Installation, Operation and Maintenance Manual

Transcription

1 MODEL DG Direct Fired Gas Make-Up Air Part # Installation, Operation and Maintenance Manual Natural or LP gas ETL Listed R **IMPORTANT** ALL FACTORY PROVIDED LIFTING LUGS MUST BE USED WHEN LIFTING ANY DG. FAILURE TO COMPLY WITH THIS SAFETY PRECAUTION COULD RESULT IN PROPERTY DAMAGE, SERIOUS INJURY OR DEATH. Unit shown with optional evaporative cooling section **WARNING** DISCONNECT AND SECURE ALL ELECTRICAL POWER TO THE "OFF" POSITION ON THE DG PRIOR TO INSPECTION OR SERVICING. FAILURE TO COMPLY WITH THIS SAFETY PRECAUTION COULD RESULT IN 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 for 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. January 2001

2 Installation Electrical Instructions Airflow System Start-Up Airflow Trouble Shooting Gas Piping Instructions Gas Burner Start-up STORAGE Table of Contents Sequence of Operation Gas Burner Trouble Shooting Maintenance Safety Shut-off Valve/Dimensions System Start-Up Documentation Evaporative Cooling (optional) When a fan is not going to be in service for an extended amount of time, certain procedures should be followed to keep the fan in proper operating condition. Rotate fan wheel monthly and purge bearings once every three months Cover unit with tarp to protect from dirt and moisture (Note: do not use a black tarp as this will promote condensation) Energize fan motor once every three months Store belts flat to keep them from warping and stretching Store unit in location which does not have vibration After storage period, purge grease before putting fan into service If storage of fan is in a humid, dusty or corrosive atmosphere, rotate the fan and purge the bearings once a month. Improper storage which results in damage to the fan will void the warranty. LIFTING Greenheck make-up air units must be lifted by the factory supplied lifting lugs only. The unit must also remain upright as shipped, during lifting. THE USE OF ALL LIFTING LUGS IS MANDATORY WHEN LIFTING. All access doors and panels must be closed during lifting to avoid damage. Supply Unit To prevent damage to the unit cabinetry, use spreader bars. Spreader bars must be in position to stop cables from rubbing the unit frame or panels. Before hoisting into position, test lift to insure stability and balance. Avoid twisting or uneven lifting of the unit. NEVER LIFT BY THE WEATHERHOOD. Lifting Lugs (4 places) 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. When suspending this unit the following ANSI standards must be followed: The standard for aircraft hangars, ANSI/NFPA ; the standard for parking structures, ANSI/NFPA 88A- 1985; and the standard for repair garages, ANSI/NFPA 88B 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 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. This manual is the property of the owner, and is required for future maintenance. Please leave it with the owner when you complete the job. 2

3 Installation with Downblast Discharge Before beginning this installation: When locating this unit, make sure that there is room to access the unit from all sides. The inlet must be located at least 10 feet away from any exhaust vents. If this unit does not have insulation, it has a 6 inch clearance tolerance to combustibles on all sides, top, and bottom. Roof Opening and Duct Dimensions Housing Blower Roof Duct Min. Straight Size Size Opening Size Duct Length* x x x x x x x x x x * 50% effective duct length per AMCA publication Supply Ductwork by Others Step 1 Roof Opening Determine the center of the supply duct roof opening. The chart on the left shows the maximum recommended roof opening dimensions. These sizes can be smaller based on codes and ductwork sizes. Step 2 Install Roof Curb Position the curb around the roof opening. Level the curb and shim if necessary. Attach the curb to the roof and flash in place. Step 3 Install Ductwork The chart on the left shows the duct sizes and straight duct lengths recommended for optimal performance (AMCA Publication ). Using duct sizes less than the recommended lengths will affect fan performance. Good duct practices should be followed for the remaining ductwork. The use of a duct adapter with the supply duct is strongly recommended to properly align the ductwork with the supply fan discharge. The duct adapter is only a guide and is not intended to be used as support for the ductwork. Supply Unit Step 4 Apply Sealant Before installing the fan, apply a sealant around the perimeter of the supply duct adapter to isolate the fan and minimize vibration. Lifting Lugs (4 places) Step 5 Install Supply Unit Use a crane and a spreader bar hooked to the factory lifting lugs (as shown in the diagram) to lift and center the DG unit on the curb. Use selftapping sheet metal screws to fasten the unit to the curb. Electrical and gas connections can be made at this time. 3

4 Installation with Horizontal Discharge Before beginning this installation: When locating this unit, make sure that there is room to access the unit from all sides. The inlet must be located at least 10 feet away from any exhaust vents. If this unit is direct fired gas without insulation, it has a 6 inch clearance tolerance to combustibles on all sides, top and bottom. Step 1 Mounting the Unit The unit can be mounted on a curb, hanging platform or rails, inline as part of an air handling system or base mounted. Mounting hardware to be provided by others. Step 2 Attach Ductwork to Unit Discharge The chart and drawing below show the opening size (ID) and location. Also included is the recommended straight duct lengths for optimal performance. Greenheck recommends using a rubber duct section at the unit to eliminate vibration. Step 3 Attach Ductwork to Unit Intake The chart and drawing below show the dimension for the supply opening (ID). Attach the ductwork to the perimeter flange using a rubber duct section at the unit to eliminate vibration. Design the remaining ductwork for minimal losses to allow the unit to operate properly. Discharge Duct and Intake Dimensions: A C Housing Blower Duct Size Size Size A B C D x x x x x x x * 50% effective duct length per AMCA publication Min. Straight Duct Length* Discharge Dimensions Opening Dimensions B Intake Opening Dimensions (Filter Section) D Typical Installations Intake Intake Discharge Discharge Roof mounted with weatherhood, mounted on roof curbs. Ductwork is attached to discharge collar with rubber boot transition. Shown as an indoor hanging installation with intake and discharge ductwork installed. (Hanging support structure for unit is by others.) 4

5 Installation with Fan Package Extension Before beginning this installation: When locating this unit, make sure that there is room to access the unit from all sides. The inlet must be located at least 10 feet away from any exhaust vents. If this unit is direct fired gas without insulation, the clearance tolerance to combustibles is 6 inches on all sides, top, and bottom. Roof Opening Curb Footprint Step 1 Roof Opening Determine the center of the exhaust and supply duct roof openings. The chart below shows the maximum recommended roof opening dimensions. These sizes can be smaller based on codes and ductwork sizes. Exhaust Duct Supply Duct A Maximum Recommended Roof Opening Dimensions Housing Size A B Note: All dimensions are shown in inches. Roof Curb B Step 2 Install Roof Curb Center curb over roof openings and place on the roof. Level the curb and shim if necessary. Attach curb to roof and flash in place. Step 3 Install Curb Extension Install curb extension over curb, use wood screws to lag in place. Locate extension so the tall, louvered side is over the exhaust opening, as shown in illustration. 1in. Inside Flange Exhaust Supply Step 4 Install Ductwork Exhaust: Exhaust ductwork must be built in accordance with NFPA 96 and any local codes. Ductwork terminating at the fan should be square in shape or of smooth transition so as not to to affect the fans performance. Supply: The chart below shows the duct sizes and straight lengths recommended for optimal performance (AMCA Publication ). Using duct sizes less than the recommended lengths will affect fan performance. Good duct practices should be followed for the remaining ductwork. Exhaust Ductwork by Others Supply Ductwork by Others Recommended Supply Ductwork Sizes Min.Straight Blower Duct Duct Size Size Length* x x x x x x x * 50% effective duct length per AMCA publication

6 Step 4 continued. The use of a duct adapter with the supply duct is strongly recommended to properly align the ductwork with the supply fan discharge. The duct adapter is only a guide and is not intended to be used as support for the ductwork. Exhaust Duct Installed Sealant Supply Duct with Adapter Installed Step 5 Apply Sealant Before installing fans, apply a sealant around the perimeter of the exhaust and supply duct adapter to isolate the fan and minimize vibration. Model Cube Exhaust Fan Step 6 Install Exhaust Fan Install CUBE exhaust fan on curb extension. Fasten with self-tapping sheet metal screws through existing holes in curb cap. NFPA 96 requires the exhaust fan be hinged. Greenheck offers an optional hinge kit with restraining cables and a grease trap with drain connection. Install these options at this time. NOTE: Installing the exhaust fan prior to the supply unit will allow for easier installation of options. Step 7 Install Supply Unit Use a crane and a spreader bar hooked to the factory lifting lugs to lift and center the DG unit on the curb and equipment support (as shown in the diagram). Electrical and gas connections can be made at this time. Use caution to avoid damaging exhaust fan when installing supply unit. Lifting Lugs (4 places) Supply Unit Complete Installation Illustration shows the complete wired installation. NOTE THAT THE ELECTRICAL POWER CABLE FOR THE EXHAUST FAN IS ROUTED THROUGH THE SIDE BREATHER TUBE. The cable should be of sufficient length to allow the fan to hinge open to the point where the restraining cables support the fan. Exhaust Fan Electrical Cable 6

7 Electrical Instructions Before connecting power to the unit, read and understand the following instructions and wiring diagrams. Complete wiring diagrams are attached inside the door(s) of the unit. All wiring should be done in accordance with the National Electrical Code ANSI/NFPA-70 latest edition and any local codes that may apply. In Canada, wiring should be done in accordance with the Canadian Electrical Code. The equipment must be properly grounded. CAUTION! If any of the original wire must be replaced, the replacement wire must have a temperature rating of at least 105 C, except for energy cutoff or sensor lead wire which must be 150 C. DANGER! High voltage electrical input is needed for this equipment. This work should be performed by a qualified electrician. CUBE Exhaust Fan Field wiring to CUBE Control Center Door NOTE: Any wiring running through the DG unit in the airstream must be protected by flexible metal conduit, metal clad cable or raceways. Sequence for wiring DG unit: 1. The unit s nameplate states the voltage and total amperage required. The main feeder supplying power to the unit should be sized for the labels voltage and amperage. 2. The main power line should be connected to the disconnect switch. Make sure that the disconnect lugs are securely tightened. 3. Connect control panel wiring to terminal strip in the control center. Greenheck s standard control voltage is 120/60/1. 4. Wire any remote temperature selectors (optional) at this time. These wires should be shielded cable if they are to be run with other power wires. 5. When an optional convenience outlet is provided, a separate power supply must be provided to the receptacle. This circuit must be on a ground fault breaker. CAUTION Any wiring deviations may result in personal injury or property damage. Greenheck is not responsible for any damage to, or failure of the DG unit caused by incorrect final wiring. 7

8 Airflow System Start-up For proper unit function and safety, follow everything in this start-up procedure in the order presented. This to be done after the electrical and gas connections are complete. Pre-Start Check List 1. Disconnect and lock-out all power switches to fan. See warning below. 2. Check all fasteners, set screws and locking collars on the fan, bearings, drive, motor base and accessories for tightness. 3. Rotate the fan wheel by hand and assure no parts are rubbing. 4. Check the V-belt drive for proper alignment and tension. Special Tools Required Voltage meter Incline manometer or equivalent Tachometer Thermometer Amperage meter 1. Check Voltage Before starting the unit compare the supplied voltage with the unit s nameplate voltage and the motor voltage. 2. Check Blower Rotation If the blower is rotating in the wrong direction, the unit will move some air but not perform properly. To check the rotation, open the blower access door and run the blower momentarily to determine the rotation. To reverse the rotation, turn the power off and use the following procedure: For single phase units, rewire the motor per the instructions on the motor. For three phase units, interchange any two power leads. This can be done at the motor starter. Blower Housing Rotation varying air volume, but the actual air volume should be known for making final adjustments. The most accurate way to measure the air volume is by using the pitot traverse method in the ductwork away from the blower. Other methods can be used but should be proven and accurate. To adjust the air volume, change the fan rpm or the system losses. See Trouble Shooting section in this guide. 5. Measure Motor Voltage, Amperage and Fan rpm All access doors must be installed except the control center / direct gas controls door. Measure and record the input voltage and motor amperage(s). To measure the fan rpm, the blower door will need to be removed. Minimize measurement time because the motor may over amp with the door removed. Compare measured amps to the motor nameplate full load amps and correct if over amping. See the Trouble Shooting section in this guide. 6. Settings for Optional Components 3. Check for Vibration Check for unusual noise, vibration or overheating of bearings. Refer to the Troubleshooting section of this manual if a problem develops. 4. Air Volume Check and Measurement Along with the building balance, the units air volume (cfm) should be measured and compared with its rated air volume. This unit is flexible for Optional Freeze Protection This shuts down the blower if the output temperature is below the set point. A timer allows the blower to operate during start-up. This will reset when turned off. Typical settings are: Discharge temperature = 45 F Timer = 5 minutes Optional 2 Hour Time Delay: This allows the unit to operate for up to 2 hours after the control panel switch has been turned off. The timer is adjustable. 8

9 Airflow Trouble Shooting The following is a Possible Cause and Corrective Action list for common problems with these units. Also included in the unit owner s packet are the Maxitrol Systems owner s manual plus the Flame Safeguard owner s manual. The sequence of operation should be used to help determine where the problems could be when trouble shooting the unit. Blower Unit Symptom Possible Cause Solution Blower fails Blown fuse or open circuit breaker Replace fuse or reset circuit breaker and to operate check amps Broken fan belt Replace Defective motor or capacitor Replace Motor starter overloaded Reset starter and check amps Motor over amps Cfm too high Check cfm and adjust drives if needed Static pressures are higher or lower If higher, ductwork should be improved than design If lower, fan rpm should be lower Blower rotation is incorrect Check rotation and correct Motor voltage incorrect Check motor nameplate and supplied voltage Motor horsepower too low See specifications and catalog for fan curves to determine if horsepower is sufficient Shorted windings in motor Replace motor Insufficient airflow Unit damper not fully open Adjust damper linkage or replace damper motor System static pressure too high Improve ductwork to eliminate losses using good duct practices Blower speed too low Check for correct drives and rpm with catalog data Dampers or registers closed Open and adjust Dirty or clogged filters Clean or replace Leaks in ductwork Repair Elbows, or other obstructions may restrict fan outlet Correct or improve ductwork Belt slippage Adjust belt tension Too much airflow Blower fan speed too high Check for correct fan rpm Filter(s) not in place Install filters Insufficient static pressure (Ps) Induce Ps into system ductwork (airflow resistance) Excessive noise Wheel rubbing on housing Center wheel or vibration Loose wheel on shaft Tighten wheel setscrew Loose motor or blower sheave Tighten sheave setscrew Belts too loose Adjust belt tension after 24 hours of operation Belts too tight Loosen to maintain a 3/8 inch deflection per ft. of span between sheaves Worn belt Replace Motor base or blower loose Tighten mountings bolts Worn bearings Replace Bearing and drive alignment Realign Motor out of balance Replace Wheel out of balance Replace or rebalance Sheaves eccentric or out of balance Replace or rebalance Accumulation of material on wheel Clean wheel and housing 9

10 Gas Piping Instructions Warnings Leak Testing Components 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. See page 20 for safety shut off valve leak testing. High Pressure Testing The heater and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psig (3.5 KPa). The heater must be isolated from the gas supply system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig (3.5 KPa). Location of Gas Connection Piping Guidelines All gas piping must be installed in accordance with the National Fuel Gas Code ANSI/Z latest edition 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; which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made. The nameplate on the direct gas section door describes all the requirements about the gas being supplied to the unit. For typical operation, units need a minimum of 6 inches to a maximum of 14 inches wg for natural gas and 2 inches to 6 inches wg pressure for LP gas. When the supply pressure exceeds the maximum pressure an additional regulator (furnished by others) is needed to step down the pressure. The regulators in the unit are used to adjust the maximum output temperature of the unit. Piping should be of adequate size to provide a sufficient supply of gas to meet the maximum demand with minimal pressure loss between the meter and the unit. A manual shut off valve (gas cock) and a 1/8 inch plugged tapping and a 6 inch drip leg must be installed prior to the gas train and must be accessible for connection to test gauge. Connections are to be made by a qualified installer and are not furnished by Greenheck. Finally, check for leaks in the supply lines to the unit. The factory piping has been checked for leaks, but should be rechecked due to shipping and installation. See leak test warnings above. All piping should be clean and free of any foreign matter. Foreign material entering the gas train can cause problems with the valves, regulators, and the burner. From Gas Gas Cock Gas Line Connection Standard Inlet Gas Pipe Size (Nat.) Max. <400, ,000 1,200,000 BTUs 1,200,000 2,400,000 Pipe 3 / /2 Size Note: Pipe size dimensions shown in inches. Ground Joint Union 6 in. Trap 1/8" Plugged Tap Make-Up Air Unit 10

11 Gas Burner System Start-up For proper unit function and safety, follow everything in this start-up procedure in the order presented. This to be done after the electrical and gas connections are complete. Special Tools Required Voltage meter Incline manometer or equivalent Tachometer Thermometer Amperage meter 1. Check Gas Pressure Check the gas pressure with the unit s nameplate pressure requirements. 2. Burner Air Pressure Differential Proper air velocity over the burner is critical on a direct fired gas unit. If the air velocity is not within specifications, the unit will not operate efficiently, can produce excess carbon monoxide (CO) or other gases, and may have sporadic shutdowns. Proper air velocity is determined by measuring the static pressure drop across the burner. To measure the static pressure drop, the fan should be running and be discharging 70 F air. Locate the dual air flow switch (reference page 16 for location). Notice the probes that extend into the unit - one on each side of the burner. Using an Incline Manometer, insert the Manometer sensors along side these probes - one on each side of the burner. The proper static pressure reading should be from inches to inches. If this reading is higher or lower and the air quantity (cfm) delivered to the building is acceptable, then the burner baffles will need to be adjusted (see diagram). Open the blower access door. Using a wrench loosen the 4 bolts to adjust the baffles. To increase the static pressure loss, decrease the opening size and to decrease the loss, increase the opening size. The top and bottom baffles should be of equal distance from the burner. Tighten the baffle fasteners, replace the door, turn unit on, and recheck the loss. This process may need to be repeated until the proper pressure reading is attained. This adjustment will change the air quantity delivered by the unit and therefore should be rechecked (see start up in Base Unit IOM). Adjustable Top Baffle 3. Pilot Pressure (Does not apply to burners 400,000 Btu/hr) The pilot pressure is preset at the factory and should not require adjustment. Pilot pressure will vary by unit size. 4. Set Maximum Discharge Temperature Do not set the burner based on gas pressure. The burner's maximum fire rate needs to be set or the unit will over fire at start-up causing unit shutdowns. To do this, the inlet air and outlet air temperatures of the unit need to be measured with the burner on high fire. a. Determine Required Temperature Rise Based on the geographical area, determine the winter design temperature. Subtract the winter design temperature from the desired output temperature to get the required temperature rise. Desired output temperature - winter design temperature = temperature rise. Example: For Schofield, WI 70 - (-15 ) = 85 F b. Set Unit to Run at High Fire. 1. On Maxitrol Series 14 systems remove and isolate the wire attached to terminal #4 of the A1014 or AD1014 amplifier. 2. On Maxitrol Series 44 systems remove and isolate the wire attached to terminal #3 of the A1044 amplifier. Air Flow Adjustable Bottom Baffle Burner 11

12 Gas Burner System Start-up (continued) c. Adjust High Fire Monitor the temperature difference between the inlet air and blower discharge temperature. Adjust the main regulator by turning the adjustment screw inside the main regulator until the required temperature rise is equal to the actual temperature rise. On units over 1,000,000 BTUs, the regulator is built into the modulating valve. d. Replace Wire Reattach wire to proper terminal. NOTE: This test procedure can be done in the summer, however, there will be hot air being blown into the building and the high limit may trip out, requiring manual resetting. 5. Low Fire For safe operation, the burner should have a flame across the entire burner at all times. This is factory set but should be field inspected. To check this, adjust the discharge temperature air to its lowest setting, disconnect the power wire going to the modulating valve and view the flame. This should be done when the outside air temperature is above the lowest discharge temperature setting. At all times there should be a small flame present across the entire length of the burner. If adjustment is required, refer to the Maxitrol manual provided with this guide. A low fire start-up Maxitrol amplifier is used. The delay should be set to the maximum of 30 seconds. 6. Set Unit s Discharge Temperature Maxitrol Series 14 Systems Set the temperature selector to the desired discharge temperature. Maxitrol Series 44 Systems For Maxitrol Series 44 units the selectrastat T244 adjusts the discharge temperature according to the building requirements. The discharge setting temperatures on the A1044E amplifier should be set. Greenheck recommends the minimum be set to 50 F and the maximum be set at 100 F. 7. Flame Signal Check (Does not apply to burners less than or equal to 400,000 Btu/hr.) To ensure trouble free operation, the flame rod signal to the flame safeguard should be checked. Readings should be recorded in the following flame conditions: Pilot only, low fire, mid-fire and high fire. The readings should be steady and be at or above the recommended minimum reading shown below. If problems do exist with this, see the Trouble Shooting section of this manual for more information. To measure the flame signal, a standard DC volt meter can be used and connected at the flame amplifier test jacks + and - (com) on the outside of the flame safeguard. The keyboard display module Honeywell #S7800A1001 (not provided) can also be used to measure the flame signal. The signal will be in DC volts and should be above or at 1.25v and stable for all flame conditions. 8. Optional High/Low Gas Pressure Switch These switches cut power to the heater if the gas pressures are above or below the limits. Both switches are manual resetting. Typical settings are: Low pressure at 2 inches wg High pressure at 8 inches wg for natural gas and 4 inches wg for L.P. gas. 12

13 Sequence of Operation This is included to help in determining if the unit is functioning properly upon initial start-up. Control Center 1. Turn the fan switch to the On position. 2. (Optional) Damper actuator is energized. 3. Supply starter is energized. Supply fan runs*. 4. Turn the heater switch to On if using separate switches. Heater 5. Open all manual gas valves. 6. High temperature limit switch contact is closed. (Normally closed.) 7. Optional high/low gas pressure switch contacts are closed. (High pressure is normally closed, low pressure is normally open.) 8. Optional inlet air sensor contact is closed. 9. Airflow sensing switch A. Low Airflow contact is normally open. B. High Airflow contact is normally closed. 10. Flame safeguard starts cycle Direct Spark Ignition System ( < 400,00 Btu/hr.) A. 15 second purge B. Main valves open, unit will spark for up to 10 seconds. If the flame is sensed the spark will stop, the valves will stay open and the safeguard will monitor the flame. C. If the safeguard does not sense the flame or looses the flame during operation, the flame safeguard will lockout and will only attempt to light if the heater power is interrupted and restored. Pilot Ignition System ( > 400,000 Btu/hr.) A. 10 second purge B. Spark generator will be energized for 10 seconds and the pilot solenoid valve will be energized. C. Pilot flame signal will be sensed. D. With proof of pilot after 10 seconds, the main solenoid valves will open. The optional vent valve will close at this time. E. Flame will be continually checked by safeguard. 11. The Maxitrol system will modulate 30 seconds after unit first attempts to light. NOTES: *1. If exhaust starter is included, it must operate first before the supply starter. 2. If an off delay timer (1-120 minutes) is included, the unit will continue to operate after the switch is turned to the off position. 3. If freeze protection is included, a timer (1 to 5 minutes) and a discharge temperature sensor is included. The unit must heat up to above the discharge temperature before the timer runs out or the unit will shut off. 13

14 Gas Burner Trouble Shooting The following is a possible cause and correction action list for common problems with these units. Also included in the unit owners packet are the Maxitrol Systems owner s manual plus the Flame Safeguard owner s manual. The sequence of operation should be used to help determine where the problems could be when trouble shooting the unit. Symptom Possible Cause Solution Blower runs but Gas is not on Turn gas on heater will not operate Heater is not getting power Check switch and wiring Gas piping is not purged of air Purge line Inlet clogged Clear inlet of unit Filter(s) clogged Clean or replace filters Ductwork clogged Check ductwork for obstructions Registers in building closed Open registers Airflow pickups clogged or Unclog pickups tubing crimped. Straighten or replace tubing Blower rotating in the wrong direction Inlet damper closed or not fully open Bad airflow sensing switch Flame safeguard is not getting power Reverse blower rotation Open damper Replace Note: Do not replace or adjust airflow switch without determining burner air pressure differential, step 4 in the system start-up A. Check heater main voltage B. Check high limit switch (requires manual reset) C. Check High/Low Gas Switch D. Check inlet air sensor setting (if supplied) E. Check wiring F. Check airflow and switch ( < 400 MBH) Flame safeguard is getting A. Reset manual switch on cover of flame power but will not operate safeguard ( > 400 MBH ) B. Check airflow and switch C. Check purge card Inlet clogged with ice or snow Unit not grounded or improperly grounded Check for building or unit exhaust near intake Moist air can clog filter with snow and frost The flame safeguard will not operate if unit is not grounded Blower runs, heater tries Air in pilot line Cycle unit to purge air to light, no visible pilot or Spark rod and flame flame rod wires crossed Check wires to be sure they are correct Bad connections to spark generator and to spark plug Spark plug gap not set Cracked porcelain Dirty or corroded spark plug Check all wire connections from flame safeguard Adjust spark plug gap to inches Replace spark plug Clean and remove any matter from the spark plug or porcelain or replace with AC or equivalent 14

15 Heater Symptom Possible Cause Solution Blower runs, heater tries Cracked flame rod Porcelain can be cracked to light with visible spark Replace flame rod and possibly pilot, but No gas to pilot A. Check gas pressure shuts down prior to main ( > 400 MBH) B. Check pilot solenoid valve for fire. restrictions C. Check pilot regulator for restrictions D. Check for bend in aluminum pilot line, repair or replace Low fire is set too low Adjust low fire (#5 in system start-up) ( < 400 MBH) Check flame rod wiring and connections Check for ground A. Unit should be well grounded B. Flame safeguard has a grounding screw in it, check to see if it is grounded. Pilot will not work if unit is not grounded Dirty flame rod Clean flame rod with emery cloth and wipe porcelain clean Flame rod is grounded out Check that flame rod is not touching burner or that foreign debris is not grounding out unit, clean or adjust. Blower runs, High limit switch not high limit trips out set correctly High limit should be set to 160 F Modulation device is not Check modulation system and see modulating owners manuals for repair Blower runs, flame High gas pressure not set properly See start-up instructions for safeguard goes out on setting high fire safety after operating, or unit cycles on and off Pilot regulator not set properly Pilot is too large causing flame to go ( > 400 MBH) past flame rod, turn down gas pressure Airflow too low or marginal for unit A. Adjust cfm to increase Ps Unit heats, lowering airflow loss across the burner causing switch to open B. Adjust baffles across the burner to increase Ps Microamps not steady with pilot on A. Check wiring for spark rod and ( > 400 MBH) flame rod B. Check for cracks in porcelain on flame rod, if present, replace. C. Soot buildup on flame rod, if present clean rod Blower runs, unit heats, Output temperature not set properly See start-up section for proper setting output air not warm enough Main regulator not set properly See setup section for setting high fire on main regulator Clogged vent orifice on regulator Clean or replace vent Supply pipe too small Recheck pipe size going to unit and re-pipe with larger pipe if necessary Discharge bulb not sensing Check placement, should be in discharge air blower discharge Maxitrol System A. Refer to Maxitrol manuals, not functioning properly make adjustments as manuals suggests Supply pressure too low B. Contact utility company 15

16 TRANSFORMER TRANSFORMER O O Typical Gas Control Compartment Layout: Direct Spark Ignition ( < 400,000 Btu/hr) TEMPERATURE SELECTOR MAXIMUM DISCHARGE FLAME SETTING IS 75 ON SAFEGUARD CANADIAN UNITS AMPLIFIER 24v TRANSFORMER 120v TRANSFORMER TRANSFORMER FUSES MOTOR FUSES INLET AIR SWITCH (OPTIONAL) STARTER OVERLOAD HIGH LIMIT SWITCH FREEZE PROTECTION (OPTIONAL) DISCONNECT DUAL AIRFLOW SWITCH HIGH/LOW GAS PRESSURE (OPTIONAL) GAS SUPPLY CONNECTION MANUAL SHUTOFF MODULATING VALVE COMBINATION VALVE Typical Gas Control Compartment Layout: Pilot Ignition ( > 400,000 Btu/hr) TEMPERATURE SELECTOR MAXIMUM DISCHARGE SPARK SETTING IS 75 ON GENERATOR CANADIAN UNITS AMPLIFIER 24v TRANSFORMER 120v TRANSFORMER TRANSFORMER FUSES MOTOR FUSES INLET AIR SWITCH (OPTIONAL) STARTER OVERLOAD FLAME SAFEGUARD HIGH LIMIT SWITCH FREEZE PROTECTION (OPTIONAL) DISCONNECT DUAL AIRFLOW SWITCH PILOT SOLENOID VALVE PILOT REGULATOR HIGH/LOW GAS PRESSURE (OPTIONAL) PILOT SHUTOFF VALVE GAS SUPPLY CONNECTION MANUAL SHUTOFF MAIN REGULATOR MODULATING VALVE MAIN SOLENOID VALVE MAIN SOLENOID VALVE Note: See page 20 for the safety shut off valve leak test procedure. 16

17 Maintenance - Fans and Filters Greenheck recommends these procedures to insure trouble free operation of this unit. It is especially important to maintain gas heater units for clean and efficient operation. Most unit failures can be attributed to poor setup or poor maintenance. A record of maintenance performed on this unit should be kept. This information will provide essential information if problems are encountered. A section at the back of this manual is provided for recording the units maintenance history. CAUTION: When performing any maintenance on this unit be sure that the power is disconnected and cannot be accidentally turned on. The control center disconnect can be locked in the off position. 2 Weeks After Start-up Check belt tension - Belts tend to stretch after a period of time. They should be periodically checked for wear and tightness. Approximately 3 /8 inch of deflection per ft. of span between sheaves is standard for belt tightness. When replacing belts, use the same type as supplied with the unit. Matched belts should always be used on units with multi-groove pulleys. Motor Belt Wheel Rotation Replacement of belts - should be accomplished by loosening the tensioning device to the point where the belts can be removed by hand. Do not force belts on or off as this may cause breakage of cords leading to premature belt failure. Belts should be adjusted as above. Too Loose Too Tight Every 3 Months The filter in the unit should be inspected at least every 3 months. Depending on the environment, filters could require changing or cleaning more or less often. The filters can be slid out of either side of the unit. If washable filters are installed, they can be washed in warm soapy water. An adhesive spray can be applied to increase filter efficiency. If disposable filters are installed, check by holding up to a light source. If light cannot pass through the filter, it should be replaced. Replacement filters should be of the same manufacturer and size. When reinstalling filters be sure to install with the airflow in the correct direction indicated on the filter and with any factory spacers that came with the unit. Yearly All bearings are factory lubricated and require no further lubrication under normal use. Normal use being considered -20 F to 180 F and in a relatively clean environment. Motor maintenance is generally limited to cleaning and lubrication (where applicable). Cleaning should be limited to the exterior surfaces only. Removing dust and grease buildup on motor housing assures proper motor cooling. Greasing of motors is intended only when grease fittings are provided. Many fractional motors are permanently lubricated and require no further lubrication. Motors supplied with grease fittings should be greased in accordance with manufacturer's recommendations. When motor temperature does not exceed 104 F (40 C), the grease should be replaced after 2000 hours of running time as a general rule. Wheels require very 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 smooth and safe operation. Inspect fan impeller and housing for fatigue, corrosion or wear. Routinely check all fasteners, set screws and locking collars on the fan, bearings, drive, motor base and accessories for tightness. 17

18 VIBRATION Excessive vibration maybe experienced during initial start-up. Left unchecked, excessive vibration can cause a multitude of problems, including structural and/or component failure. The most common sources of vibration are listed below. 1. Wheel Unbalance 2. Drive Pulley Misalignment 3. Incorrect Belt Tension 4. Bearing Misalignment 5. Mechanical Looseness 6. Faulty Belts 7. Drive Component Unbalance 8. Poor Inlet/Outlet Conditions 9. Foundation Stiffness Many of these conditions can be discovered by careful observation. Refer to the troubleshooting section of this manual for corrective actions. If observation cannot locate the source of vibration, a qualified technician using vibration analysis equipment should be consulted. If the problem is wheel unbalance, inplace balancing can be done providing there is access to the fan wheel. Generally, fan vibration and noise is transmitted to other parts of the building by the ductwork. To eliminate this undesirable effect, the use of heavy canvas connectors is recommended. Maintenance - Gas Burner System Greenheck recommends these procedures to ensure trouble free operation of this unit. It is especially important to maintain gas heater units for clean and efficient operation. Most unit failures can be attributed to poor setup or poor maintenance. A record of maintenance performed on this unit should be kept. This information will provide essential information if problems are encountered. A section at the back of this manual is provided for recording the unit's maintenance history. CAUTION: When performing any maintenance on this unit be sure that the power is disconnected and cannot be accidentally turned on. The control center disconnect can be locked in the Off position. Yearly The burner system should be inspected for accumulation of scale on both the upstream and downstream sides of the mixing plates. Any scaling or foreign material should be removed with a wire brush. Check visually that no holes in the mixing plates are blocked. If any burner ports are plugged (even partially), clear them with a piece of wire or a drill bit. WARNING: Do not enlarge burner ports or performance may be drastically affected. If any mixing plates are loose or missing fasteners, tighten/replace as necessary. Always use zinc plated or stainless fasteners. After inspection and cleaning, put system back into operation and if possible view from downstream side while cycling burner through full firing range. This will give a visual check for blocked burner ports. Observe flame pattern and if necessary, take steps to correct velocity and/or air distribution problems. Flame rods can last many years, but because of the high heat and expansion and contraction on the porcelain, flame rods can fail. Nuisance shutdowns of the burner can be caused by cracks in the flame rod porcelain. Some cracks may be too small to be seen with the naked eye but will still cause shutdowns. Inspection, cleaning, and occasional replacement of the flame rods and spark rods may be necessary to insure optimum unit performance. Beginning of the Heating Season 1. Turn the main gas valve to the On position. 2. The Heat/Off/Cool switch should be switched to the Heat position (in the remote panel, if provided). 3. The unit should be allowed to operate. Inspect the flame through the burner view port to make sure it is operating normally. Turn off the main gas to make sure the flame safeguard locks on safety. End of the Heating Season 1. Turn the Heat/Off/Cool switch to the Cool position (in the remote panel, if provided). 2. Turn the main gas valve to the Off position for the summer. 18

19 Safety Shut Off Valve (SSOV) Leak Test Procedure 1) Turn the unit off and attach a pressure gauge to the downstream side of the first SSOV. 2) Turn the unit on and allow the burner to go to main flame. 3) With the unit running, close the hand-valve located just upstream of the burner. 4) Turn the unit off and read the pressure between the SSOV s. 5) Remove the test port on the upstream side of the second SSOV and allow the pressure to go to zero. 6) Replace the plug and wait 10 minutes to see if there is a change in the pressure between the SSOV s. 7) If the pressure between the valves increase, the valve needs to be replaced. 8) To test the second valve, move the pressure gauge from the downstream side of the first SSOV to the downstream side of the second SSOV. Replace the plug in the first SSOV. 9) Turn the unit on, allow the burner to go to main flame, then shut the unit down. 10) Open the hand-valve upstream from the burner and allow the pressure to drop to zero. 11) Close the hand valve and wait 10 minutes to see if there is a change in pressure. 12) If the pressure increases, the second SSOV needs to be replaced. 13) Remove the pressure gauge and replace the plug. On units with a vent line remove the plug from the vent line. 14) Open the hand-valve. 15) The unit is now ready for operation. C A Dimensions A B B Standard DG unit DG unit with optional evaporative cooling Downblast Discharge - Arrangement DB or Horizontal Discharge - Arrangement HZ Housing Size A B C Width Housing Size A B Width* Note: All dimensions shown are in inches. * Based on width of evaporative cooling section. Weights Housing Base Unit with Base Unit with Size Filters and Weatherhood Evaporative Cooling * , ,240 2,050 * Wet weight of evaporative cooling section All weights are shown in pounds 19

20 System Start Up Documentation Job Information Job Name: Address: City: State: Zip: Phone: Fax: Contact Person: Service Organization: Address: City: State: Zip: Phone: Fax: Work Done By: Name Plate Information Min. BTU/hr: Max. BTU/hr: Type of Gas: Natural L.P. Minimum in. wg Maximum Normal Manifold Pressure in. Max. Output Minimum Gas Pressure in. wg for Max. Output SCFM against an E.S.P. of in. wg Model: Volts: Hertz: Phase: Amps: Mark: Supply Hp: Exhaust hp: Serial Number: Field Start-Up Documentation Actual Voltage: Hertz: Phase: Actual Amperage: Gas Pressure: Inlet in. wg psi Burner in. wg Blower Rotation Correct Air Volume Design cfm Actual cfm Burner Baffle Opening: Length in. Width in. Burner Air Pressure Differential in. wg Motor Voltage: Motor Amperage: Discharge Temperature Setting F Fan rpm: Flame Signal Pilot On Vdc Low Fire Vdc Mid Fire Vdc High Fire Vdc Maintenance Date Time Notes: (Person calling, problem, contact person, etc.) 20

21 Field Installation 1. Evaporative cooling sections for housing 20 and 30 units ship separately. After the DG base unit and the equipment support rail is installed, the evaporative cooing section may be installed. A weather tight seal is required between the evaporative cooling section and base unit. Apply a heavy bead of caulk around the airstream opening to create weather tight seal. Using a spreader bar and factory lifting lugs (see Figure 1), lift and center the cooling section on the equipment support. Make sure that the U-shaped flange on the evaporative cooling section fits over the flange of the DG base unit. Evaporative Cooling (optional) Installation Instructions When mounting this unit, it is important that it is level to ensure proper operation and water drainage. Piping should be of adequate size to provide sufficient supply of water to meet the maximum demand of the unit. Figure 1 Sump drain pipe Sump overflow pipe Use self tapping screws to fasten the cooling section to the DG unit along the top and down both sides (see Figure 1). Fasten at the top through the flanges. Fasten along the sides from inside the cooling section. Remove cooling section access doors and evaporative media for access to the side fastening points. System Start-Up 1. After the unit is set in place, run the overflow and drain lines to the exterior fittings on the unit. The supply line can be attached at the downstream side of the evaporative section. A manual shut off valve should be mounted in the supply line near the unit for servicing purposes. The drain line should have an air vent for clean out purposes. Also, a trap should be installed in the drain line to prevent sewer gas from being drawn into the unit (see Figure 2). 2. The cooler will be prewired by the factory. Housing size 20 and 30 units ship in separate sections and will need to be field wired to the 2 x 4 handy box in the cooling section. Wires should be run in a metal conduit from terminals 1 and 10 to the junction box. 3. Check to make sure that the pump filter is around the pump inlet. 4. Turn the water on and allow the pan to fill up with water. The float should be adjusted to provide 2 inches of water depth in the sump. 5. Saturate the media without any air flow through the unit. A jumper wire is required on the terminal strip to provide power to the evaporative cooler pump. See the wiring diagram for the proper location. This saturation process will break-in the media and eliminate the odors associated with the media. The media s break-in period should be no less than 20 minutes. When the process is complete, remove the jumper wires in the control center. Note: Evaporative media may foam for a short period following the initial start-up. Leave the bleed-off valve fully open until the foaming stops. 6. After the media break-in period, the water flow rate over the media needs to be checked. The pumps should provide enough water to saturate the media in 45 to 60 seconds. If adequate flow rate is not achieved, consult with the factory. 7. The water bleed-off rate will now need to be adjusted. This measurement is 3 to 6 percent of the media flow rate. The recommended flow rate is to 2 GPM per square foot of media pad top area. After the unit has been installed and running for approximately two weeks the unit should be checked for mineral deposits. If there are deposits, the bleedoff rate needs to be increased. Some areas of the country have water with greater amounts of mineral deposits which then require a higher bleed-off rate. 8. Verify that both airflow and system static pressure are in agreement with the specifications. If these conditions are met, check for water carry over from the discharge side of the media. If carry over is observed, check the distribution header for holes or tears and the water standoff tube for blockage. 9. After all final adjustments are made, remove the jumper wires and replace all access panels. The unit is now ready to be put into operation. 21

22 Figure 2 Drain Line Air Vent Trap Overflow Evaporative Cooling Media Sump Drain Line Manual Shutoff Valve Manual Shutoff Valve Supply Line Freeze Protection Shuts down evaporative cooling module when out door temperature falls below auto-freeze thermostat set point. Factory supplied solenoid valves shut off supply water and drain all water lines. When outdoor temperature rises above thermostat set point, (suggested setting 45º to 50º F) evaporative cooling operation is restored. Plumbing 1. Run water supply line to the unit and install Water Supply Solenoid Valve (A) in this line as close to the water source as possible. Water Control Options for Evaporative Cooling Auto Drain and Fill Drain and fill flushes mineral build-up and debris from the sump. An auto-flush system drains the sump at field adjustable intervals, typical once every 24 hours. Freeze protection is also included with this option. Figure 3 2. Install Drain Solenoid Valve (B) in the supply line as indicated below. From the outlet on the drain valve, run line to a suitable drain location. 3. Run an unobstructed drain line from the sump overflow to the drain as shown below. Sump overflow pipe Sump drain pipe Solenoid Valve (C) Roof Line 4. Install Sump Drain Solenoid Valve (C) in the drain line from the sump as indicated below. From the outlet on this drain valve, run a line to a suitable drain location. Drain Line Note: Water Supply Solenoid Valve (A) is not the same as the Drain Solenoid valves (B) and (C). Make sure to use the proper valve for each location. Check your local code requirements for proper installation of this type of system. Additional drain and supply plumbing may be needed to meet your local code. Caution: All solenoid valves A, B, and C must be installed below the roof to protect the supply water line from freezing. If these valves cannot be installed below the roof, an alternate method must be used to protect these lines from freezing. 22 Trap Solenoid Valve (B) Supply Line Solenoid Valve (A)