site with rating plate information.
  2. Review the wiring diagram connections between remote panel and control panel. Do the electrical connections match the supplied wiring diagram?
  3. Compare gas type and supply pressure on site with rating plate information. 
  4. Check for proper blower rotation on air handler and any exhaust blowers.
    • Blowers powered with a three phase motor can be reversed by swapping any two incoming power legs. For blowers powered by a single phase motor refer to the motor rating plate for reversing instructions. 

 MOTOR PROBLEM: MOTOR DOES NOT OPERATE

 POSSIBLE CAUSE

 SOLUTION

 Main disconnect switch is OFF

 Turn disconnect switch ON

 Blown fuse(s) in disconnect

 Replace fuse(s)

 Blown fuse(s)/breaker tripped in control transformer

 Replace fuse(s)/reset breaker (with disconnect off)

 Fan switch on, power on terminals 3 / 3A

 Check wiring between remote panel and air handler. Replace switch.

 Cool down timer TD4 (if equipped) does not reset. Power on 3A?

 Replace TD4 timer.

 Optional: Damper does not open

 Check that damper is not obstructed. Check that linkage is tight and secure. Verify 120V at terminal 3B. Replace damper actuator.

 Time delay relay defect. Power on terminal 3D after set time delay?

 Replace time delay relay TR1.

 Motor starter (contactor) does not operate. Power on terminal 3D and 2?

 Replace starter.

 Tripped motor overload. Power out to MUA motor when motor starter is energized?

 Reset. Check for proper FLA setting. Replace overload. If applicable, tighten screws on heater packs or overload.

 BLOWER PROBLEM: BLOWER DOES NOT OPERATE

 POSSIBLE CAUSE

 SOLUTION

 Belts broken or loose?

 Replace/tighten belts.

 Loose motor or blower sheaves (pulleys)?

 Reinstall and properly torque set-screws.

 Blower bearings, doe they turn freely?

 Replace bearing(s).

 BURNER PROBLEM: FLAME CONTROL DOES NOT TRY FOR IGNITION

 POSSIBLE CAUSE

 SOLUTION

 Auxiliary contact "M1" not closed. Power on terminal "4"?

 Properly mount contact or replace.

 Burner/winter switch closed? Power on terminal "7"?

 Replace switch.

 High temp limit switch tripped? Power on terminal "8"?

 Manually reset switch or replace.

 Low airflow pressure switch contacts not made. Power on terminal "8A"?

 Check blower operation. Reconnect tubes to pressure switch. Clean pressure test tubes. Check filters/duct work for restrictions.

 High airflow pressure switch contacts not made. Power on terminal "9"?

 Check blower FLA and compare to data plate. Cabinet pressure too high check system setup and for restrictions downstream of blower.

 Optional: Mild weather stat, dial set too low

 Set dial higher. Replace stat.

 Optional: High gas pressure switch

 Manual reset. Verify gas pressure.

 Optional: Low gas pressure switch

 Manual reset. Verify gas pressure.

 No power between terminals 3 and L2 (neutral) or 6 and L2 (neutral) for RM7890A (5 and L2 (neutral) or 7 and L2 (neutral) for RM7897C) of the burner control base

 Verify wiring.

 Flame control defect

 Replace.

 BURNER PROBLEM: BURNER LOCKOUT

 POSSIBLE CAUSE

 SOLUTION

 Failure to ignite pilot or main flame. Flame control failure.

 Reset the flame control module at the unit and proceed to the next step, observing the unit to indicate at which step lockout condition occurs.

BURNER PROBLEM: NO PILOT FLAME

 POSSIBLE CAUSE

 SOLUTION

 UV flame sensor indicating presence of flame before ignition. Flame indicator light present? Is there 5VDC on UV flame amplifier?

 Separate spark wire and UV scanner wires. Replace UV flame sensor, UV flame amplifier or burn control. 

 No spark

 Check wiring from burner control to ignition transformer. Check high tension wire to spark plug. Replace ignition transformer.

 No gas

 Open manual gas shut off valves. Check wiring from burner control to pilot gas valve. Verify inlet gas pressure. Adjust pilot gas pressure. Replace pilot gas valve. Check burner pilot opening for obstruction.

 BURNER PROBLEM: PILOT FLAME DOES NOT STAY LIT

 POSSIBLE CAUSE

 SOLUTION

 Improper pilot gas pressure

 Adjust pilot gas pressure.

 UV flame scanner does not detect flame. Is there 5VDC on UV flame amplifier?

 Replace UV scanner. Replace UV flame amplifier.

 UV flame scanner dirty

 Clean UV scanner

 BURNER PROBLEM: NO MAIN FLAME

 POSSIBLE CAUSE

 SOLUTION

 Manual shut off valve closed

 Open manual shut off valve

 Safety Shut Off Valve not operating. Is there positive gas pressure downstream of SSOV?

 Check wiring from burner control to SSOV. Verify inlet gas pressure. Replace SSOV.

 Minimum gas supply pressure

 Verify minimum gas supply pressure as per data plate is available

 Burner openings obstructed

 Remove obstruction. Clean burner orifices holes.

 Improper burner lower fire adjustment on modulating valve

 Adjust low fire as per the relevant temperature control instructions.

 

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. 


Maintenance for Paint Booth Make-Up Air & Direct-Fired Air Handlers

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.
 

 

Annual Inspection for Paint Booth Make-Up Air & Direct-Fired Air Handlers

To avoid "no-heat" situations in the middle of winter, Bananza recommends that customers get a thorough inspection of their equipment on an annual basis by a contractor qualified in the installation and service of direct-fired air handlers.

The list below is not comprehensive. For complete product and service instructions, see the Installation, Operation and Service Manual

 

 Area Around the Direct-Fired Air Handler*

 Do not store or use flammable objects, liquids or vapors near the equipment. Do not  hang anything or place anything on the air handler. Keep area under and around  equipment free of all objects. Minimum clearances to combustibles around the vent  pipe are significantly higher than the air handler. Maintain a minimum of 36" (91.4 cm) around the vent pipe. 

 Mounting Equipment  / Accessories

 Check strength of mounting equipment (stands, legs, suspension kit, roof curb etc.). Repair or replace as required.

 Cabinet

 Check paint (if applicable) and caulking. Inspect housing insulation for loose areas. Repair as required Lightly grease all door latches. 

 Blower

 Check blower wheel. Clean as required.

 Blower Bearings

 Check condition and tightness of blower bearings and set screws. Check alignment. Lubricate blower bearings. Replace as required.

 Direct-Fired Burner

 Check and clean as per manufacturer's supplier instructions. Inspect vertical models for accumulation of condensation. Clean burner plates and drill burner orifices annually.

 Belts

 Check blower belt tension and re-adjust as required. Check belts for wear and replace as required.

 Sheaves

 Check sheaves for wear and alignment. Adjust or replace as required.

 Flame Sensor

 Check UV scanner or flame rod. Clean scanner lens; check position of flame rod. Replace as required.

 Burner Igniter

 Inspect and clean or replace as required. Set the gap to 0.778" (2mm).

 Blower Motor

 Check and lubricate as per manufacturer's instructions. Replace as required.

 Controls / Remote Panel

 There should be no exposed wire or damage to the device or wiring. Replace as required.

 Gas Controls

 Check gas control assembly and internal / external piping for leaks. Relief vent lines to outdoors should be checked for blockages. Clean as required.

 Electric Controls

 Check all electrical connectors for tightness. Tighten as required.

 Safety and Control Components

 Check and clean all safety and control components. Inspect tubing for obstructions. Confirm operation of all safety switches. Clean or replace as required.

 Temperature Transmitters

 Check and calibrate as required.

 Dampers

 Check linkage and tighten set screws as required. Clean and lubricate, as required.

 Filters

 Check filters and clean or replace as required. Calibrate clogged filter switch (if applicable).

 Ductwork

 Consult an indoor air quality professional for proper cleaning procedures. Check flexible duct connection for deterioration. Repair as required. Minimum temperature rating for flexible duct connections must be 500°F (260°C).

 Wall Tag

 If a wall tag is present, make sure it is legible and accurate. Please contact Bananza or your BANANZA® independent distributor if you need a wall tag. 

 Safety Labels and Signs

 Product safety signs or labels should be replaced by the product user if they are no longer legible. Please contact Bananza or your BANANZA® independent distributor to obtain replacement signs or labels.  

 Vent Pipe and Terminals

 Look for dirt, obstructions, cracks on the pipe, gaps in the sealed areas or corrosion. Clean or replace as required. Do not use the heater if there is dirt, sagging, cracking or distortion. Remove any carbon deposits or scale using a wire brush. If applicable, check insulation of vent pipe. Repair as required. Insulation must have a minimum temperature rating of 1000°F (538°C)

* Maintain clearances to combustibles at all times for safety. Clearances are the required distances that combustible objects must be away from the air handler to prevent serious fire hazards. Items found within the clearances to combustibles area must be immediately removed. Please contact Bananza or a BANANZA® independent distributor to obtain the latest version of the Installation, Operation and Service Manual.