Corporate Profile and Operation Summary

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2 MAFNA AIR TECHNOLOGIES Inc. 475 Sheldon Dr, Cambridge, ON, Canada, N1T 2B7 V: (519) F: (519) Corporate Profile and Operation Summary About MAFNA MAFNA Air Technologies, Inc. established in the year 1999 as a result of over 22 years of knowledge and experience in innovative design & engineering in the field of Heating, Ventilation and Air-conditioning, business management, marketing and customer relationship. The principals of MAFNA started in the HVAC industry 23 years ago. Driven by their passion for designing innovative equipment and providing highest level of engineering services in the HVAC Industry, it was evident that their technical and entrepreneurial spirit of honesty and integrity would be the foundation for a reliable and dependable company in the long term. Since its inception MAFNA has demonstrated exemplary growth and is now represented in major local, US and Overseas market through a network of reputable representatives in the respective region. This growth convinced MAFNA that a combination of a team of top professionals and innovative thinking held huge national potential for this local based design, engineering and manufacturing company. Manufacturing: MAFNA has developed unique interactive manufacturing program that allows the firm to tap into manufacturing talent and technology of other industries as well. In addition to owning its own plant on a 3 acre land in an Industrial subdivision of the City of Cambridge, ON, Canada, MAFNA has excellent alliances and partnerships with dedicated fabricators and facilities. This alliance provides MAFNA the unique ability to offer enhanced products and services to its customers in Steel, Aluminum or Stainless Steel based custom built manufacturing. Knowledge: Delivering an innovative and affordable Air Handling Solution does not happen by chance. It requires a comprehensive understanding of all available technologies that can be delivered by a team of trained and experienced engineering professionals. MAFNA understands this reality and continuously invests in training and development of their engineers with an eye on excellence. All MAFNA Engineers have in-depth experience in all facets of design and engineering within the HVAC field, as is evident in the development of MAFNA s numerous products in Air Handling Solutions...1

3 MAFNA AIR TECHNOLOGIES Inc. 475 Sheldon Dr, Cambridge, ON, Canada, N1T 2B7 V: (519) F: (519) Customer and Client Partnerships: Choosing MAFNA as your Air Handling and Custom Built Equipment solution provider is a significant decision that we take very seriously. We believe in developing long lasting relationships with our clients built on repeated success and professionalism. We accomplish this by assuming a complete engineering and design responsibility for solutions that we provide from concept to commissioning. Innovation & Engineering: The various US patents awarded to Principals of MAFNA are a testimony to the ingenuity of MAFNA s Engineering team. Each of MAFNA s design and layout of custom-built equipment is premised on significant but proven innovation and creativity, majority of which are patent enabled. This is achieved by strong aptitude and commitment towards incorporating new technologies including computation fluid dynamics and 3D Technologies in critical Engineering and design applications. MAFNA s engineering team has a strong background in the application of aero-acoustics and aero-dynamics principles to Air Handling Solutions. MAFNA is currently supported by mix of Five (5) full time qualified engineers including two full time professional engineers in addition to three (3) part time / contract professional engineers, PHD scientists for the purpose of ongoing product development and innovation resulting in now three (3) additional patent applications in progress. In addition to engineering staff, MAFNA has at any point of time team of average of ten (10) shop floor personnel under various contract arrangements premised on flexible manufacturing. MAFNA leads the way with an extensive continuous support program. We are committed to assisting our local representatives & engineers with solid design, engineering and manufacturing backup. MAFNA s Business: Creative engineering and innovative product design based on principles of aero-acoustic and aerodynamic engineering are two principal offerings of MAFNA Air Technologies. The firm has strength in integrating different technologies to achieve multiple psychrometric process in a single compact and efficient custom design HVAC Equipment. The result is saving in space by up to 25% and energy by up to 30%...2

4 MAFNA AIR TECHNOLOGIES Inc. 475 Sheldon Dr, Cambridge, ON, Canada, N1T 2B7 V: (519) F: (519) What gives us the competitive edge? Location in a city that offers diversified national & international pool of talents in engineering and manufacturing with almost six world s top class universities within 2 hours drive. Strong commitment to ongoing technological development. Global approach to communication Brand name recognition. Proven operation system Enormous growth potential. Comprehensive training program Marketing program. Low fixed overheads Business Mix: MAFNA s business began as design and engineering arm for primary manufacturers with a role for sales, engineering, design and application which grew to 8.0 Million USD by the year MAFNA has since then repositioned itself and now offers the benefits of innovative design, engineering and manufacturing integrated with intimate knowledge of Heating, Ventilation and Air Conditioning and application of aero-acoustic principles & technologies in Air Handling Applications directly to the customers through reputable representation in respective region. -- End --..3

5 G A S F I R E D U N I T S S Air Technologies Inc. C USTOM B UILT H VAC E QUIPMENT

6 This typical specification is presented as a guide for typical specifications describing MAFNA Series IGF Indirect Fired, CSA/ETL approved, industrial gas furnace. Custom designs and accessories are available. Please consult your local MAFNA representative for additional specification details. Base Bid Specification The INDIRECT GAS FIRED INDUSTRIAL GAS FURNACE shall be a MAFNA Model IGF Indoor/outdoor design, factory fabricated, assembled, pre wired and fire tested prior to shipment. The unit will be split when necessary to facilitate shipment. Field installation will include mechanical and electrical reassembly at the shipping splits. The unit shall be capable of providing at design conditions the following: Airflow Rate: ACFM Entering Air Temperature: F Leaving Air Temperature: F External Static Pressure: "W.C. Main Fan Motor Size: HP Induced Draft Fan Motor Size: HP Heat Output: BTUH Heat Input: BTUH Power Supply: V P CY Fuel Supply: Natural Gas / Propane/ #2 Light Oil Fuel Pressure: Unit Casing The unit casing and accessories shall be heavy gauge G-90 Galvanized steel. Outdoor units include a weatherized enclosure rated to -40 F, to house the controls and valve train, c/w hinged access doors secured with captive type fasteners. The paneled casing is to be fastened with zinc plated neoprene grommeted metal screws equally spaced at 6" centers and sealed at seams. The unit casing shall be airtight (and weather-proof/outdoor). Hinged access panels incorporating stainless steel piano type hinges with stainless steel pin shall be supplied to allow physical access to all components requiring periodic maintenance and inspection. Access panel frames shall be gasketted and doors shall be equipped with captive type fasteners to ensure airtight closure. The integral channel base will come complete with lifting lugs. All insulated units (walls, roof and floor) come complete with 2" - 3 lb. non wicking insulation and full metal liner to eliminate air born fibers from entering the air stream. Fan Section The unit shall be supplied with AMCA rated centrifugal plenum fan designed without a scroll type housing. Fans shall incorporate a non-overloading type backward inclined airfoil blade wheel, heavygauge reinforced steel inlet plate, structural steel frame and shaft and bearings. The fan assembly shall be located downstream of the burner. Fan shall be belt driven by high efficiency EPAC type ODP motor installed within the fan plenum and the entire fan assembly mounted on Open type spring vibration isolators and having an OSHA belt guard. The Supply voltage shall be volts cycle phase. The motor shall be pre wired in flexible conduit to the control panel. Heat Exchanger The heat exchanger shall be rated at a minimum 80% efficiency at rated output. The flue gas travel shall be of four pass design, with no internal baffles. The primary heat transfer surface and heater shall be of stainless steel; the secondary heat transfer surface steel boiler tube (specify stainless steel for 1

7 100% outside air applications). The heating surface area of the primary and secondary heat transfer surface shall be ft² and ft² respectively. The heat exchanger design shall permit unrestricted lateral and peripheral expansion during the heating and cooling cycle. The surface temperature of the heat exchanger shall not exceed 75% of its scaling temperature when operating at rated capacity. A pressure relief door complete with an observation window to view the complete flame and pilot shall be provided. The heat exchanger is also available in two and three pass design, without induced draft fan. Induced Draft Fan An integrally mounted, heavy duty, radial blade induced draft fan shall be provided. The induced draft fan shall be equipped with a manual damper complete with locking quadrant to ensure proper draft, rated efficiency and extended heat exchanger performance. Electrical Controls An EEMAC 1 control panel complete with hinged access door shall be mounted on the unit and wired. All control components are to be labeled and individually wired to a numbered terminal strip to aid in servicing. All wiring shall be color coded and number tagged at each end to match the control diagram supplied. Full operating and maintenance instructions shall accompany each unit. All wiring between the controls and valves on indoor units shall be enclosed in flexible conduit. All wiring on outdoor units outside of the weather enclosure shall be enclosed in liquid tight flexible conduit. The control system shall include the following components required for automatic operation: Control circuit transformer Control circuit fuses Fan motor starter and overloads Low fire hold relay Electronic flame relay complete with alarm contacts Supply air high and low velocity air sensing switches High air temperature limit switch Heavy duty ignition transformer UV flame sensor(s) / flame rod(s) Discharge air temperature control system with unit mounted temperature sensor Gas Burners Gas burner shall be of the low pressure forced draft type with integral combustion air blower and motor, combustion air proving switch and removable pilot assembly. An electronic programming relay with flame rod (scanner) shall be used for flame supervision. The pre wired and pre piped valve train shall be mounted on the furnace, complete with appliance gas pressure regulator; automatic shut off valve; firing cock; manual pilot shut off cock; pilot gas pressure regulator; automatic pilot valve; and an adjustable orifice/shut-off cock. A lubricated plug cock shall be provided for field mounting of unit. The burner shall fire natural gas (propane gas) and be arranged for: a) "on/off" control with low fire start b) "high/low/off" control with low fire start c) full modulation with low fire start and a turndown ratio. Light Oil Burners The oil burner shall be of the high pressure atomizing type with integral combustion air blower and motor, air diffuser ring, two-stage fuel pump and combustion air damper. The removable drawer assembly shall contain oil nozzles and ignition electrodes. An electronic programming relay with the scanner shall be used for flame supervision. The pre wired, pre piped valve train shall be mounted on the unit and come complete with oil filter; shut-off valve; union; oil shutoff and pressure reducing valve; heat dissipating coil; and solenoid valve(s). Burner shall fire No. 2 fuel oil with a maximum viscosity of 40 SSU at 100ºF and be arranged for: a) "on/off" control with low fire start b) "high/low/off" control with low fire start c) full modulation with low fire start and a turndown ratio. 2

8 Optional Accessories Room thermostat (specify operation) Low limit controller (specify operation) - mounted and wired Mixed air controller (specify operation) - mounted and wired Discharge controller (specify operation) - mounted and wired Damper potentiometer (panel mounted or remote) Panel mounted circuit analyzer lights (specify function) EEMAC 12 remote control station c/w oil tight "summer / off / winter switch", oil tight "burner on" pilot light and oil tight "fan on" pilot light (specify additional annunciation and control as required: eg. "filter clogged") EEMAC 1 remote control station c/w "summer / off / winter switch", "burner on" pilot light and "fan on" pilot light (specify additional annunciation and control as required: eg. "filter clogged") Programmable day / night / week-end temperature set-back system with spring carry over Built to (FM or CIRI) standards Inlet cowl and bird screen Prefabricated perimeter roof curb with wooden nailer strip Discharge plenum c/w adjustable discharge nozzles High gas pressure regulator with full relief for field mounting at unit (required when gas pressure exceeds 14" W.C.) Return air screen - removable Motorized parallel blade (fresh air inlet, return air, and/or discharge) damper(s) c/w 16 gauge galvanized steel blades and cycoloy bearings. Blade and jamb seals - optional Suspension lugs Stainless Steel secondary tubes and headers Fan and motor assembly mounted on rubber in shear/spring type vibration isolators Cooling coil section c/w condensate pan and drain V-Bank filter box c/w 20% (ASHRAE ) 2", 4" replaceable filter media mounted in permanent galvanized steel frames. V-Bank 30% (ASHRAE ) 2, 4 pleated throwaway filters Magnahelic filter gauge - unit mounted Prefabricated 16 gauge exhaust stack (outdoor units only) Arrangement (H or V) service platform c/w high guard rails, safety chain and 6" kick plates Internal bypass c/w (manual or motorized) bypass damper Weatherized enclosure to house controls and valve train, rated -40 F design, c/w hinged access doors secured with captive type fasteners Heated (thermostatically controlled) and insulated weatherized enclosure to house controls and valve train, rated -60 F design, c/w hinged access doors secured with captive type fasteners "Filter clogged" light and unit mounted adjustable pressure differential sensing switch Freezestat mounted and wired c/w override timer to allow unit to start during purge cycle Enclosure service light, receptacle and switch mounted and wired for separate 120 volt supply Backward inclined fan assembly c/w discharge evases for efficient operation and shaft coupling to aid in alignment and servicing Lubricated main manual shut off valve for field mounting at the unit Backward inclined or backward inclined airfoil fans Fan and motor assembly mounted on rubber in shear/spring type vibration isolators TEFC motors Variable volume bypass section Corrosion resistant epoxy paint Dead front door interlocked disconnect switch Subcircuit fuses Electronic building pressure control systems 3

9 Engineering Ratings Chart -Horizontal IGF Model Model Number HIGF-250 HIGF-350 HIGF-400 HIGF-500 HIGF-550 HIGF-650 HIGF-750 Output Capacity btu/hr Air volume - Delta T 85 F Fan TSP/ESP - " Wg 3.5/ / / / / / /2.0 Supply Fan Size ( Plenum Type ) 161-I 201-I 201-I 221-I 251-I 251-I 281-I Fan RPM Fan BHP Motor HP Max Fan Size /Motor Frame 221/ / / / / / /286 Model Number HIGF-850 HIGF-1000 HIGF-1250 HIGF-1500 HIGF-1750 HIGF-2000 HIGF-2500 Output Capacity btu/hr Air volume - Delta T 85 F Fan TSP/ESP - " Wg 3.5/ / / / / / /2.0 Supply Fan Size ( Plenum Type ) 281-I 281-I 321-I 321-II 321-II 391-II 441-II Fan RPM Fan BHP Motor HP Max Fan Size /Motor Frame 281/ / / / / / /365 Model Number HIGF-2750 HIGF-3000 HIGF-3500 HIGF-4000 HIGF-5000 HIGF-6000 Output Capacity btu/hr Air volume - Delta T 85 F Fan TSP/ESP - " Wg 4.0/ / / / / /2.0 Supply Fan Size ( Plenum Type ) 441-II 491-II 491-II 491-II 631-II 631-II Fan RPM Fan BHP Motor HP Max Fan Size /Motor Frame 441/ / / /365 '711/365 '711/365 4

10 H ORIZONTAL U NIT 5

11 Engineering Ratings Chart -Vertical IGF Model Model Number VIGF-250 VIGF-350 VIGF-400 VIGF-500 VIGF-550 VIGF-650 VIGF-750 Output Capacity btu/hr Air volume - Delta T 85 F Fan TSP/ESP - " Wg 3.5/ / / / / / /2.0 Supply Fan Size (Plenum Type) 161-I 201-I 201-I 221-I 251-I 251-I 281-I Fan RPM Fan BHP Motor HP Max Fan Size /Motor Frame 221/ / / / / / /286 Model Number VIGF-850 VIGF-1000 VIGF-1250 VIGF-1500 VIGF-1750 VIGF-2000 VIGF-2500 Output Capacity btu/hr Air volume - Delta T 85 F Fan TSP/ESP - " Wg 3.5/ / / / / / /2.0 Supply Fan Size (Plenum Type) 281-I 281-I 321-I 321-II 321-II 391-II 441-II Fan RPM Fan BHP Motor HP Max Fan Size /Motor Frame 281/ / / / / / /365 Model Number VIGF-2750 VIGF-3000 VIGF-3500 VIGF-4000 VIGF-5000 Output Capacity btu/hr Air volume - Delta T 85 F Fan TSP/ESP - " Wg 4.0/ / / / /2.0 Supply Fan Size (Plenum Type) 441-II 491-II 491-II 491-II 551-II Fan RPM Fan BHP Motor HP Max Fan Size /Motor Frame 441/ / / /365 '551/365 6

12 V ERTICAL U NIT 7

13 MATI SERIES Indirect Fired Gas Furnace G AS F URNACE Components: 1. Tube cleanout 2. Induced draft fan 3. Indirect fired burner 4. Control panel c/w disconnect 5. Valve train 6. Alternate down discharge 7. Inspection port Notes: 1. All dimensions are shown in inches and are subject to manufacturing tolerances gauge stainless steel primary chamber gauge stainless steel secondary chamber. E L E V A T I O N P L A N MODEL A B C D E F G MATI MATI MATI MATI MAT N/A 13 MATI N/A 13 MATI N/A 16 MATI N/A 14 MATI N/A 14 8

14 Engineering Ratings Chart For Burners Model Number (MATI) Input Capacity btu/hr Output Capacity btu/hr Main supply fans - quantity/size 2/9 2/10 2/12 2/15 2/15 2/15 2/18 Discharge heads - quantity/size 2/15 2/15 3/15 3/15 3/15 4/15 4/15 Nominal air volume FDT Throw in feet with 90 deg. Nozzles Throw in feet with 45 deg. Nozzles Induced draft fan motor horsepower 1/3 1/3 1/3 1/3 1/3 1/3 1/3 Standard gas burner motor horsepower 1/4 1/4 1/3 1/3 1/3 1/3 1/3 Standard oil burner motor horsepower 1/2 1/2 1/2 1/2 1/2 1/2 1/2 Recommended stack diameter - inches Primary heating surface - square feet Secondary heating surface - square feet Primary combustion chamber - gauge Secondary tubes - gauge Natural gas connection with 7" - 14" W.C. inlet pressure - inches N.P.T 3/4 3/ /4 1 1/4 Natural gas connection with 14" W.C. and over inlet pressure - inches N.P.T 3/4 3/4 3/

15 Engineering Ratings Chart Model Number (MATI) Input Capacity btu/hr Output Capacity btu/hr Main supply fans - quantity/size 2/18 2/20 2/20 2/22 2/25 2/25 2/27 Discharge heads - quantity/size 4/15 4/15 4/18 4/18 4/18 5/18 5/18 Nominal air volume - DT=85F Throw in feet with 90 deg. Nozzles Throw in feet with 45 deg. Nozzles Induced draft fan motor horsepower 1/2 1/2 3/4 3/4 3/4 3/4 2 Standard gas burner motor horsepower 1/2 1/2 1/2 3/4 3/4 1 1 Standard oil burner motor horsepower 1/2 1/2 1/2 3/ Recommended stack diameter - inches Primary heating surface - square feet Secondary heating surface - square feet Primary combustion chamber - gauge Secondary tubes - gauge Natural gas connection with 7" - 14" W.C. inlet pressure - inches N.P.T 1 1/4 1 1/2 1 1/ Natural gas connection with 14" W.C. and over inlet pressure - inches N.P.T 1 1/4 1 1/4 1 1/4 1 1/4 1 1/2 1 1/2 1 1/2 10

16 Engineering Ratings Chart Model Number (MATI) Input Capacity btu/hr Output Capacity btu/hr Main supply fans - quantity/size 2/27 2/30 2/30 2/36 2/36 2/36 Discharge heads - quantity/size 6/18 7/18 7/18 7/ Nominal air volume - DT 85F Throw in feet with 90 deg. Nozzles Throw in feet with 45 deg. Nozzles Induced draft fan motor horsepower Standard gas burner motor horsepower 1 1 1/ Standard oil burner motor horsepower Recommended stack diameter - inches Primary heating surface - square feet Secondary heating surface - square feet Primary combustion chamber - gauge Secondary tubes - gauge Natural gas connection with 7" - 14" W.C. inlet pressure - inches N.P.T 2 1/2 2 1/ Natural gas connection with 14" W.C. and over inlet pressure - inches N.P.T /2 2 1/2 2 1/2 2 1/2 11

17 MATI SERIES Indirect Fired Gas Furnace VALVE T RAIN Components 1. A low pressure manifold with full modulation control is standard. Minimum inlet pressure is 7 W.C., maximum 14 W.C. 2. A high pressure manifold is optional. A high pressure regulator with overpressure relief is supplied for field mounting. 3. A gas overpressure relief valve may be omitted if the primary pressure regulator is a full internal relief type and can provide limiting downstream pressure to a maximum of 2 PSI. 4. Not required when proof of closure switch is used. 5. When units have inlet ductwork, filters or dampers where leaking gas could pocket, F.M. requires a vented manifold. 6. All vents to atmosphere by installing contractor. 7. Vent valve is required over 1,000,000 btu/hr. 8. Auxiliary valve is required over 1,000,000 btu/hr. 1 T BURNER 3/8" T T T T ITEM DESCRITION STD. STD. FM TO 5PSI OVER 5PSI FM WITH VENT CIRI OPT. 1 MANUAL GAS VALVE X X 2 HIGH PRESSURE GAS REGULATOR X 3 RELIEF VALVE X 4 PILOT MANUAL VALVE X X X X X 5 PILOT PRESSURE REGULATOR X X X X X 6 PILOT SOLENOID VALVE X X X X X 7 APPLIANCE PRESSURE REGULATOR X X X X X 8 MAIN SAFETY SHUT-OFF VALVE X X X X X 9 LOW PRESSURE GAS SWITCH X X X 10 LEAK TEST VALVE X X X 11 N.O.VENT VALVE X X (7) 12 HIGH PRESSURE GAS SWITCH X X X X 13 AUXILLIARY SAFETY SHUT-OFF VALVE X (4) X (4) X X (8) 14 FIRING VALVE X X X X X 15 MODULATING GAS VALVE X X X X X 16 PILOT FIRING VALVE X X X X X 12

18 MATI SERIES Indirect Fired Gas Furnace E LECTRICAL WIRING D IAGRAM 13

19 MATI SERIES Indirect Fired Gas Furnace S T A C K Notes: 1. Cleanout supplied with 3/4 diameter drain gauge continuously welded, painted with high temperature paint. 3. Stack must be supported from building structure. MODEL A B C MATI MATI MATI MATI MATI MATI MATI MATI MATI

20 MATI SERIES Indirect Fired Gas Furnace INDUCED DRAFT FAN Components: 1. ODP induced fan motor, available in TEFC. 2. Exhauster damper c/w locking quadrant. 3. High temperature, heavy duty radial paddle wheel. Notes: 1. All dimensions are shown in inches and are subject to manufacturing tolerances wheels to be belt driven. MODEL WHEEL A B C D E F MATI MATI MATI MATI

21 MATI SERIES Indirect Fired Gas Furnace TYPICAL ROOF CURB A B RETURN AIR OPENING TOP OUTLINE OF PRE-FABRICATED CURB NOTE 3 SUPPLY AIR DISCHARGE OPENING Notes: 1. Roof curbs are fabricated from heavy gauge G Roof curbs are shipped knocked down, asembly hardware is supplied for field assembly. INSULATION AS REQUIRED UNIT CASING RAISED OPENING INTEGRAL BASE OF UNIT CAULKING (BY OTHERS) 2" 2" INSULATION CUSTOMER DUCTING (BY OTHERS) 14" CURB INSULATION (BY OTHERS) 3" BUILDING STRUCTURE (BY OTHERS) TYPICAL VIEW THROUGH CURB ASSEMBLY 16

22 MATI SERIES Indirect Fired Gas Furnaces Gas Furnace I.D Fan Air Proving Switch Combination High Limit & Fan Switch Firing Valve FM High Limit Switch Induced Draft Fan Maxon Ovenpak II Burner Modulating Air & Gas Actuator Appliance Gas Regulator Low Pressure Gas Switch Maxon Safety Shut off Valves High Pressure Gas Switch Low Ambient Stat Valve Train Control Panel (inside) 17

23 Standard 4 Pass Combustion Chamber Fused Dead Front Disconnect Airflow Motor Starters Air Flow Primary Section Secondary Section Puff Door Puff Door Easy access to cleanout tubes 18

24 Locking Quadrant Heavy Gauge Steel Motor Slide Base Induced Fan Note: Purchased high temperature heavy duty radial paddle wheel. Full Voltage Motor Induced Fan Otional Induced Draft Fan Guard 19

25 INDEX 1. Installation Instructions for Indirect Gas Fired Industrial Space Heaters 1. Gas Installation 2. Combustion Air Requirements 3. Exhaust Stacks 4. Electrical Connections 2. Starting and Operating the Heater 1. Precautions before Starting the Heater General 2. Precautions before Starting the Heater Gas 3. Start-up Instructions General 4. Start-up Instructions Gas 3. Shut Down Instructions 1. General Instructions 2. Emergency Shut Down 3. Summer Shut Down 4. Maintenance 1. Qualifications of Maintenance Personnel 2. Monthly Maintenance 3. Quarterly Maintenance 4. Off-season or Yearly Maintenance 5. Lubrication of Bearings 6. Electrical Maintenance 5. Sequence of Operation 1. Basic Operation 1.1 Gas Installation Gas fired heaters shall be installed in accordance with the Installation Code for Gas Burning Appliances and Equipment, CAN/CGA 1-B.149, an appli cable Provincial Regulations for the class of heater being installed. Authorities having jurisdiction should be consulted before installations are made. Mount the manual shut-off valve and the high-pressure gas regulator and relief valve, if required, in the gas line to the heater. The high-pressure regulator and relief valve should be, if possible, mounted at least 5 to 10 feet upstream from the appliance regulator on the heater. Run the gas line to the heater and mount these items so as not to interfere with or access to the heater or any of its com ponents. The gas line to the heater should be taken off the top of the gas line. A drip leg with screwed cap should be installed at the bottom of the vertical drop in the gas line to the heater. Vent the main appliance regulator, the pilot regulator, the main automatic gas valve, the auxiliary gas valve (if supplied), to atmosphere. Gas pressure switches, if supplied, must also be vented. The high-pressure regulator relief valve and normally open vent valve, if supplied must be vented to atmosphere separately from all the components. Vent lines should terminate outside the building with turndown elbow and bird screen. Vent lines must be sloped to a condensate drip leg. Locate the drip leg ahead of the item being vented, to prevent any con densate that may form from draining back into the vented item. Gas piping must not be used to support, hang or steady the heater. 1.2 Combustion Air Requirements The heater shall be located such that a negative pressure will not be creat ed, which shall starve the burner of combustion air. Heaters installed in furnace rooms or other refined areas must have provi sion for combustion air. The minimum requirement is one square inch of free area for each 10,000 BTU/hr of heater input. When the heater is installed in an enclosed heater room, it is imperative that the heater room itself is not used as an air plenum. Ductwork must be used for all supply and return air to and from the heater, as well as any other fans, which may be installed in the same room. The combustion air intake should be doubled in size if there are other exhaust systems in the heater room. In some cases, local authorities require that combustion air be ducted directly to the burner. 1.3 Exhaust Stacks Install the proper size and type of stack in accordance with Federal, Provincial or local authorities having jurisdiction. The exhaust stack should be so constructed that any water that should collect in the stack will remain in the stack drip leg. The exhaust stack should be fitted with a drip leg with a clean out. A tee fitting used as either a clean out or condensate drain, shall have a tight fitting cap to prevent entrance of air into the stack at that point. If a rain cap is used, the clearance between the top of the stack and the cap should be equivalent to the stack diameter. Do NOT use a type B vent. Do NOT support the weight of the stack on the heater. Do NOT use elbows greater than 45 degrees. Do NOT twin a stack into a common vent or chimney from another heater. Run the stack such that if for any reason, water does collect in the drip leg and the drain plug is removed, the water will not fall on the heater or its controls. Keep elbows and horizontal runs to a minimum. If possible, slope all horizontal runs upward. The stack should not interfere with, or hinder access to the heater or any of its components. The stack must be an approved distance from fresh air intakes, adjacent building roof lines, windows, etc. Allow approximately three inches linear expansion per hundred feet of steel stacks. Approved methods must be followed when putting the stack through walls, floors, roofs, etc. Guy wires may be necessary to brace the stack above roof lines. Local jurisdiction may require that the installer obtain a stack permit. 1.4 Electrical Connections All electrical connections to the heater and main disconnect switch shall conform to the CSA C22.1 Canadian Electrical Code Part 1 and all local codes. The correct power supply requirements are shown on the heater nameplate. Temperature controllers, remote selector switches, remote panels, door switches, or any other auxiliary electrical items shall be connected to the terminals provided and shown on the wiring diagram. Dotted lines on a wiring diagram indicate field wiring by the installer. Solid lines on the wiring diagram indicate factory wiring by the manufacturer. Fuses are furnished and installed in accordance with the Canadian Electrical Code. If replacement is necessary, the original fuse amperage shall be adhered to. Failure to do so may result in damage to the components within the electrical system. 2.1 Precautions Before Starting the Heater - General Provincial regulations frequently require the service mechanics who work on combustion equipment, must be licensed. The heater should NOT be started by unqualified personnel. Set the electrical disconnect in the OFF position. Set all additional switches in the OFF position. Check all electrical connections on controls and in the control cabinet. Tighten if necessary. Check all fuse holders. All fuses must be properly installed. Check main fan wheels, bearings, and sheave set screws. Tighten if necessary. Check v-belt drive tension, adjust if necessary. Check heater inlet and discharge and stack for obstructions. Clear if necessary. Check settings of fan limit control(s). Adjust if necessary, as indicated below: Operating Auxiliary (Inverted Units) Limit Switch 200 F 165 F Set the fan selector in the automatic position for intermittent operation and in the manual position for continuous operation. Set the temperature controller, i.e. room thermostat, or discharge bulb controller, above the normal operating temperature. This will allow the heater to start even though temperature requirements may be satisfied. 2.2 Precautions Before Starting the Heater Gas Close the manual firing valve. Bleed the main gas supply line. Do NOT bleed into the combustions chamber. Check the gas pressure on the upstream side if the appliance regulator. This must NOT exceed 14 W.C. Check the setting of the spark rod. See burner manufacturers recommendations attached. Check the setting of the frame rod or scanner. See burner manufacturers recommendations attached. Proceed with the start-up. 2.3 Start-up Instructions - General Close all manual fuel valves. WARNING: Do NOT push in relays manually. Set the electrical disconnect switch in the ON position. Check the incoming voltage on each circuit to determine that the correct voltage has been supplied. Set the fan switch to the ON position, or if the heater has an optional summer/winter/off switch, set tot e SUMMER position. Check the main fan rotation. Correct if necessary. Check the current draw (amps) with the main fans running in the correct rotation. Note that the current draw (amps) should not exceed the motor full loading rating (amps) as shown on the motor nameplate. Set the fans switch to the OFF position, or if the heater has an optional summer/winter/off switch, set to the OFF position. 20

26 Set the BURNER toggle switch to the ON position or if the heater has an optional summer/winter/off switch, set to the WINTER position. 2.4 Start-up Instructions Gas Close the auxiliary hand shut-off firing valve. Open the main hand shut-off valve in the gas supply line. Press manual reset buttons on the electronic flame safeguard relay, the high limit switch, and the high and low pressure gas switches (if supplied). When the pilot is established, measure the flame signal. Set up to burner manufacturer s specifications. Set the BURNER toggle switch to the OFF position or if the heater has an optional summer/winter/off switch, set to the OFF position. Open the auxiliary hand shut-off valve. Set the BURNER toggle switch to the ON position or if the heater has an optional summer/winter/off switch, set to the WINTER position. Set up the burner to manufacturers specifications attached. 3. SHUT DOWN INSTRUCTIONS 3.1 General Instructions Set the BURNER toggle switch to the OFF position or if the heater has an optional summer/winter/off switch, set to the SUMMER position. Close the main manual fuel valve at the heater. If the heater was firing immediately before shutting down, allow the fans to run approximately five minutes to cool the heat exchanger. Set the fans switch to the OFF position, or if the heater has an optional summer/winter/off switch, set to the OFF position. Set the electrical disconnect switch to the OFF position. 3.2 Emergency Shut Down Set the electrical disconnect switch to the OFF position. Close the main manual fuel valve at the heater. 3.3 Summer Shut Down IF the heater is not required for summer ventilation or for air circulation, or for heating during the short periods of time when the temperature drops, set all electrical switches to the OFF position and close the main fuel valve. If the heater is to be used for summer ventilation or air circulation or for short period heating, se the fan switch and BURNER toggle switch to the OFF position, or if the heater has an optional summer/winter/off switch, set to the OFF position. Set to SUMMER for ventilation or air circulation, or to WINTER for heating as required. Do NOT open the disconnect switch or close the main fuel valve. 4. MAINTENANCE 4.1 Qualifications of Maintenance Personnel Provincial regulations frequently require that service mechanics, who work on combustion equipment, must be licensed. Although many maintenance items do not require the service of a licensed mechanic, it is recommended that any work done on the heater by unlicensed personnel be supervised by a licensed mechanic. Unqualified personnel should not be allowed to work unsupervised. 4.2 Monthly Maintenance Check all valves, piping and connections for leaks. Check the flame and combustion air setting. Check the fuel pressure in the fuel supply line to each heater. Clean the flame sensor. Inspect the filters. Clean or replace as necessary. (Replace only with filters of same size and type). Inspect the main fan bearings. Check all dampers, damper actuators and linkages. Adjust and tighten if necessary. Inspect the area and make sure that no combustible or hazardous material has been stored within the clearances as shown in the nameplate. 4.3 Quarterly Maintenance Complete the monthly maintenance schedule. Inspect the stack and make sure that there is no blockage. Inspect all the belt drives and adjust tension if necessary. Check alignment of all sheaves. Inspect all bearings and lubricate if necessary. (See Section 4E) Inspect the burner. Clean and adjust if necessary. Check the operation of all safety controls individually. Off Season or Yearly Maintenance Complete the monthly and quarterly maintenance schedule. Inspect and if necessary, clean all fan wheels and housings. Check that all fan wheels and sheaves are securely set to the shaft. Inspect all bearings and check condition and alignment. Inspect all v-belts for condition. Replace if worn. Inspect all electrical components, connections and terminals. Clean and tighten where necessary. Test ignition spark. Adjust gap if necessary. Clean ignition electrodes and check for cracks. Test the flame supervisor relay and replace components if necessary. Inspect all regulators, relief valves, motorized valves, solenoid valves, vent valves, manual shut off valves and safety shut off valves. Check their operation and clean if necessary. Check all vents to atmosphere. They must be cleaned and free from obstruction. Inspect and clean all drip legs in fuel lines and in the stack. Remove the front panel and the header box. Inspect the header box and tubes. Look for carbon deposits, soot, scale or rust. Clean if necessary. Inspect the combustion chamber for carbon deposits, soot, scale, or flame impingement. Clean if necessary. If there is evidence of flame impingement, a complete burner adjustment must be made. 4.5 Lubrication of Bearings All bearings are pre-lubricated by the manufacturer and extended grease lines have been filled. The grease used is chosen for the service and for chemical and mechanical stability. Lubrication should be scheduled as required to suit the operating and atmos pheric conditions. Generally, bearings operating in clean atmosphere should be lubricated at two to six month clean intervals, and bearings operating in dirty atmosphere should be lubricated at two week to two-month intervals. Each installation requires a lubrication schedule to suit the conditions. Grease should be added slowly and, if possible, when the shaft is rotating. Approximately seven shots from a grease gun are usually sufficient. A slight bead of grease will appear at the seal. NOTE: Over greasing can be very damaging to the bearings. Avoid rupturing the bearing seal. When bearing is full to capacity, the bearing temperature will rise as much as 30F. A partial list of recommended lubricants is listed below: Gulf Oil Gulfcrown EP2 Imperial Oil Esso MP Grease H Shell Oil Alvania Grease 2 Sun Oil Sun Prestige 42 Grease Texaco Regal AFB2 Consult local bearing representatives if conditions are abnormally dirty or corrosive. 4.6 Electrical Maintenance Electrical motors are essentially very reliable machines and require very little attention. Frequently they tend to suffer from over attention rather than inattention. Motor bearings require schedule lubrication, similar to that described in section 4E. Grease having a melting point of 130 C is satisfactory to most installations. Consult local motor representative if conditions are abnormally dirty or corrosive. 5. SEQUENCE OF OPERATION 5.1 Basic Operation The main disconnect switch energizes or de-energizes the heater electrical circuit. The FAN switch (if supplied) energizes or de-energizes the main fan circuit when the main disconnect switch is ON. The BURNER switch (if supplied) energizes or de-energizes the burner circuit when the main disconnect switch is ON. The summer/winter/off switch (if supplied) acts as follows: When set to the OFF position, both the burner circuit and the fan circuit are de-energized. When set to the SUMMER position, the fan circuit is energized and the burner circuit is de-energized. When set to the WINTER position, the burner circuit and the fan circuits are energized. When the heater is to be used as a heating unit, the main disconnect switch, the burner switch and the fan switch will be in the ON position, or the summer/winter/off switch will be in the WINTER position. With the limit circuit complete, the electronic flame safeguard relay is energized and the burner is powered. Trail for ignition will occur. If flame is not established, the electronic flame safe guard relay will lock out and must be manually reset before a new trial for ignition. When a stable flame is established, the flame sensor will send a signal back to the electronic flame safeguard relay and the fuel valves will be held open. When the combustion chamber has been heated up and the bonnet air temperature reaches the temperature setting for the fan switch and the auxiliary fan switch (if supplied), the fan starter coil will be energized starting the main fans. Heater air will be delivered until the temperature controller is satisfied. The burner circuit is then de-energized. The main fans will continue to run until the combustion chamber has cooled down and the bonnet air temperature drops below the temperature setting of the fan switch and the auxiliary fan switch (if supplied). When the temperature controller calls for heat again, the sequence will repeat.

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30 DX GAS HEAT ROOF TOP UNITS Design and Engineering Smart Air Solutions PROJECT Queen Elizabeth Building Roof Top Units RTU-1, 2, 3, 4 & 5 CLIENT The Board of Governors of Exhibition Place Toronto, ON DATE SHIPPED July

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