MODEL DG / DGX (Direct Spark)

Transcription

1 MODEL DG / DGX (Direct Spark) Make-Up Air Unit Part # Installation, Operation and Maintenance Manual FOR YOUR SAFETY If you smell gas 1. Open windows 2. Don t touch electrical switches 3. Extinguish any open flames 4. Immediately call your gas supplier **WARNING** Disconnect and secure all electrical power to the OFF position prior to inspection or servicing. Failure to comply with this safety precaution could result in serious injury or death. **IMPORTANT** FOR YOUR SAFETY The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous. **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. All factory provided lifting lugs must be used when lifting any unit. Failure to comply with this safety precaution could result in property damage, serious injury or death. Report any damaged equipment to the shipper immediately! All units are shipped on a skid or packaged to minimize damage during shipment. The transporting carrier has the responsibility of delivering all items in their original condition as received from Greenheck. The individual receiving the equipment is responsible for inspecting the unit for obvious or hidden damage, recording any damage on the bill of lading before acceptance and filing a claim (if required) with the final carrier. Some accessory items are stored inside the unit during shipping. Care must be taken during installation to prevent damage to units. Installation Start-Up Operation Troubleshooting Maintenance Reference

2 TABLE OF CONTENTS I Installation Unit - Indoor Unit - Arrangement DB/HZ Unit - Arrangement DBC Evaporative Cooler Electrical Wiring Direct Gas Piping Evaporative Cooler Piping Water Wizard Direct Expansion (DX) Coil Piping Chilled Water Coil Piping Building Pressure Control T M Troubleshooting Blower Heater Evaporative Cooling Vibration Water Wizard Maintenance Routine Fall Log S Start-Up Blower Direct Gas Evaporative Cooling Water Wizard R Reference Gas Train Layout Control Center Layout O Operation Recirculating/VAV Units Electrical Water Wizard STORAGE When a unit is not going to be in service for an extended period of time, certain procedures should be followed to keep the unit in proper operating condition: Plug all piping Rotate fan wheel monthly and purge bearings once every one to three months (depending on environment). Energize fan motor once every three months Store belts flat to keep them from warping and stretching Store unit in location without vibration Cover unit with tarp to protect from dirt and moisture After storage period, purge grease before putting fan into service Do not cover unit with a black tarp, this would promote condensation. Improper storage which results in damage to the unit will void the warranty. 2

3 Installation - Indoor Installation Step 1 Install Hangers Install threaded hangers from ceiling supports. When locating hangers, allow enough room to open access panel(s). Two nuts must be used on the end of each threaded hanger. Ceiling supports are supplied by others. See figure #1. Step 2 Install Unit Using sheet metal screws, attach the weatherhood/thru-wall/filter section to the blower/burner section. The flange on the weatherhood/thru-wall/filter section should overlap the flange on the blower/burner section. Raise the assembled unit into place. Ceiling Supports Ductwork Installation Using two nuts per hanger, fasten the unit supports to the hangers under the unit. Appropriate unit supports, such as the optional Greenheck hanging bracket kit or c-channel and angle iron (supplied by others) should be used. See figure #1. Using self-tapping screws, attach ductwork to unit. In order to prevent the unit from swinging and to provide a safe environment for service and maintenance, additional measures must be taken to secure the unit in all directions. Hangers Unit Supports Figure 1. Indoor Mounting Two nuts must be used on each end of each threaded hanging rod for proper support. Good duct practices should be followed for all ductwork. Ductwork should be installed in accordance with SMACNA and AMCA guidelines, NFPA 96 and any local codes. Reference the CAPS submittal for duct sizes. Step 3 Seal Wall Opening Apply sealant around the perimeter of the weatherhood to prevent water penetration and drafts into the building. See figure #2. Sealant Figure 2. Sealing Wall Opening 3

4 Installation - Arrangement DB / HZ Installation Step 1 Install Curb and/or Equipment Support(s) Position curb/equipment support(s) on the roof (reference the CAPS submittal for placement of curb/equipment support(s) in relation to the unit). Verify that unit supports are level, shim if necessary. Attach curb to roof and flash into place. Attach the equipment support(s) to the roof, remove metal cover, flash to wooden nailer and reinstall cover. Refer to figure #3. Step 2 Install Ductwork Good duct practices should be followed for all ductwork. All ductwork should be installed in accordance with SMACNA and AMCA guidelines, NFPA 96 and all local codes. Reference the CAPS submittal for ductwork sizes. See figure #4. Step 3 Apply Sealant Apply an appropriate sealant around the perimeter of the curb and duct adapter(s) to isolate fan vibration and prevent water penetration. See figure #4. Metal Cover Equipment Support Optional Return Air Duct (Arrangement HZ and DB) Roof Curb Figure 3. Roof Curb The use of a duct adapter is recommended on a downblast (DB) arrangement to align the ductwork with the supply unit and is only a guide and is not to be used as support for the ductwork. Supply Air Duct Work (Arrangement DB only) Sealant Step 4 Install Unit Use a crane and a set of spreader bars hooked to the factory lifting lugs to lift and center the unit on the curb/equipment support(s). See figure #5. Figure 4. Duct Work Use self-tapping sheet metal screws to fasten the unit to the curb/equipment support(s). The use of all lifting lugs and a set of spreader bars is mandatory when lifting the unit. Some units come with the weatherhood attached and step 5 may not apply. Step 5 Assemble and Attach Weatherhood The weatherhood can now be assembled and attached to the unit. Detailed assembly instructions can be found with the weatherhood. If the optional evaporative cooling module was selected, this step does not apply, refer to the installation instructions for the optional evaporative cooling module. Figure 5. Placing Unit Step 6 Seal Weatherhood Seam Using an appropriate sealant, seal the seam between the weatherhood and the unit. Figure 6. Complete Rooftop Installation 4

5 Installation - Roof Mounted Unit Arrangement DBC Step 1 Install Curb/Equipment Support(s) Position curb/equipment support(s) on the roof (reference the CAPS submittal for placement of curb/equipment support(s) in relation to the unit). Verify that all unit supports are level, shim if necessary. Attach curb to roof and flash into place. Attach the equipment support(s) to the roof, remove metal cover, flash to wooden nailer and reinstall cover. See figure #7. Metal Cover Equipment Support Roof Curb Figure 7. Curb and Unit Support Supply Exhaust 1 inch Inside Flange Installation Step 2 Install Combination Extension Install combination extension over curb. Lag into place using wood screws. Locate the extension so the tall vented side is over the exhaust opening. See figure #8. Figure 8. Combination Extension Step 3 Install Ductwork Good duct practices should be followed for all ductwork. All ductwork should be installed in accordance with SMACNA and AMCA guidelines, NFPA 96 and any local codes. Reference the CAPS submittal for ductwork size and location. Refer to figure #9. Supply Ductwork by Others Exhaust Ductwork by Others The use of a duct adapter is recommended on a downblast (DBC) arrangement to align the ductwork with the supply unit and is only a guide and is not to be used as support for the ductwork. Figure 9. Ductwork Step 4 Apply Sealant Apply an appropriate sealant around the perimeter of the curb and duct adapter(s) to isolate fan vibration and prevent water penetration. See figure #10. Supply Duct with Duct Adapter Installed Exhaust Duct Installed Sealant Figure 10. Sealing Ductwork 5

6 Installation - Roof Mounted Unit Arrangement DBC Step 5 Install Exhaust Fan Fasten exhaust fan to curb extension with selftapping sheet metal screws. See figure #11 Model CUBE Exhaust Fan Installing the exhaust fan prior to the supply unit will allow for easier installation of options. Installation Step 6 Install Exhaust Options Install optional Greenheck hinge kit with restraining cables and grease trap with drain connection. Figure 11. Exhaust Fan Step 7 Install Supply Unit Use a crane and a set of spreader bars hooked to the factory lifting lugs to lift and center the unit on the curb/equipment support(s). See figure #12. Use self-tapping sheet metal screws to fasten the unit to the curb/equipment support(s). The use of all lifting lugs and a set of spreader bars is mandatory when lifting unit. Some units come with the weatherhood attached and step 8 may not apply. Step 8 Assemble and Attach Weatherhood The weatherhood can now be assembled and/or attached to the unit. Detailed assembly instructions can be found with the weatherhood. If the optional evaporative cooling module was selected, this step does not apply, refer to the installation instructions for the optional evaporative cooling module. Figure 12. Installing Supply Unit Step 9 Seal Weatherhood Seam Using an appropriate sealant, seal the seam between the weatherhood and the unit. Figure 13. Complete Combination Installation 6

7 Installation - Evaporative Cooler (Optional) Small evaporative coolers ship attached to the base unit and require no additional mounting. Step 1 Locate Equipment Support(s) Position equipment support(s) on the roof (reference the CAPS submittal for placement of equipment support(s) in relation to the unit). Verify that all unit supports are level, shim if necessary. Attach equipment support to the roof, remove metal cover, flash to wooden nailer and reinstall cover. Refer to figure #14. Step 2 Apply Sealant Apply an appropriate sealant around the airstream opening to create an air tight seal. See figure #15. Metal Cover Equipment Support Figure 14. Equipment Support Sealant Installation Figure 15. Equipment Support Step 3 Set Evaporative Cooling Module Use a crane and a set of spreader bars hooked to the factory lifting lugs to lift and center the module on the equipment support(s). The flange on the evaporative cooler should overlap the flange on the unit. See figure #16. The use of all lifting lugs and a set of spreader bars is mandatory when lifting the evaporative cooling module. Figure 16. Placing Evaporative Module Step 4 Secure Cooling Module to Unit Use self-tapping screws to fasten the cooling module to the base unit along the top and down both sides. Fasten at the top through the flanges. To fasten the sides, the media must be removed. To remove the media, first remove the access panel on the evaporative module and disconnect the evaporative pump(s). The media will now slide out. With the media removed, you can access the side fastening points inside the evaporative module. With all the screws in place, reinstall the media, reconnect the pumps and reinstall the access panel. Figure 17. Securing Evaporative Module When mounting the evaporative cooler, it is important that it is level to ensure proper operation and water drainage. 7

8 Installation - Electrical Wiring Before connecting power to the unit, read and understand the following instructions and wiring diagrams. Complete wiring diagrams are attached to the inside of the control center door(s). All wiring should be done in accordance with the latest edition of the National Electrical Code ANSI/NFPA-70 and any local codes that may apply. In Canada, wiring should be done in accordance with the Canadian Electrical Code. CAUTION! If replacement wire is required, it must have a temperature rating of at least 105 C, except for energy cut-off or sensor lead wire which must be rated to 150 C. Installation The equipment must be properly grounded. Any wiring running through the unit in the airstream must be protected by metal conduit, metal clad cable or raceways. DANGER! High voltage electrical input is needed for this equipment. This work should be performed by a qualified electrician. CAUTION! Any wiring deviations may result in personal injury or property damage. Greenheck is not responsible for any damage to, or failure of the unit caused by incorrect final wiring. Greenheck s standard control voltage is 24 VAC. Control wire resistance should not exceed 0.75 ohms (approximately 285 feet total length for 14 gauge wire; 455 feet total length for 12 gauge wire). If the resistance exceeds 0.75 ohms an industrial-style, plug-in relay should be wired in place of the remote switch. The relay must be rated for at least 5 amps and have a 24 VAC coil. Failure to comply with these guidelines may cause motor starters to chatter or not pull in, resulting in contactor failures and/or motor failures. Step 1 Determine the Size of the Main Power Lines The units nameplate states the voltage and the unit s total amps. The main power lines to the unit should be sized accordingly. See figure #18. The nameplate is located on the outside of the unit on the control panel side. MODEL VOLTS Unit s Total Amps HTZ Voltage, Hertz, and Phase PH Step 2 Provide the Opening(s) for the Electrical Connections Electrical openings vary by unit size and arrangement and are field supplied. AMPS SUP HP MARK S/N EXH HP Figure 18. Electrical Nameplate Step 3 Connect the Main Power Connect the main power lines to the disconnect switch and main grounding lug(s). Torque field connections to 20 in-lbs. See the control center layout in the reference section for main disconnect and grounding lug(s) locations. Step 4 Wire the Optional Convenience Outlet The convenience outlet requires a separate 115V power supply circuit. The circuit must include short circuit protection which may need to be supplied by others. 8

9 Installation - Electrical Wiring Step 5 Wire the Accessories Reference the ladder diagram on the inside of the control center door for correct wiring of the following accessories: Selectrastat Room Override Blower Switch Heat Switch Indicating Lights Dirty Filter Indicator TSCP KSCP Step 6 Wire the Optional Evaporative Cooler Reference the ladder diagram on the inside of the control center door for correct wiring of the pump and the optional auto-drain and flush. Wiring to the Maxitrol 14 or 44 should be in separate conduit or run with shielded cable. TSCP has number-to-number wiring. Large evaporative coolers may require a separate power supply. Installation Step 7 Check Recirculation / VAV Operation Blower start-up (S-1), steps 1-4 should be performed before the blower is run. EXHAUST (OPTIONAL) SUPPLY HEAT RECIRCULATION BLOWER MAIN VALVES ALARM DIRTY FILTERS Two Position Damper Control Turn the recirculating switch on the remote control panel to each position and confirm that the return air damper adjusts accordingly. The damper actuator may take a few minutes to open or close. Two Speed Turn the fan speed switch on the remote control panel to each positions and confirm that the fan speed adjusts accordingly. Potentiometer Control To test potentiometer operation, turn the potentiometer to the two extremes. With 80/20 recirculation, confirm that the return air damper fully opens and fully closes. The damper actuator may take a few minutes to open or close. With variable volume, make sure the fan goes to maximum and minimum speed. Building Pressure Control See I-16 for building pressure set-up and operation check. EXHAUST SUPPLY HEAT (OPTIONAL) (OPTIONAL) GREENHECK Figure Position Damper Control BLOWER MAIN VALVES ALARM DIRTY FILTERS (OPTIONAL) GREENHECK Figure 20. Potentiometer Control For maintenance issues associated with variable frequency drives, consult the drive s manual supplied with the unit. The drives are programmed at the factory and should not need any adjustment during installation and start-up. For kitchen applications, the drive may be located in the kitchen or in the unit. EXHAUST (OPTIONAL) SUPPLY HEAT PHOTOHELIC BLOWER MAIN VALVES ALARM DIRTY FILTERS (OPTIONAL) GREENHECK Figure 21. Building Pressure Control 9

10 Installation - Direct Gas Piping All gas piping must be installed in accordance with the latest edition of the National Fuel Gas Code ANSI/Z223.1 and any local codes that may apply. In Canada, the equipment shall be installed in accordance with the Installation Code for Gas Burning Appliances and Equipment (CGA B149) and Provincial Regulations for the class. Authorities having jurisdiction should be consulted before installations are made. Installation WARNING! All components of this or any other gas fired heating unit must be leak tested prior to placing the unit into operation. A soap and water solution should be used to perform this test. NEVER test for gas leaks with an open flame. WARNING! If pressure testing in excess of 1/2 psig (3.5 kpa), the heater and manual shutoff valve must be disconnected from the supply gas line. WARNING! If pressure testing at or below 1/2 psig (3.5 kpa), the heater must be isolated from the supply gas line by closing its manual shutoff valve. All piping should be clean and free of any foreign matter. Foreign material entering the gas train can damage the valves, regulators and burner. Do NOT connect the unit to gas types other than what is specified and do NOT connect the unit to gas pressures that are outside of the pressure range shown on the label. Step 1 Determine the Supply Gas Requirements The unit s direct gas nameplate states the requirements for the gas being supplied to the unit. See figure #22. The direct gas nameplate is located on the outside of the unit on the control center side. Minimum and maximum gas pressures Minimum gas pressure for maximum output MAX BTU/HR BTU/H MAX MIN BTU/HR BTU/H MIN NORMAL MANIFOLD PRESSURE PRESSION D ADMISSION NORMALE W.C. MIN GAS PRESSURE FOR MAX OUTPUT PRESSION DE GAZ MIN POUR PUISSANCE MAX W.C. Type of Gas MIN GAS PRESSURE PRESSION DE GAZ W.C. MAX GAS PRESSURE PRESSION DE GAZ MAX W.C. MIN BURNER PRESSURE DROP PERTE MIN DE PRESSION DANS LE BRULEUR W.C. MAX BURNER PRESSURE DROP PERTE MAX DE PRESSION DANS LE BRULEUR PSI TYPE OF GAS NATURE DU GAZ DESIGN T T NORMALE F EQUIPPED FOR AGAINST EXTERNAL STATIC PRESSURE SCFM W.C. CONCU POUR CONTE PRESSION STATIQUE EXTERIEURE Figure 22. Direct Gas Nameplate 10

11 Installation - Direct Gas Piping Step 2 Install Additional Regulator if Required When the supply gas pressure exceeds the maximum gas pressure shown on the direct gas nameplate, an additional regulator (by others) is required to reduce the pressure. The regulator must have a listed leak limiting device or it must be vented to the outdoors. The regulator located inside the unit is used to adjust the unit s maximum output temperature. Step 3 Connect the Supply Gas Line A manual shut off valve (gas cock), 1/8 in. plugged test port and 6 in. drip leg must be installed prior to the gas train. The valve and the test port must be accessible for the connection of a test gauge. Supply gas connections must be made by a qualified installer and are not furnished by Greenheck. See figure #23. From Gas Supply Gas Cock Ground Joint Union 6 in. Trap 1/8 in. Plugged Tap Make-Up Air Unit Installation Figure 23. Supply Gas Line Step 4 Test the System for Leaks Check both the supply lines and the factory piping for leaks. Apply a soap and water solution to all piping and watch for bubbling which indicates a leak. WARNING! NEVER test for a gas leak with an open flame. WARNING! The factory piping has been checked for leaks, but should be rechecked due to shipping and installation. 11

12 Installation - Evaporative Cooling Piping (Optional) Evaporative Cooling with Recirculating Pump. Supply Line Installation Drain Line Valve Drain Line Trap Overflow Supply Line Valve Figure 24. Recirculating Evaporative Piping All supply solenoids, valves and all traps must be below the roofline or be otherwise protected from freezing. The supply line should be of adequate size and pressure to resupply the amount of water lost due to bleed-off and evaporation. The drain line should be the same size or larger than the supply line. CAUTION! Provisions must be taken to prevent damage to the evaporative cooling section during freezing conditions. The sump, drain lines and supply lines must be drained prior to freezing conditions or an alternate method must be used to protect the lines and media. Step 1 Install the Water Supply Line Connect the water supply line to the float valve in the evaporative cooling unit. Install a manual shutoff valve in the supply line as shown above. Refer to figure #24. Step 2 Install the Drain Line Connect an unobstructed drain line with a manual shut-off valve from the sump overflow to the main drain line as shown above. A trap should be used to prevent sewer gas from being drawn into the unit. See figure #24 and #25. Step 3 Check/Adjust Water Level Check the water level in the sump tank. The water level should be above the pump intake and below the overflow. Adjust the float as needed to achieve the proper water level. Figure 25. Drain Trap 6 in. min. 6 in. min. 12

13 Installation - Evaporative Cooling Piping (Optional) Evaporative Cooling with Auto Drain and Fill Evaporative Cooling Section Supply Line Sump Overflow Sump Drain Valve C Valve A To Water Supply Installation Valve B Drain Line Figure 26. Auto-Drain and Fill Evaporative Piping The supply line should be of adequate size and pressure to resupply the amount of water lost due to bleed-off and evaporation. The drain line should be the same size or larger than the supply line. CAUTION! All solenoids valves and traps must be installed below the roof to protect the supply water line from freezing. If they cannot be installed below the roof, an alternative method must be used to protect the lines from freezing The supply solenoid (Valve A) is NOT the same as the drain solenoids (Valve B and Valve C). Make sure to use the proper solenoid for each location. Check you local code requirements for proper installation of this type of system. Step 1 Install the Water Supply Line Connect the water supply line to the float valve in the unit. Install the 1/2 in. normally closed solenoid (Valve A) in the supply line as shown above. Install the 1/4 in. normally open solenoid (Valve B) between the supply line and the drain line. See figure #26. Step 2 Install the Drain Line Connect an unobstructed drain line to the sump drain. Install the 3/4 in. normally open solenoid (Valve C) between the sump drain connection and the drain line. A trap should be used to prevent sewer gas from being drawn into the unit. See figure #26 and #27. 6 in. min. Step 3 Check/Adjust Water Level Check the water level in the sump tank. The water level should be above the pump intake and below the overflow. Adjust the float as needed to achieve the proper water level. Figure 27. Drain Trap 6 in. min. 13

14 Installation - Water Wizard (Optional) Evaporative Cooling with the Water Wizard WARNING! Disconnect and lock-out all power and gas before performing any maintenance or service to the unit. Failure to due so could result in serious injury or death and damage to equipment. Step 1 Install Supply Line/Solenoid Connect the water supply line to the manual supply valve in the unit. Install the supply solenoid in the supply line, upstream of the manual supply valve and below the roofline. See figure #28. Installation Step 2 Install Drain Line/Solenoid Connect the drain line to the supply line between the manual supply valve and the supply solenoid. Install a drain solenoid in the drain line, below the roof line. See figure #28. CAUTION! Any wiring deviations may result in personal injury or property damage. Greenheck is not responsible for any damage to, or failure of the unit caused by incorrect final wiring. Step 3 Wire the Solenoid(s) Wire the supply solenoid to terminals X and 25. Wire the drain solenoid to terminals X and 26. Roof Line Trap Sump Drain To Media Drain Solenoid Pressure Gauge Manual Supply Valve Supply Solenoid Figure 28. Water Wizard Installation Step 4 Wire the Temperature Sensor (Optional) If the evaporative cooler shipped separate from the unit, the temperature sensor must be field wired. The sensor wire is bundled inside the discharge end of the cooler. Wire the sensor wire to terminals AI2 and AIC on the terminal strip in the unit s control center. 14

15 Installation - Direct Expansion (DX) Coil Piping (Optional) Guidelines for the installation of direct expansion cooling coils have been provided to insure proper performance and longevity of the coils. These are general guidelines that may have to be tailored to meet the specific requirements of any one job. As always, a qualified party or individual should perform the installation and maintenance of any coil. Protective equipment such as safety glasses, steel toe boots and gloves are recommended during the installation and maintenance of the coil. All field brazing and welding should be performed using high quality materials and an inert gas purge (such as nitrogen) to reduce oxidation of the internal surface of the coil. All field piping must be self supporting and flexible enough to allow for the thermal expansion of the coil. Installation (by others) Figure 29. General Installation (by others) Figure 30. Installation with Hot Gas By-Pass 15

16 Installation Installation - Direct Expansion (DX) Coil Piping (Optional) Step 1 Verify zzle Placement Inspect the refrigerant distributor and verify that the nozzle is in place. The nozzle is generally held in place by a retaining ring or is an integral part of the distributor itself. See figure #31. If a hot gas bypass kit was ordered, the nozzle will not be located in the distributor, it will be located in the hot gas bypass kit. Step 2 Install the Optional Hot Gas Bypass Kit (By Others) If a hot gas bypass kit was ordered with the coil, install it now. Consult the IOM from the bypass kit supplier for complete installation instructions. Align the side port with the hot gas line prior to brazing into place. Refer to figure #30. Step 3 Install Suction Line Install a suction line from the compressor to the suction connection. See figures #29 and #30. Step 4 Install the Thermal Expansion Valve (TEV) (By Others) Follow the TEV manufacturer s recommendations for installation to avoid damaging the valve. If the valve is externally equalized, use a tubing cutter to cut off the plugged end of the factory installed equalizer line. Use a de-burring tool to remove any loose metal from the equalizer line and attach it to the TEV. If the valve is internally equalized, the factory installed equalizer line can be left as is. See figures #29 and #30. Step 5 Mount the Remote Sensing Bulb (By Others) The expansion valve s remote sensing bulb should be securely strapped to the horizontal run of the suction line at the 3 or 9 o clock position and insulated. See figures #29 and #30. Step 6 Check Coil Piping for Leaks Pressurize the coil to 100 psig with dry nitrogen or other suitable gas. The coil should be left pressurized for a minimum of 10 minutes. If the coil holds the pressure, the hook-up can be considered leak free. If the pressure drops by 5 psig or less, re-pressurize the coil and wait another 10 minutes. If the pressure drops again there is likely one or more small leaks which should be located and repaired. Pressure losses greater than 5 psig indicate a large leak that should be isolated and repaired. Step 7 Evacuate and Charge the Coil Use a vacuum pump to evacuate the coil and any interconnecting piping that has been open to the atmosphere. Measure the vacuum in the piping using a micron gauge located as far from the pump as possible. Evacuate the coil to 500 microns or less then close the valve between the pump and the system. If the vacuum holds to 500 microns or less for one minute, the system is ready to be charged or refrigerant in another portion of the system can be opened to the coil. A steady rise in microns would indicate that moisture is still present and that the coil should be further vacuumed until the moisture has been removed. Failure to obtain a high vacuum indicates a great deal of moisture or a small leak. Break the vacuum with a charge of dry nitrogen or other suitable gas and recheck for leaks. If no leaks are found, continue vacuuming the coil until the desired vacuum is reached. Step 8 Install the Drain Line Connect an unobstructed drain line to the drain pan. A trap should be used to prevent sewer gas from being drawn into the unit. See figure #32. Retainer Ring zzle Distributor Figure 31. zzle Placement 6 in. min. All traps must be installed below the roofline or be otherwise protected from freezing. Figure 32. Drain Trap 6 in. min. 16

17 Installation - Chilled Water Coil Piping (Optional) Guidelines for the installation of the cooling coil have been provided to insure proper performance of the coils and their longevity. These are general guidelines that may have to be tailored to meet the specific requirements of any one job. As always, a qualified party or individual should perform the installation and maintenance of the coil. Protective equipment such as safety glasses, steel toe boots and gloves are recommended during the installation and maintenance of the coil. When installing couplings, do not apply undue stress to the connection. Use a backup pipe wrench to avoid breaking the weld between the coil connection and the header. All field piping must be self supporting. System piping should be flexible enough to allow for the thermal expansion and contraction of the coil. Installation Step 1 Verify Coil Hand Designation Check the coil hand designation to insure that it matches the system. Coils are generally plumbed with the supply connection located on the bottom of the leaving air side of the coil and the return connection at the top of the entering air side of the coil. This arrangement provides a counter flow heat exchanger and positive coil drainage. See figure #33 Hot Return Connection Entering Air Leaving Air Cold Supply Connection Figure 33. Coil Connections Step 2 Check the Coil for Leaks Pressurize the coil to 100 psig with dry nitrogen or other suitable gas. The coil should be left pressurized for a minimum of 10 minutes. If the coil holds the pressure, the hook-up can be considered leak free. If the pressure drops by 5 psig or less, re-pressurize the coil and wait another 10 minutes. If the pressure drops again there is likely one or more small leaks which should be located and repaired. Pressure losses greater than 5 psig indicate a large leak that should be isolated and repaired. Step 3 Connect the Supply and Return Lines Connect the supply and return lines. Refer to figure #33. Step 4 Install the Drain Line Connect an unobstructed drain line to the drain pan. A trap should be installed to prevent sewer gas from being drawn into the unit. See figure #34. 6 in. min. All traps must be installed below the roofline or be otherwise protected from freezing. 6 in. min. Figure 34. Drain Trap 17

18 Installation - Building Pressure Control (Optional) Step 1 Mount Pressure Tap Using the factory provided bracket, mount the pressure tap to the outside of the unit. Choose a location out of the prevailing winds and away from supply or exhaust fans to assure accurate readings. See figure #35 Installation Step 2 Run Pressure Tap Lines A pressure tap line must be run from the pressure tap mounted on the outside of the unit to the low pressure tap on the back of the photohelic gauge (see figure #36). A second pressure tap line must be run from the high pressure tap on the back of the photohelic to the space. The high pressure line must be run even if the photohelic is mounted in the space. Fifty feet of tubing is supplied with the unit. Factory Wiring Figure 35. Pressure Tap High Pressure Tap To Space Step 3 Set the Building Pressure The pressure gauge (see figure #37) is used to set the desired building pressure. The pressure is set by adjusting the knobs for the upper and lower pressure limits. Typical settings are 0.0 in. wc for the lower and 0.10 in. wc for the upper pressure setting. Low Pressure Tap To Outside Figure 36. Pressure Tap Connections Step 4 Check Control System Blower start-up (S-1), steps 1-4 should be performed before the blower is run. Pressure Indicating Needle Pressure Setting Needles Before the unit is left in service, the recirculation control system should be tested. This can be accomplished by turning both knobs to the upper most pressure setting. You may have to remove the outdoor pressure tap tubing. The return air damper should close (VAV systems should go to max speed). Then set both knobs at the lowest setting, and the damper should open (VAV systems should go to minimum speed). It may take one to two minutes for the damper to reach the desired position. Reset the correct pressure limits before starting the unit. The picture on the bottom right shows a typical photohelic setting. The needle in this photo indicates a negative building pressure. During correct operation the indicating needle will remain between or near the setting needles. Pressure Setting Knobs Figure 37. Building Pressure Settings 18

19 Start-Up - Blower Pre-Start-Up Check Rotate the fan wheel by hand and make sure no parts are rubbing. Check the V-belt drive for proper alignment and tension (a guide for proper belt tension and alignment is provided in the belt maintenance section). Check fasteners, set screws and locking collars on the fan, bearings, drive, motor base and accessories for tightness. Remove any shipping fasteners from the blower vibration isolators. WARNING! Disconnect and lock-out all power and gas before performing any maintenance or service to the unit. Failure to due so could result in serious injury or death and damage to equipment. WARNING! Check the housing, blower, weatherhood, filter section and ductwork for foreign objects and debris before the blower is run. SPECIAL EQUIPMENT REQUIRED Below is a list of special tools that are required. A recommended model is shown, but equivalent products may be used. Description Manufacturer-Model Phone Website Voltage Meter Fluke FLUKE Amperage Meter Fluke FLUKE Thermometer Fluke FLUKE U-Tube manometer Dwyer-Slack Tube Tachometer Monarch-Pocket Tach Start-Up Step 1 Check the Voltage Before starting the unit, compare the supplied voltage, hertz, and phase with the unit and motor s nameplate information. See figure #38. The nameplate is located on the outside of the unit on the control panel side. MODEL Voltage, Hertz, and Phase VOLTS AMPS SUP HP MARK Hz S/N EXH HP PH Figure 38. Electrical Nameplate Step 2 Check the Blower Rotation Open the blower access door and run the blower momentarily to determine the rotation. Arrows are placed on the blower scroll to indicate the proper direction or reference figure #39. To reverse the rotation on three phase units, disconnect and lock-out the power, then interchange any two power leads. To reverse the rotation on single phase units, disconnect and lock-out the power, then rewire the motor per the manufacturer s instructions. If the blower is rotating in the wrong direction, the unit will move some air, but will not perform as designed. Be sure to perform a visual inspection to guarantee the correct blower rotation. Rotation Blower Housing Figure 39. Blower Rotation 19

20 Start-Up - Blower Step 3 Check for Vibration Check for unusual noise, vibration or overheating of the bearings. Reference the troubleshooting section for corrective actions. Excessive vibration may be experienced during the initial start-up. Left unchecked, it can cause a multitude of problems including structural and/or component failure. Generally, fan vibration and noise is transmitted to other parts of the building by the ductwork. To minimize this undesirable effect, the use of heavy canvas duct connectors is recommended. Step 4 Motor Check Measure the motor s voltage, amps and RPM s and compare to the specifications on the motor s nameplate. Check the overload setting and make sure it matches the motor s amperage rating. If the motor s actual amps are greater than the nameplate amps, check and correct the supply voltage or air volume of the blower. Start-Up Additional starters and overloads may be provided in the make-up air control center for optional exhaust blowers. Any additional overloads must be checked for proper voltage, amps and RPM s. Step 5 Air Volume Measurement and Check Measure the unit s air volume (CFM) and compare it with its rated air volume. If the air volume is off, adjust the fan s RPM s by changing the drive. The most accurate way to measure the air volume is by using a pilot traverse method downstream of the blower. Other methods can be used but should be proven and accurate. Changing the air volume can significantly increase the motor s amps. If the air volume is changed, the motor s amps must be checked to prevent overloading the motor. To insure accuracy, be sure the dampers are open when checking the air volume. Step 6 Set-up Optional Components Adjust the settings on the optional components. See the control center layout in the reference section for location of optional components. Heating Inlet Air Sensor (typical setting: 60-70ºF) Cooling Inlet Air Sensor (typical setting: 75ºF) Building Freeze Protection (typical setting: 5 min at 45ºF) Dirty Filter Gauge (typical setting: settings vary greatly for each unit) Solid Fuel Time Delay (typical setting varies per application) 20

21 Start-Up - Direct Gas For proper unit function and safety, follow the start-up procedure in the exact order that it is presented. This start-up should begin after all of the installation procedures and the Blower start-up have been completed. Step 1 Check the Supply Gas Pressure Check the supply gas pressure and compare it with the unit s nameplate pressure requirements. Adjust the supply regulator as needed until the supply gas pressure is within the specified range. See figure #40. The nameplate is located on the outside of the unit on the control panel side. Minimum and maximum gas pressures MAX BTU/HR BTU/H MAX MIN BTU/HR BTU/H MIN Start-Up NORMAL MANIFOLD PRESSURE PRESSION D ADMISSION NORMALE W.C. MIN GAS PRESSURE FOR MAX OUTPUT PRESSION DE GAZ MIN POUR PUISSANCE MAX W.C. MIN GAS PRESSURE PRESSION DE GAZ W.C. MAX GAS PRESSURE PRESSION DE GAZ MAX W.C. MIN BURNER PRESSURE DROP PERTE MIN DE PRESSION DANS LE BRULEUR W.C. MAX BURNER PRESSURE DROP PERTE MAX DE PRESSION DANS LE BRULEUR PSI TYPE OF GAS NATURE DU GAZ DESIGN T T NORMALE F EQUIPPED FOR AGAINST EXTERNAL STATIC PRESSURE SCFM W.C. CONCU POUR CONTE PRESSION STATIQUE EXTERIEURE Figure 40. Direct Gas Nameplate Step 2 Check the Optional High and Low Gas Pressure Switches Check the settings on the high and low gas pressure switches. The high pressure setting is typically 8 inches wc and the low pressure is setting is typically 3 inches wc. The switches are set at the factory and should not need adjustment. Adjust the setting only if needed. See the gas train layout diagram in the reference section for the high and low pressure switch location. The purpose of the high and low gas pressure switches is to automatically shut down the burner if the inlet gas pressure is too low for the burner to safely light, or if the manifold pressure is to high for the burner to operate properly. 21

22 Start-Up - Direct Gas Proper air velocity over the burner is critical on direct fired gas units. If the air velocity is not within the unit specifications, the unit will not operate efficiently, may have sporadic shutdowns and may produce excessive carbon monoxide (CO) or other gases. Step 3 Set the Burner Air Pressure Differential With all access panels in place, the fan running and discharging 70 F air, connect a U-Tube manometer to the outer sensing probes (see figure #42) and measure the static pressure across the burner. Adjustable Top Baffle Air Flow Start-Up The proper static pressure should be between and inches wc. If needed, evenly adjust the baffles above and below the burner, keeping the burner centered in the opening until the required pressure is obtained. See figure #41. The pressure drop was set at the factory and may not need adjustment. Burner When required pressure is obtained be sure to reconnect the outer sensing probes. Adjustable Bottom Baffle This process may need to be repeated until the proper pressure is achieved. This adjustment will change the air quantity delivered by the unit and therefore the air quantity delivered should be rechecked. Refer to the blower start-up section. Figure 41. Burner and Baffles To increase the static pressure decrease the opening. To decrease the static pressure increase the opening. Outer Sensing Probes U-Tube Manometer in. W.C. 7 6 Figure 42. Measuring the Pressure Drop 22

23 Start-Up - Direct Gas Step 4 Set the Low Fire Time Delay Set the low fire time delay to 75% of its maximum setting. See figure #44 or #45 for the location of the time delay setting. The low fire time delay must be set high enough to provide at least 10 seconds of low fire while the unit tries to light. MAX BTU/HR BTU/H MAX NORMAL MANIFOLD PRESSURE PRESSION D ADMISSION NORMALE MIN GAS PRESSURE PRESSION DE GAZ MIN BURNER PRESSURE DROP PERTE MIN DE PRESSION DANS LE BRULEUR W.C. MIN BTU/HR BTU/H MIN MIN GAS PRESSURE FOR MAX OUTPUT PRESSION DE GAZ MIN POUR PUISSANCE MAX MAX GAS PRESSURE PRESSION DE GAZ MAX MAX BURNER PRESSURE DROP PERTE MAX DE PRESSION DANS LE BRULEUR PSI TYPE OF GAS NATURE DU GAZ DESIGN T T NORMALE F Step 5 Set the Maximum Firing Rate Monitor the unit s actual temperature rise by placing a thermocouple in the unit s inlet and a second in the discharge, three duct diameters downstream of the burner. Send the unit to maximum fire by disconnecting and isolating the proper wire on the Maxitrol amplifier (Terminal #4 for Maxitrol 14, #3 for Maxitrol 44 as shown in figure #44 and #45). EQUIPPED FOR CONCU POUR SCFM AGAINST CONTE WARNING! Do not set the burner maximum firing rate based on gas pressure. It should be set based on the unit s designed temperature rise shown on the direct gas label. W.C. EXTERNAL STATIC PRESSURE PRESSION STATIQUE EXTERIEURE Start-Up Continues on next page... Figure 43. Direct Gas Nameplate Maxitrol Series 14 (7 or 8 terminals) Maxitrol Series 44 (9 terminals) Remove the wire from terminal #4 to send the unit to maximum fire Minimum discharge temperature setting (50 F Typical) Remove the wire from the #3 terminal to send the unit to maximum fire Low fire time delay setting (75% of maximum) Low fire time delay setting (75% of maximum) Maximum discharge temperature setting (100 F Typical) Figure 44. Maxitrol 14 Figure 45. Maxitrol 44 23

24 Start-Up - Direct Gas Step 5 Set the Maximum Firing Rate (...continued) While monitoring the units temperature rise, set the maximum firing rate by adjusting the regulator (shown in figure #46) until the designed temperature rise is achieved. After setting the maximum firing rate, reconnect the wire to the amplifier. Maximum firing rate adjustment Setting the maximum firing rate during mild weather conditions may cause the high limit to trip out during extreme conditions requiring manual resetting. Figure 46. Regulator Clockwise rotation increases the temperature rise, counterclockwise rotation decreases the temperature rise. Start-Up The minimum setting for the maximum firing rate may be higher than required. This is acceptable, the burner will modulate as needed. Step 6 Set the Minimum Firing Rate Disconnect and isolate one of the wires running to the modulating valve to send the unit to its minimum firing rate. Set the minimum firing rate by adjusting the needle valve shown in figure #47. After setting the minimum firing rate, reconnect the wire to the modulating valve. The proper minimum firing rate setting results in a small ribbon of continuous flame which covers the flame rod and runs across the entire burner. The minimum firing rate setting is critical. If the settings is too high, the unit may not light, too low and the flame rod may not detect the flame. Do not allow the disconnected wire to come in contact with a potential ground, damage to the amplifier or transformer could result. Remove one wire to send the unit to the minimum firing rate. Adjusting the maximum and minimum fire may require the inlet air sensor to be initially set higher than desired in order to start the burner(s). Once high and low fire have been set, the inlet air sensor should be turned down to the desired temperature. Counterclockwise rotation increases the minimum fire rate setting, clockwise rotation decreases the setting. Minimum firing rate adjustment Figure 47. Modulating Valve 24

25 Start-Up - Direct Gas Step 7 Set the Unit s Operating Temperature Set the operating temperature. The operating temperature setting depends on which Maxitrol controller is used and the desired space temperature. See figure #48 or #49. Maxitrol Series 14 (Discharge temperature control) The Maxitrol Series 14 should be set to the desired discharge temperature. The temperature selector may be built into the amplifier or may be a stand-alone dial. The stand-alone dial may be mounted remotely. Maxitrol Series 44 (Space temperature control) The Maxitrol Series 44 should be set to the desired room temperature. The Selectrastat must be mounted in the space. Set the space temperature (70 F Typical) Start-Up Set the discharge temperature (65 F Typical) Figure 48. Series 14 Discharge Temperature Setting Figure 49. Series 44 Discharge Temperature Setting Step 8 Flame Signal Check To measure the flame signal connect a standard DC voltmeter to terminals (FC+) and (FC-) on the Fenwal flame safe guard. See figure #50. The flame signal should be above 1.25 VDC and steady. Check the flame signal with the burner at minimum fire, mid-fire and high-fire. If the flame signal is not above 1.25 VDC and steady, consult the troubleshooting section. FC+ FC- Figure 50. Flame Safe Guard 25

26 Start-Up Start-Up - Evaporative Cooling (Optional) Step 1 Check the Installation The media may have been removed during installation, so its orientation should be double checked. The media should be installed with the steeper flute angle sloping down toward the entering air side. See the figure #51. Verify that the stainless steel caps and distribution headers are in place. The headers should be located over the media towards the entering air side. The caps should be placed over the headers. Step 2 Check the Pump Filter Check that the pump filter is around the pump inlet. See figure #52. Entering Air Step 6 Adjust the Water Bleed-Off Rate The water bleed-off rate is dependent on the water s mineral content. The bleed-off should be adjusted based on the media s mineral deposits after two weeks of service. See figure #52. Step 8 Put the Unit into Service Remove the jumper, and energize the blower(s). Verify proper operation Leaving Air Step 3 Fill the Sump and Adjust the Float Turn on the water supply and allow the pan to fill. Adjust the float valve to shut-off the water supply when the sump is filled to within 1 in. of the bottom of the overflow. See figure #52. Step 4 Break-in the Media Open the bleed-off valve completely and saturate the media with the blower(s) off for no less than 20 minutes. Figure 51. Media Orientation A jumper will need to be installed in the control center to power the evaporative pumps with the blower(s) off. Reference the unit s ladder diagram to determine proper terminals. Step 5 Check the Flow Rate The pumps should provide enough water to saturate the media in 45 to 60 seconds. Consult the factory, if adequate flow is not achieved. Step 7 Set the Optional Auto Drain and Fill Set the auto drain and fill timer and temperature settings. Timer settings are t1: 1.0, 10min and t2: 0.4, 60h Temperature is typically set to 45ºF. See figure #52. Check the media for minerals after two weeks of service and adjust the bleed-off rate accordingly. Bleed-Off Valve Pump Filter Supply Connection Float Valve Threaded Float Adjustment Evaporative Freeze Protection Evaporative Timer Temperature Setting Overflow t2 settings t1 settings Figure 52. Evaporative Cooler Set-Up 26

27 Start-Up - Water Wizard (Optional) Step 1 Open the Solenoid Confirm that the manual water supply valve is closed. Press and hold the Function Button for one second. L3 will begin blinking (short on, long off), indicating that Flow Test Mode is active and the supply solenoid is open. Step 2 Set the Water Pressure With the solenoid open, set the supply water pressure to the correct setting from table 2. Use the manual supply valve to adjust the supply pressure. A pressure gauge is provided between the manual supply valve and the media. See figure #53. Water Pressure (in. w.c.) MSU MSU 22 ( in. wide*) 36 MSU 22 (48 in. wide*) 42 MSU 22 (60 in. wide*) 61 MSU 32 (66 in. wide*) 72 MSU 32 (96 in. wide* + ) 42 MSU MSU MSU *Total media width + Two 48 inch media sections Table 2. Recommended Water Pressure The manual supply valve ships closed and must be adjusted for proper performance. Step 3 Close Solenoid With the pressure set, press the Function Key for one second to deactivate Flow Test Mode and allow the supply solenoid to close. Roof Line Trap Sump Drain To Media Drain Solenoid Pressure Gauge Manual Supply Valve Supply Solenoid Start-Up Figure 53. Water Wizard Installation Step 4 Check Media Start the cooling cycle and check the media after one hour of operation. If the media is continuously dry or if too much water is draining from the sump tank, refer to the Trouble Shooting section. The inlet air sensor function overrides and shuts down the evaporative cooler if the outside temperature falls below the minimum cooling temperature. The minimum cooling temperature is preset to the factory recommended 75ºF. Steps 5-7 should only be complete if the minimum cooling temperature needs adjustment. Step 5 Enter Program Mode Press and hold the Enter Key for three seconds. The display will read Pro when Program Mode is active. See figure #54. Figure 54. Program Display 27

28 Start-Up - Water Wizard Step 6 Adjust the Minimum Cooling Temperature While in the Program Menu, use the Up and Down Keys to navigate the Menu Options until tof is displayed (see figure #55). Press the Enter Key to access the selected Menu Option setting. Use the Up and Down Keys to adjust the Minimum Cooling Temperature as needed. Press the Enter Key to save the Minimum Cooling Temperature setting and return to the Program Menu. Figure 55. Minimum Cooling Temperature Display The Enter Key must be pressed to save the new Minimum Cooling Temperature. Step 7 Exit Program Mode After ten seconds of idle time the controller will exit Program Mode. Start-Up The Freeze Temperature is preset to the factory recommended 41ºF. Steps 8-10 should only be completed if the Freeze Temperature needs adjustment. The Freeze Temperature is the temperature at which the supply solenoid closes and the drain solenoid opens to drain the supply line, preventing possible freeze damage. A drain solenoid is required for this option. Step 8 Enter Program Mode Press and hold the Enter Key for three seconds. The display will read Pro when Program Mode is active (see figure #56). Figure 56. Program Display Step 9 Adjust the Freeze Temperature While in Program Mode, use the Up and Down Keys to navigate through the Menu Options until Frt is displayed (see figure #57). Press the Enter Key to access the selected Menu Option setting. Use the Up and Down Keys to adjust the Freeze Temperature setting as needed. Press the Enter Key to set the Freeze Temperature and return to the Program Menu. Figure 57. Freeze Temperature Display Step 10 Exit Program Mode After ten seconds of idle time the controller will exit Program Mode. The Enter Key must be pressed to save the new Freeze Temperature. 28

29 Operation - Recirculating / VAV Units Burner By-Pass Damper The self adjusting burner by-pass damper is a device used in variable volume and recirculation units. Its function is to maintain proper combustion by providing a constant airflow over the burner when outside air volumes are changed. It is located underneath the burner as shown in figure #58. Burner By-Pass Damper WARNING! The burner by-pass damper is set-up at the factory. The weights and springs should not be adjusted in the field. The damper may not fully close during minimum outside air mode. Figure 58. Burner By-Pass Damper 80/20 Operation (Optional) Manual Quadrant Damper Control A manual quadrant damper in the return airflow controls the amount of recirculated air. This damper can be adjusted by hand and locked in position for either 100% outside air or maximum recirculation air. 2-Position Damper Control A 2-position spring return actuator is used to control the return air amounts. The damper moves from open to closed. If power is cut to the unit, the damper will fail close. The volume of recirculation air is set in the factory by baffles in the return air opening. These baffles should not be removed or adjusted in the field. Potentiometer Control A modulating spring return actuator is used to control the return air amounts. The damper moves from fully open to fully closed. The amount of return air is determined by the position of a remote potentiometer. Building Pressure Control A modulating spring return actuator is used to control the return air amounts according to input from a pressure sensing device. The recirculation damper moves from fully open to fully closed. Operation Variable Volume Operation (Optional) 2-Speed Control A 2-speed motor is used to control air volumes. The motor can be switched to low or high speed from a remote control panel. One-half or one-third reduction motors are used. Potentiometer Control A variable frequency drive is controlled by input from a remote speed selector (potentiometer). This unit allows easy manual adjustment of make-up air volumes. Building Pressure Control A variable frequency drive is controlled according to input from a pressure sensing device. Variable Frequency Drives For maintenance issues associated with the variable frequency drives, please consult the drive s manual supplied with the unit. The drives are programmed in the factory and should not need any adjustment during installation and start-up. For kitchen applications, the drive is located in the kitchen, not in the unit. 29

30 Operation - Electrical Electrical Sequence 1. Exhaust Fan Switch (S1) Closed Power passes to exhaust starter(s) ST2(3) N.O. exhaust starter switches are energized and closed Power passes to exhaust fans Exhaust fans start 2. Supply Fan Switch (S2) Closed N.O. contact(s) ST2(3) are closed Power passes to optional freeze protection relay (FZ1) and if temperature is acceptable N.C. contact (FZ1) remains closed Power passes to damper which opens When damper is fully opened, damper relay (D1) is energized and N.O. damper limit switch (DL1) closes. Power passes to and energizes supply starter relay (ST1) Supply starter contact (ST1) closes and power reaches and energizes supply fan Supply fan starts Direct Gas Burner Sequence 1. Supply Fan Switch Closed Power passes to the supply fan and heat switch 2. Heat Switch Closed Power passes to the heat relay then to the Flame Safe Guard 3. Flame Safe Guard (FSG) Sequence Checks for proper airflow Verifies no flame present at burner Initiates 15 second prepurge Sends power to open gas valve (V2) and energizes the spark generator (clicking of the spark generator may be heard). Tries for up to 10 seconds to light and confirm flame. Shuts down spark generator Continuously monitors the flame and airflow Operation 3. Heat Switch (S3) Closed Power passes to N.O. ST1 which is energized and closed Power passes to inlet air sensor contact (TS1) which is energized and closed if proper inlet air temperature is present Power passes to and energizes heat relay (R2) N.O. heat relay contact (R2) closes Power passes to N.C. high limit control contact (HLC1) which is closed if temperature has remained below set point Power passes to N.O. and N.C. gas pressure contacts (PS1) which are both closed if gas pressure is within the set range Power passes to N.O. and N.C. airflow switch (PS2) which are closed if there is proper airflow across the burner Power passes to terminal L1 on the FSG which begins it s sequence (see direct gas sequence) 4. Evaporative Cooling Switch (S4) Closed* N.O. contact ST1(AUX) is energized and closed Power passes to and energizes cool relay (R1) N.O. contact R1 is energized and closed Power passes to evaporative cooling pump (P1) *If DX or chilled water coils are used rather than an evaporative cooler, the cooling sequence of operation will depend on the coil controls. Cooling coil controls are supplied by others. 30

31 Operation - Water Wizard L1 L2 L3 Function Key Up Key Enter Key Down Key Figure 59. Water Wizard User Interface Drain Mode Drain Mode locks open the drain solenoid and drains the supply line between the supply solenoid and the media. To activate Drain Mode simultaneously press the Function and Enter Keys. To deactivate Drain Mode and unlock the drain solenoid, simultaneously press the Function and Enter Keys again. Flow Test Mode Activating Flow Test Mode opens the supply solenoid and allows water to pass to the manual supply valve. To activate Flow Test Mode, press and hold the Function Key for one second. To deactivate Flow Test Mode and allow the supply solenoid to close, press and hold the Function Key again for one second. CAUTION! The sump drain line must be clear and draining to a safe location before using Flow Test Mode. CAUTION! Be aware of the water level in the sump tank at all times when using the Flow Test Mode. Program Mode Program Mode allows the user to view the Program Menu and edit the factory default settings. To access Program Mode and view the Program Menu press and hold the Enter Key for three seconds. While viewing the Program Menu press the Up and Down Keys to scroll through the Menu Options. To view the setting of the selected Menu Option press the Enter Key. To edit the setting, press the Up or Down Key while viewing the setting. To save the setting and return to the Program Menu press the Enter Key. To return to the Program Menu without saving the change, wait 10 seconds. To exit Program Mode from the Program Menu, wait 10 seconds. Operation WARNING! Changing the default settings will significantly effect performance. Only change a setting after reading and understanding this entire manual. The Enter Key must be pressed to save any changes made to a setting. Dry Bulb Temperature The default display is the Dry Bulb Temperature of the outside air. 31 Wet Bulb Temperature To view the Wet Bulb Temperature, simultaneously press and hold the Up and Down Keys. Indicating Lights Three indicating lights are located across the top of the display to indicate the status of the Water Wizard. Light Status On Off Blinking (Long on, short off) L1 Call For Cooling Call For Cooling N/A L2 Drain Solenoid Drain Solenoid Open Closed N/A L3 Cooling On Cooling Off Supply Solenoid Locked Close Blinking (Short on, long off) N/A N/A Flow Test Mode Active

32 Blower Does t Operate Troubleshooting Troubleshooting 115 Vac across terminals 102 and 101? 24 Vac across terminals R and X? 24 Vac across terminals G and X? 24 Vac across terminals 6 and X? 24 Vac across terminals 7 and X? 24 Vac across terminals 8 and X? Check Main Voltage (See Blower Start-Up Step #1) Main Disconnect (DS1) Off (Turn Main Disconnect DS1 On) Primary Fuses (FU6) or Secondary Fuses (FU7) Blown (Replace Fuses) Main Transformer (TR1) Defective (Replace Transformer TR1) Secondary Fuse (FU8) Blown (Replace Fuses) Main Transformer (TR1) Defective (Replace Transformer) Supply Switch (S2) Off (Turn Supply Switch S2 On) Fire system contact (FSC) tripped (Correct/Replace) Optional Exhaust Fan Interlocks (ST2-ST5) Open (Correct/Replace) Freeze Protection (FZ1) Tripped (Reset) Damper Limit Switch (DL1) Holding (Wait for actuator to open fully or adjust limit switch) Damper Limit Switch Jumper Missing (Install jumper, reference the units ladder diagram for terminals) Supply Fan Overload (ST1 OL) Tripped (Reset and check motor amps, reference blower start-up #4) Broken Fan Belt (Replace - Reference maintenance section) Defective motor or capacitor (Repair/Replace) Blown Motor Fuse (Replace) One or more legs of 3 phase is out (Restore missing legs) te: At this time the supply contactor (ST1) should pull in passing power to the supply motor and the blower should start. 32

33 Heater Does t Operate Does not attempt to light ( visible spark) Troubleshooting 24 Vac across terminals W1 and X? 115 Vac across terminals 102 and 101? 115 Vac across terminals 103 and 101? 115 Vac across terminals 104 and 101? Heat Switch (S3) Off (Turn Heat Switch S3 On) Heat Switch t Wired (Wire Heat Switch S3) Secondary Fuses (FU7) Blown (Replace Fuses) Main Transformer (TR1) Defective (Replace Transformer TR1) Inlet Air Senor (TS1) Holding (Adjust TS1 setting -- Reference blower start-up step 6) Heat Relay (R2) Defective (Replace Heat Relay R2) 115 Vac across terminals 105 and 101? High Limit (HLC1) Tripped (Reset/Replace High Limit HLC1) (Check on cause of control loss) Continuity across terminals 105 and 108? High/Low Gas Pressure Switch(s) (PS1, PS3) Tripped (Correct gas pressure and reset) (Reference Direct Gas Start-Up Step #2) Airflow Switch (PS2) Holding for Proper Airflow (Correct airflow across burner) (Reference Direct Gas Start-Up Step #3) Troubleshooting At this time the heater should attempt to light 33

34 Heater Does t Operate Attempts to light but no flame (Visible spark) Troubleshooting Is the low fire set properly (Direct Gas Start-Up Step #6) Adjust the low fire setting (Reference Direct Gas Start-Up Step #6) Check inlet gas pressure. (Direct Gas Start-Up Step #1) Gas pressure between the min and max shown on the direct gas label? Correct gas pressure (Reference Direct Gas Start-Up Step #1) Air in the gas line? Purge gas line Check burner pressure drop (Direct Gas Start-Up Step #3) Troubleshooting Pressure drop across the burner between 0.60 and in. wc? Proper spark? Adjust burner baffles (Reference Direct Gas Start-Up Step #3) Crossed flame and spark wires (Uncross wires and reconnect) Incorrect spark plug gap (Set spark plug gap to in.) Defective spark plug (Replace spark plug) With proper airflow, gas pressure and spark, the unit should light. If problems remain, consult the factory 34

35 Troubleshooting Water Blows through Evaporative Cooler Are the headers in place and located near the entering side of the media? Replace headers and/or move the headers. (Reference Evaporative Cooler Start-Up Step #1) Water supply greater than evaporation and bleed-off rate? Use the main supply valve to reduce the supply of water. Air velocity greater than specified? Reduce the air velocity through the media. te: At this time the evaporative cooler should be operating without water blowing through. Troubleshooting 35

36 Excessive ise or Vibration Troubleshooting Belts worn or loose? Replace worn belts or tighten loose belts. (Reference V-Belt drive maintenance in the maintenance section) Sheaves aligned? Align sheaves (Reference V-Belt drive maintenance in the maintenance section) Wheel(s) unbalanced? Clean and/or balance wheel(s). Bearings worn or need lubrication? Replace worn bearings or lubricate bearings as needed. (Reference bearing maintenance in the maintenance section) Wheel(s) rubbing on inlet? Adjust wheel(s) or inlet. Troubleshooting te: At this time noise and vibration should be at acceptable levels. 36

37 Troubleshooting Water Wizard (Improper Water Supply) If the water supply is too low, the media will continuously appear dry. If the water supply is too high, the media will be saturated and excessive water will be draining from the sump tank. Some water drainage is desirable to reduce mineral deposits but should be minimized to best utilize the Water Wizard. Step 1 Adjust the Manual Supply Valve Adjust the manual supply valve (refer to Water Pressure Start-Up S-9, Step #2). CAUTION! Only proceed to steps two and three if the manual supply valve does not correct the problem. Step 2 Enter Program Mode Press and hold the Enter Key for three seconds to enter Program Mode. The display reads Pro when Program Mode is active (see figure #60). Figure 60. Program Display Step 3 Adjust the On Time Factor While in the Program Menu, use the Up and Down Keys to navigate through the Menu Options until ont is displayed (see figure #61). Press the Enter Key to access the setting. Use the Up and Down Keys to adjust the setting as needed. Increase the factor to increase the water supply or decrease the factor to decrease the water supply. Press the Enter Key to save the On Time Factor and return to the Program Menu. Figure 61. On Time Factor Display Changing the On Time Factor by (1) will change the water supply by approximately 3%. The Enter Key must be pressed to save the new On Time Factor. Troubleshooting Step 4 Exit Program Mode After ten seconds of idle time the controller will automatically exit the Program Mode. 37

38 Maintenance - Routine CAUTION! Lock-out the gas and the electrical power to the unit before performing any maintenance or service operations to this unit. V-Belt Drives V-belt drives must be checked on a regular basis for wear, tension, alignment and dirt accumulation. Check the tension by measuring the deflection in the belt as shown in figure #62. Check the alignment by using a straight edge across both sheaves as shown in figure #63. Premature or frequent belt failures can be caused by improper belt tension, or misaligned sheaves. Abnormally high belt tension or drive misalignment will cause excessive bearing loads and may result in failure of the fan and/or motor bearings. Abnormally low belt tension will cause squealing on start-up, excessive belt flutter, slippage and overheated sheaves Do not pry belts on or off the sheave. Loosen belt tension until belts can be removed by simply lifting the belts off the sheaves. When replacing V-belts on multiple groove drives all belts should be changed to provide uniform drive loading. Do not install new belts on worn sheaves. If the sheaves have grooves worn in them, they must be replaced before new belts are installed. Deflection = Belt Span 64 Belt Span Maintenance Figure 62. Belt tension Figure 63. Drive Alignment 38

39 Maintenance - Routine Motors Motor maintenance is generally limited to cleaning and lubrication (where applicable). Cleaning should be limited to exterior surfaces only. Removing dust and grease build-up on the motor assures proper motor cooling. Motors supplied with grease fittings should be greased in accordance with the manufacturer s recommendations. Do not allow water or solvents to enter the motor or bearings. Motors and bearings should never be sprayed with steam, water or solvents. Greasing motors is only intended when fittings are provided. Many motors are permanently lubricated, requiring no additional lubrication. Wheels Wheels require little attention when moving clean air. Occasionally oil and dust may accumulate on the wheel causing imbalance. When this occurs the wheel and housing should be cleaned to assure proper operation. Bearings The bearings for Greenheck fans are carefully selected to match the maximum load and operating conditions of the specific class, arrangement and fan size. The instructions provided in this manual and those provided by the bearing manufacturer will minimize any bearing problems. Lubricate bearings prior to periods of extended shutdowns or storage and rotate shaft monthly to aid in corrosion prevention. If the fan is stored more than three months, purge the bearings with new grease prior to start-up. Recommended Bearing Lubrication Schedule for Greenheck Fans Relubrication Schedule in Months* Fan RPM Bearing Bore Size (inches) 1/ /8-1 1/2 1 5/8-1 7/8 1 15/16-2 3/16 2 7/ * Suggested initial greasing interval is based on 12 hour per day operation and 150 F maximum housing temperature. For continuous (24 hour) operation, decrease greasing interval by 50% - If extended grease lines are present, relubricate while in operation, only without endangering personnel. - For ball bearings (operating) relubricate until clean grease is seen purging at the seals. Be sure not to unseat the seal by over lubricating. - For ball bearings (idle) add 1-2 shots of grease up to 2 inch bore size, and 4-5 shots above 2 inch bore sizes with a hand grease gun. - For roller bearings add 4 shots of grease up to 2 inch bore size, and 8 shots for 2 inch - 5 inch bore size with a hand grease gun. - Adjust relubrication frequency based on condition of purged grease. - A high quality lithium based grease conforming to NLGI Grade 2 consistency, such as those listed below. Mobil 532 Texaco Multifak #2 B Shell Alavania #2 Mobilux #2 Texaco Premium #2 Exxon Unirex N2 Maintenance 39

40 Maintenance - Routine Filters Filter maintenance is generally limited to cleaning and replacement. If aluminum mesh filters are installed, they can be washed in warm soapy water. An adhesive spray can be added to aluminum mesh filters to increase their efficiency. If disposable filters are installed, they can be check by holding up to a light source. If light cannot pass through the filter, it should be replaced. When reinstalling filters be sure to install them with the airflow in the correct direction. An airflow direction arrow is located on the side of the filters. Replacement filters should be from the same manufacturer and the same size as the original filters provided with the unit. Evaporative Coolers The media should be periodically brushed lightly with a soft bristle brush in an up and down motion while flushing with water. This aids in reducing the amount of mineral build-up. For large amounts of mineral build-up, clean or replace the media and increase the water bleed-off or flush rate. When reinstalling the evaporative media, make sure that it is installed correctly. Reference figure # The cooling media has a useful life of 3 to 5 years depending on the water quality and the bleed-off or flush rate. Maintenance Replacement media should be from the same manufacturer and be the same size as the original media provided with the unit. Cooling Coils Inspect the coil for signs of corrosion and/or leaks. Repair any leaks as required. Inspect the coil s surface for foreign material. If the coil surface needs cleaning, clean the coil from the leaving airside so that foreign material will be washed out of the coil rather than pushed farther in. Inspect and clean the drain pan to prevent the growth of algae and other organisms. Chilled Water Coils Test the circulating fluid for sediment, corrosive products and biological contaminants. Make the necessary corrective measures. Maintain adequate fluid velocities and proper filtering of the fluid. Entering Air 15 Figure 64. Media Orientation Leaving Air WARNING! Repair and replacement of the coil and the connecting piping, valves, etc., should be performed by a qualified individual. Be sure to read and follow the manufacturer s recommendations before using any cleaning fluid. CAUTION! Caution should be used to avoid injury when venting the coil. High pressure and/or high temperature fluids can cause serious injuries. If automatic air vents are not utilized, periodic venting of the coil is recommended to remove accumulated air. 40

41 Maintenance - Fall Start-Up Repeat the Blower Start-Up procedure #5 and Direct Gas Start-Up procedure #1, 2 and 3. This will ensure that the gas and air are set properly before the heating season begins, and should lead to trouble free operation all winter. High Limit The high limit switch may have tripped over the summer, it should be checked and reset if necessary. Burner Inspect the burner for accumulation of scales on both the upstream and downstream sides of the mixing plates. Any scaling or foreign material should be removed with a wire brush. Visually check that all holes in the mixing plates are clear. If any burner ports are plugged (even partially), clear them with a piece of wire or another appropriate tool. Replace or tighten any loose or missing fasteners on the mixing plates. Always use zinc plated or stainless steel fasteners. Inspect and clean the flame and spark rod. Occasional replacement of the flame rod and spark rod may be necessary to ensure optimum unit performance. WARNING! Do not enlarge burner ports when clearing a blockage, performance could be affected. Flame rods can last many years, but because of thermal expansion of the porcelain, flame rods can fail over time. Flame Rod Spark Rod Mixing Plate Holes Figure 65. Burner Burner Ports Maintenance Evaporative Coolers The water should be shut off and all the lines drained when the outside temperature drops below 45 F. Remove drain plugs for the winter. Clean all interior parts of any mineral deposits or foreign materials that may have built-up during the cooling season. Replace any worn or non-functioning parts. 41

42 Maintenance - Fall Winterizing Chilled Water Coils During the winter, chilled water coils need to be protected against freezing. Greenheck recommends protecting the coils by either blowing-out the coils or by flushing the coils. Blowing-Out Coils Isolate the coil from the rest of the system by closing the valves on both the supply and return lines. Drain the coil by opening all drain valves and/or the drain plug. Remove the vent plug to aid in the draining process. Once the coil has been fully drained, a blower can be hooked-up to the caps. The air vent and drain plug are not suitable locations for hookingup the blower. Close the vent drain plug on the header to which the blower is connected and open the drain valve or cap on the other header. Operate the blower for 45 minutes and then check if the coil is dry. A mirror placed in the discharge will become fogged if moisture is present. Repeat this procedure until the coil is dry and no fog appears on the mirror. Let the coil stand for several minutes then blow it out again. If water comes out, repeat the blowing operation. Leave all plugs out and drains open until the threat of freezing has passed. Flushing Coils Greenheck recommends the use of inhibited glycol designed for HVAC applications for corrosion protection. The use of uninhibited glycol can produced formicary corrosion in copper tubing. The complete filling of water coils with an inhibited glycol solution for freeze protection can be expensive, but in some instances it is more cost effective. Residual glycol fluid can be left in the coil without the threat of freeze damage, provided the correct concentration of inhibited glycol is used. The recovered fluid can then be used to flush other coils. It is important to select an inhibited glycol solution that will protect the coil from the lowest possible temperature that may be experienced over the cold season. See the following table for concentration recommendations. % Ethylene Glycol Freeze Point By Volume ( F) Maintenance % Propylene Glycol Freeze Point By Volume ( F)

43 Maintenance - Log Job Information Job Name: Address: City: State: Zip: Phone: Fax: Contact Person: Name Plate Information Model: Volts: Hertz: Phase: Amps: Mark: Supply hp: Exhaust hp: Serial Number: Motor Voltage: Motor Amperage: Fan rpm: Service Organization: Address: City: State: Zip: Phone: Fax: Work Done By: Field Start-Up Documentation Actual Voltage: Hertz: Phase: Actual Amperage: Blower Rotation Air Volume Design cfm Actual cfm High Fire Manifold Pressure: Low Fire Manifold Pressure: Maintenance Log Date Time tes: Maintenance 43

44 Maintenance - Log Maintenance Log Date Time tes: Maintenance 44

45 Maintenance - Log Maintenance Log Date Time tes: Maintenance 45

46 Reference Typical Gas Train Layout less than 400 MBH Burner Differential Pressure Sensor (Airflow Switch) To Burner High Gas Pressure Switch (Optional) Burner Manual Shut-off Valve High Gas Pressure Test Port Modulating Valve Combination Shut-off Valve/Regulator Low Gas Pressure Switch (Optional) Low Gas Pressure Test Port Figure 66. Direct Spark Gas Train Gas Connection This is a typical gas train. The gas train in your unit may be different. Reference 46

47 Reference Control Center Layout Figure 67. Direct Spark Gas Control Center 1. Heating/Cooling Inlet Air Sensor (Optional) - Ductstat that automatically de-energizes burner when inlet air temperature rises above set point, or shuts down cooling when temperature falls below set point. 2. Flame Safeguard/Spark Generator - Monitors flame, shuts down unit when unsafe conditions are detected. 3. High Limit - Prevents unit from discharging air above a set point. 4. Building Freeze Protection (Optional) - Prevents unit from discharging air below a set point after a time delay. Temperature and time delay are field adjustable. 5. Filter Gauge (Optional) - Monitors filter pressure drop, turns on indicating light when pressure drop is above field adjustable set point. 6. Terminal Strip - 24 Volt power strip for control wiring. 7. Main Disconnect - On/Off switch, provides single point power connection to unit. 8. Grounding Lugs - Completes electrical circuit 9. Motor Starters - 24 Volt magnetic contacts for starting motors, comes standard with electronic overload, may be provided with auxiliary contacts. 10. Amplifier - Controls modulating valve, assures the desired temperature is delivered. 11. Low Voltage Transformer - Reduces voltage to the Maxitrol system. 12. Control Transformer - Provides 24 Volts for controls and 120 Volts for valves. 13. Secondary fuses - Provides proper fusing for all electrical components other than the motors. 14. Motor Fuses - Provides proper fusing for supply and exhaust fan motor(s). Reference 47