Quest Explosion-Proof XP-300 Pro

Transcription

1 Quest DRY 150 Quest Explosion-Proof XP-300 Pro Read and Save These Instructions This manual is provided to acquaint you with the fan coil unit, so that installation, operation and maintenance can proceed successfully. Ultimate satisfaction depends on the quality of installation and a thorough understanding of the equipment. This unit is built around tested engineering principles and has passed a thorough inspection for quality of workmanship and function. Quest Explosion-proof XP-300: 300,000 BTUH 3000 CFM ETL Certified to the following standards: UL 1203 Ed. 5. UL 674 Ed. 5. ANSI/UL CSA C22.2 No. 30. CSA C22.2 No CAN/CSA C22.2 No. 236 Approved for Hazardous Locations Division 1, Class I, (Group C&D) Division 1, Class II, (Group F&G) Temp control with Glycol Mixing Valve Multiple air filter options Multiple ducting options. 20 intake & supply The Aluminum cabinet base provides liquid-tight containment that holds 6 times the glycol volume of the coil plus an exterior section to catch drips when making or breaking Quick coupler connections. PN Patent Pending quest Specifications subject to change without notice Lien Rd Phone Madison, WI Toll-Free TS /15

2 Table of Contents Safety Precautions Description Applications and Benefits Specifications Physical Specifications Electrical Supply Requirements Air Blower Specifications Heat Transfer Coil Technical Data Setup and Startup Positioning and Connecting Equipment Connect Power to Motor Startup the System Service Component Removal Cleaning Storage Warranty Serial No. Purchase Date / / Dealer s Name 2

3 Safety Precautions Read the installation, operation and maintenance instructions carefully before installing and operating this device. Proper adherence to these instructions is essential to obtain maximum benefit from your Quest Explosion-proof XP-300 Pro. READ AND SAVE THESE INSTRUCTIONS HAZARD WARNINGS! MENTIONS DE DANGER! Failure to follow correct setup and startup procedures will cause serious injury, death or long term health risk! Procedures must be performed by Qualified, Trained Professionals Only! Because this unit is used in Hazardous Locations, there Are (Or May be) Flamable materials present! Precautions necessary to prevent Fire must be taken at all times! Because this unit is used in Hazardous Locations, there Are (Or May be) Explosive Vapours and/or Dusts present! Precautions necessary to prevent Explosion must be taken at all times! Non-respect des procedures d installation et de mise en service entrafnera des blessures graves, Ia mort ou risque pour Ia sante a long terme! Des procedures doivent etre effectuees par qua/ifie, forme de profession nels uniquement! Parce que cet appareil est utilise dans des endroits dangereux, il sont (ou peut-etre etre) des materiaux innammab/es presents! Precautions necessaires pour prevenir /es incendies doivent etre prises a tout moment! Parce que cet appareil est utilise dans des endroits dangereux, il sont (ou peut-etre etre) des vapeurs explosives evou poussieres presentent! Precautions necessaires pour prevenir / Explosion doivent etre prises a tout moment! ATTENTION 3

4 1. Description The standard equipped unit is approved for use in Division I Hazardous Locations: Class I Groups C & D / Class II, Groups F & G. The XP-300 is a stationary accessory device designed for use in conjunction with any of the Quest Central Hydronic Glycol Heaters. It transfers heat from the heated glycol circuit to an air stream that is being forced through an internal hydronic heat transfer coil. This fan coil unit is designed for use in confined Hazardous spaces, as long as the Central Hydronic Glycol Heater is set up outside and well clear of the hazardous confined zone. The XP-300 consists of the following components contained inside an aluminum cabinet. A liquid to air heat exchange coil, constructed of copper tube, aluminum fin and aluminum frame. A Plug Fan style air blower that utilizes a backward-inclined aluminum impeller and a motor that is approved for operation within specific Hazardous Locations. A 3-port, manual-dial-operated, flow mixing/diverting valve. Integral air filtration which accepts various efficency-rated air filters. Slide-in, aluminum duct connector collars can be attached to either the supply air outlet or the return air inlet or both. The unit is equipped with fork lift pockets and a center-top hoisting hook. The cabinet base provides liquid-tight containment inside the cabinet that holds 6 times the glycol volume of the coil and there is an exterior section to catch drips when making or breaking the Quick-coupler connections. 2. Applications and Benefits The XP-300 can be used to provide a temporary or permanent heat solution wherever Hydronic distribution may be used. It will operate very effectively and efficiently on construction sites of all types. The single biggest advantage over all competitors is the capability of this fan coil to be used in Hazardous Locations. This unit is unique in ways that no others on the market can match. It is the best choice for any locations where volatile vapors or dusts are (or may be) present. These could include: * Gas and oil extraction sites, refineries & plants. * Mine sites. * Chemical plants. * Warehouses that store and distribute volatile substances. * Factories that produce or use volatile substances. * Cargo vessels that carry volatile substances in their holds. * Containers and tanks that are used to store or transport hazardous materials or for handling environmental cleanup residues. * Hoarded contained spaces where volatile coatings must be applied, dried or removed. * Outdoor locations such as drilling platforms, pipeline assemblies or other similar situations. This unit can direct a stream of warm dry air over the workmen and assemblies they are working on, to provide comfort, enhance quality of workmanship and improve productivity. 4

5 The unit is constructed mostly of aluminium for light weight and non-sparking exterior surfaces. It is easy to move around and quick to set up. Because this unit utilizes a backward inclined high pressure, high volume blower, it can be set up, even in Hazardous Locations, for functions that competitors cannot. * It can be connected to ducts for customized efficient distribution. This could be a flex connection to an existing duct system within the structure or a temporary set of flexible or lay-flat ducts. * It is capable of high efficient filtration of the airstream. It accepts a 20 x 30 x 2 filter available in efficiencies up to MERV 13 rating. The 3-way, manual dial-operated glycol flow valve provides a simple effective means of controlling the temperature of the output air stream and hence the comfort level within the hazardous zone. * The adjustment dial is rotated to any position between 0% and 100% of the hot glycol to be directed through the heat transfer coil. The portion of flow that does not go through the coil is diverted straight back to the outdoor glycol re-heat unit. The comfortable temperature position (for inside the contained structure) is easily found this way. * This allows the blower to run continuously to provide for conditioning requirements besides temperature control (such as drying and filtration) on a full time basis. * The simple heat control strategy eliminates the need for costly wiring and controls that would be necessary to have a thermostatic control system designed for Hazardous Location use. The Plug-fan style air blower is simple to remove from the cabinet assembly by removing 6 bolts. Access to the interior is not required to remove or replace these bolts. This simplifies blower service or motor replacement. Air filters are accessible through a slot in the side wall of the cabinet enclosure. 3. Specifications 3.1 Physical Specifications: Length of Cabinet inches (millimeters) 33 (838) Width of Cabinet inches (millimeters) 29 (737) Height of Cabinet inches (millimeters) 41 (1041) Weight: with glycol pounds (kilograms) 195 (89) 3.2 Electrical Supply Requirements: Supply Voltage 115 / Circuit Amperage 20 / 10 Hertz 60 Phase 1 Specification for cable and wiring accessories must be determined for every Setup. Must be preformed by a licensed electrician. 5

6 3.3 Air Blower Specifications: Impeller Diameter: (Backward-inclined) 400 millimeters Inches Motor: - various motors may be supplied. Must be UL & CSA approved for Hazardous Locations (At Minimum) Equal to: Division 1, Class I, (Group C&D) Division 1, Class II, (Group F&G) Motor Specifications: Power 746 watts 1.0 HP Voltage choice 115 / Full Load Amp Rating Equal or less than 14 / Temperature Code Phase 1 Hertz 60 T3C Ambient Temperature range -20 C to 40 C -4 F to 104 F Airflow: System Design 5100 CMH 3000 CFM Air: Design static pressure 250 PA 1.0 WC Air Filter: Dimensions 508 x 762 x 50.8 MM 20 x 30 x Heat Transfer Coil Technical Data: Coils from Various Manufacturers, with Equivalent specifications, may be used. Face dimensions 24 wide 35 high Frame around perimeter aluminum 1.5 Water tubes - 1/2 copper 4-rows Manifolds and Connectors copper 1.0 Fins - rippled design aluminum 10 per inch Design Performance: 50% Glycol: Flow - temperature 15 GPM 180 F Ambient Air: Flow - temperature 3000 CFM 40 F Heat Output: at above conditions BTUH 307,000 Code Approvals Listed UL, CSA 4. Setup and Startup 4.1 Positioning and Connecting Equipment. The hot water/glycol mixture, known as heat transfer fluid HTF is circulated from either a CHH- 980 or CHH-300, HTF heating system, to the XP-300 and back again for reheating. Up to three XP-300 s can be connected to a CHH- 980 and only 1 can be connected to a CHH-300. The CHH-980 or CHH-300 must be positioned far enough outside the Hazardous Zone to be certain that it will operate in a Hazard-free outdoor space. By adding additional pre-charged hose lengths, the HTF re-heat unit can be positioned as much as 300 or 400 feet away from the enclosed, heated, hazardous space (if necessary). 6

7 The XP-300 (s) should be strategically placed inside the enclosed, hazardous space with consideration to minimize the length of circulation hoses and electrical cable required to reach each unit, while still distributing conditioned air uniformly throughout the space. * The backward-inclined-impeller blower is capable of generating plenty of static pressure to allow for ducted air distribution. Either the supply or the return or both air streams can be connected to ducts with the use of the interchangeable 20 duct collars. * The units may be connected to existing ducts, within the structure, by using short flex connector duct. * Lay-flat collapsible duct may be directly connected to the supply air collar. A pair of 1 pre-charged HTF hoses must be laid-out from the (CHH-980 or CHH-300) to each of the XP-300 heat transfer coil(s) located inside the enclosed hazardous space. * All hoses are pre-charged with HTF and are connected together and to the units with hydraulic-style quick-couplers. * Every hose has a male coupler on one end and a female coupler on the other end, which allows any hose of correct type and size to be used in any position. Double check to be certain all quick-couplers are fully engaged. Even 1 coupler connection that has not depressed the poppets fully, will prevent circulation of the HTF. * All hose running outside the conditioned space to the (CHH-980 or CHH- 300), should be insulated with special blanket wraps, to prevent excessive heat loss and increase efficiency. The XP-300 is equipped to accept a filter which measures, 20 x 30 x 2 thick (nominal dimensions). * It is advantageous to always use (at minimum) a dust-stop furnace-grade filter which will help prevent pre-mature clogging of the internals of the unit when dusty conditions exist. * More efficient, pleated style, filters are available up to MERV 13 rating that will fit the slot. This can be very effective to clean up the IAQ (indoor air quality) of the space. 4.2 Connect Power to the Blower Motor Connection of power supply to the blower motor must be performed EXCLUSIVELY by a Licensed Electrician every time the unit is setup on a site that is/or may be a Hazardous Location. For every Hazardous Location setup, the electrician must: Determine the type of hazard that is or may be present at any time within the area that this unit will operate for the given setup. Determine if the Hazardous categories for which the motor is approved, will meet the requirements for the hazards of the given project. (See motor labels to verify). If the Hazard(s) DO NOT fall within those approved for use with this motor, DO NOT USE THIS UNIT ON THE GIVEN PROJECT! Select a safe location from which to run the power supply. This may be either: * An electrical panel or generator located well outside the Hazardous Zone. * An electrical panel or junction box, located within the Hazardous Zone that is approved for use within that zone. 7

8 Select electrical cable and accessories to meet the requirements of the project. * Cable and connectors must be UL and CSA approved for the Hazards of each given location. * The proper wire gauge must be provided based on the length of cable required and Volt/Amp connection strategy. * The power source must offer motor protection with a UL/CSA approved breaker switch of adequate amperage. (20Amps at 115Volts or 10Amps 2-pole at 230Volts). Start up, test run and verify compliance of the Hazardous Location electrical connection. The only electrical component in this system is the blower motor. There are no switches, thermostats, capacitors or other electrical devices integral to this unit other than the connection cable. Various motors of equivalent specifications and approvals may be used, so the installing technician should always consult the permanent labels attached to the motor. Details may vary slightly from one motor manufacturer to another. The motor used on this unit is clearly labelled with a specific wiring schematic diagram that is permanently affixed to the motor. (See figure 1 below). Another label is permanently affixed which lists the actual specifications and electrical characteristics of the motor. (See figure 2 below). A third label is permanently affixed which lists the Hazardous Locations in which the motor is approved to operate. The approval mark of the agency that has tested the motor to UL and CSA standards also appears on this label. (See figure 3 below). The motor has a permanently attached junction box that is approved for hazardous Locations as marked. It is to this box that the power supply will be connected. (See figure 4 below) Figure 1: Electrical Schematic on Motor Figure 2: Electrical Characteristics on Motor 8

9 4.3 Startup the System Figure 3: Approvals Label on Motor Figure 4: Electrical Junction Box on Motor Once the blower is running safely, the Heat Transfer Fluid circulation through the XP-300 should be initiated. The operator must go outside the conditioned space to start the (CHH-980 or CHH- 300). Follow all instructions as outlined in the Operator s Manual which accompanies each of these HTF heaters. If not already familiar with the operation of these systems be sure to read through the manual and make certain the system is used correctly. * Start the circulating pump first. This will begin circulating HTF through the hose circuit(s) and heat exchange coil unit(s). * After a couple minutes, the burner should be turned ON and it should fire within a minute or less. The burner will continue to run until set temperature for the HTF is reached. Normal operating HTF temperature is 150 F to 180 F. The (CHH-980 or CHH-300) should NEVER be set above 200 F supply temperature. Back inside the conditioned space the XP-300 unit(s) will be heating up. * The flow-valve control dial should be turned counter clockwise until the indicator points straight up. This position directs 100% of the HTF flow through the internal heat exchange coil. This will provide the highest temperature of supply air delivered from the coil. (see Figure 5 below). * If the flow-valve control dial is turned clockwise 90 until the indicator points to the right. This position diverts 100% of the HTF flow straight back to the outdoor unit and 0% of the HTF flow will be going through the internal heat exchange coil. This will provide only Room temperature supply air delivered from the coil unit. * Volume of HTF flow through the coil can be adjusted anywhere between 0% and 100% by rotating the flow-valve control dial within its 90 range. * The blower within the XP-300 runs continuously, so temperature control is achieved by finding the position of the manually operated flow-valve control dial which provides a comfortable supply air temperature. * This temperature control strategy does not require any type of electrical thermostatic components and is therefore perfectly safe within a volatile hazardous zone. Figure 5: 9

10 5. Service 5.1 Component Removal for cleaning, repair or replacement: To remove the lid of the cabinet, remove all the 1/4 cap screws that hold it in place and lift it off. The complete blower assembly can now be easily removed. There are (six) 1/4 capscrews holding the entire assembly securely to the cabinet wall. Once these are removed the motor, impeller and mounting frame can be extracted, in one piece,from the outside. (See Figures 6 & 7). Figure 6: Figure 7: The filter box is easily removed next, by removing the (five) 1/4 cap screws which hold it in place. (See Figure 8). With both the blower assembly and filter box removed, the heat transfer coil can be lifted out the top of the cabinet, without draining the glycol. By removing (four) 1/4 capscrews (See Figure 5) that hold the 3-way flow mixing valve to the cabinet wall, it can be left attached to the hoses of the coil. Attach a line to the top of the coil frame and use any convenient hoisting device to lift the coil, hoses and valve clear of the cabinet. (See Figure 9). Figure 8: Figure 9: Once service is complete, reverse the procedures above to re-assemble the unit. 10

11 5.2 Cleaning: Air filters should always be used in the XP-300. Not only to improve the indoor air quality of the structure, but also to prevent the heat transfer coil and blower impeller from becoming loaded with dust or other air-borne particles. Filters of various efficiencies are available and these should be checked and changed as frequently as site conditions dictate. Filter size is 20 x 30 x 2 (nominal dimensions). The coil should be checked periodically to ensure it is free of dirt and dust accumulation. Dust can usually be removed with compressed air (preferred method). If the coil becomes too heavily loaded, it may need to be washed down with water and detergent and then blown dry with compressed air. Take care NOT to flatten or otherwise damage the thin aluminum fins of the coil. If water pressure or air pressure is too high or directed to close-in, the light aluminum may bend and flatten out. If the impeller of the fan should become coated with dust, dirt and impurities, it can be wiped clean with a cloth and paint thinner or any other suitable de-greasing liquid. 5.3 Storage: The unit should be stored in a dry indoor location when not in service. If placed in cold storage during a low temperature period, check the strength of the glycol mixture inside the coil by using a Hygrometer to verify adequate freeze-protection strength. 11

12 Warrantor: Therma-Stor LLC 4201 Lien Rd Madison, WI Telephone: Quest Explosion-proof XP-300 Pro Limited Warranty Who Is Covered: This warranty extends only to the original end-user of the Quest Explosion-proof XP-300 Pro, and may not be assigned or transferred. One Year Warranty: Therma-Stor LLC warrants that, for one (1) year the Quest Explosion-proof XP-300 Pro will operate free from any defects in materials and workmanship, or Therma-Stor LLC will, at its option, repair or replace the defective part(s), free of any charge. End-User Responsibilities: Warranty service must be performed by a Servicer authorized by Therma-Stor LLC. If the end-user is unable to locate or obtain warranty service from an authorized Servicer, the end-user should call Therma- Stor LLC at the above number and ask for the Therma-Stor Service Department., which will then arrange for covered warranty service. Warranty service will be performed during normal working hours. The end-user must present proof of purchase (lease) upon request, by use of the warranty card or other reasonable and reliable means. The end-user is responsible for normal care. This warranty does not cover any defect, malfunction, etc. resulting from misuse, abuse, lack of normal care, corrosion, freezing, tampering, modification, unauthorized or improper repair or installation, accident, acts of nature or any other cause beyond Therma-Stor LLC s reasonable control. Limitations and Exclusions: If any Quest Explosion-proof XP-300 Pro part is repaired or replaced, the new part shall be warranted for only the remainder of the original warranty period applicable thereto (but all warranty periods will be extended by the period of time, if any, that the Quest Explosion-proof XP-300 Pro is out of service while awaiting covered warranty service). UPON THE EXPIRATION OF THE WRITTEN WARRANTY APPLICABLE TO THE QUEST EXPLOSION-PROOF XP-300 PRO OR ANY PART THEREOF, ALL OTHER WARRANTIES IMPLIED BY LAW, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, SHALL ALSO EXPIRE. ALL WARRANTIES MADE BY THERMA- STOR LLC ARE SET FORTH HEREIN, AND NO CLAIM MAY BE MADE AGAINST THERMA-STOR LLC BASED ON ANY ORAL WARRANTY. IN NO EVENT SHALL THERMA-STOR LLC, IN CONNECTION WITH THE SALE, INSTALLATION, USE, REPAIR OR REPLACEMENT OF ANY QUEST EXPLOSION-PROOF XP-300 PRO OR PART THEREOF BE LIABLE UNDER ANY LEGAL THEORY FOR ANY SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES INCLUDING WITHOUT LIMITATION WATER DAMAGE (THE END-USER SHOULD TAKE PRECAUTIONS AGAINST SAME), LOST PROFITS, DELAY, OR LOSS OF USE OR DAMAGE TO ANY REAL OR PERSONAL PROPERTY. Some states do not allow limitations on how long an implied warranty lasts, and some do not allow the exclusion or limitation of incidental or consequential damages, so one or both of these limitation may not apply to you. Legal Rights: This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. 12