CS 2 Central Station Air Handlers Double Wall & Single Wall Installation, Operation & Maintenance Manual Form No. 6120A
TABLE OF CONTENTS Page Inspection... 2 Shipment of Units... 2 Handling... 2 Installation... 3-5 Motors & Drives...3 Steam Coils... 3-4 Water Piping...4 Direct Expansion... 4 Start-Up...4 Maintenance...5-7 Condensate Drain Traps...5 Internally Isolated Units...5 Section to Section Assembly...6 Water Coils Exposed to Freezing Temperatures...7 Draining Coils Using Supplemental Air Blower...7 Installation of Anti-Freeze Solution... 7 Net Weights... 8 Type FS, AS & Accessories Weights... 8 ODP "T" Frame Motor & Adjustable Drive Weights...8 Water Coil Operating Weights... 8 Steam & Water Coil Connection Sizes & Locations... 8 Filter Arrangements...9-11 Angle Filter... 9 Bag/Cartridge Filter... 10 Flat Filter... 11 Top View of Side Wall Double Wall Construction... 12 Shipping Modules... 13 INSPECTION & HANDLING Inspection Handling Shipment should be checked against the bill of lading to verify that all items listed have been received. All parts should be carefully inspected to determine if any damage was incurred in shipment. Any shortages and/or claims for damage should be immediately reported to the delivering carrier followed by filing a claim for shortages and/or damages. Shipment of Units Special care should be taken when handling and assembling component sections of the unit. Rough handling at the job site can result in damaged bearings, bent shaft, etc. All units are shipped on wooden skids. It is recommended that units not be removed from skids until they are at place of installation. The mounting legs/rails provided for isolators should be used when lifting units into place. 2 Depending on the unit size and accessories included, the shipment may be made in two or more sections.
INSTALLATION It is very important that the unit be installed in a level position to prevent distortion and to insure proper damper operation and coil drainage. Allow sufficient space around the unit for proper maintenance. Major factors to be considered are filter removal for cleaning or replacement, access to all removable panels, removal of coils and shaft if ever necessary, lubrication access and motor and belt adjustment. Canvas duct connections should be used between the unit and both supply and return air ducts. Units are furnished with a 1 1/4" M.P.T. drain connection on the coil connection side of the unit. The drain line from the drain pan connection must be adequately pitched and should have a water seal of sufficient depth to compensate for the air pressure within the unit. (See Condensate Drain Traps, page 5.) When the unit is located on the roof, it must be mounted on support beams that span load-bearing walls. If this is not done, excessive vibration may occur due to the resiliency of the roof. Fan noise is a function of the fan design, volume flow, pressure, and the efficiency of the fan. Present methods of measuring fan noise do not evaluate the pure tones generated by some fans and these tones can be objectionable when radiated into occupied spaces. Therefore, on critical applications we recommend extra sound attenuation in the octave band containing the tone. Motors & Drives All units will normally be shipped with motor and drive installed. When mounting a motor on the adjustable base (installed on the unit) extreme care should be taken to insure proper alignment and belt tension. All electrical work should be done in strict accordance with local codes and regulations. Steam Coils Type NFS coils have supply and return connections on the same end. Types NFO and S coils have supply and return connections on opposite ends. Type NFD coils have supply connections on each end of the coil, with a single return connection, one end only. All piping should be in accordance with accepted industry standards and local codes. Support all piping independent of coil and provide adequate swing joints in all piping to absorb expansion and contraction strains. Run return piping the full size of the coil return connection from the coil to a dirt pocket. (Do not use reducing fittings.) Install drip traps in steam mains ahead of coils. Do not drip steam mains thru the coils. Install a vacuum breaker (1/2" 15 check valve) ahead of the trap on low pressure open gravity return systems and on high pressure systems. Install a 1/2" 15 swing check valve in a 1/2" vacuum equalizing line, bypassing the condensate trap, on low pressure vacuum systems. When two or more steam coils are furnished in a unit, provide separate traps for each coil. Size traps with ample capacity using the maximum heating load and service factor recommended by the trap manufacturer. Select control valves in accordance with the recommendations of the control manufacturer using actual heating loads. Install suitable strainers ahead of all automatic valves and traps to catch dirt and scale. Provide adequate air vents to expel air and other noncondensibles. Control valves used for Type NFS and NFD coils must be gradual acting modulating type with Veeport. Where a control valve is used for Type S coils and when the entering air temperature is below 35 F, use a two position type valve. Locate control element in the entering air stream so that valve will remain open with a minimum of five pounds steam pressure when the entering air temperature is below 35 F. When the system is started up, the dampers should remain closed for approximately ten minutes after the steam valve is opened. Properly locate all temperature sensing elements at a point of true average air mixture temperature. Refer to Page 4 for Typical Steam Coil Piping Diagrams for controls positioning and piping configuration. When face and bypass dampers are used, it is good practice to install on the coil a valve which closes as the face damper closes to prevent overheating due to damper leakage or heat picked up by air wiping the exposed coil face. 3
Typical Steam Coil Piping Diagrams LOW PRESSURE OPEN GRAVITY RETURN SYSTEM 12" MIN UNION VENT HIGH PRESSURE SYSTEM Water Piping 12" MIN UNION VENT STEAM MAIN GATE VALVE STRAINER CONTROL VALVE VACUUM BRKR 1/2" 15 CHK. VALVE GATE VALVE UNION COMBINATION FLOAT AND THERMOSTATIC UNION TRAP STRAINER DIRT POCKET RETURN MAIN STEAM MAIN GATE VALVE STRAINER CONTROL VALVE UNION FLOAT OR BUCKET TRAP UNION STRAINER DIRT POCKET RETURN MAIN OPEN VENT All piping must be supported independent of coils. Swing joints or flexible fittings must be provided to absorb expansion and contraction strains. Rigid piping may also reduce effectiveness of vibration isolators. The water supply should always be connected to the bottom inlet of the coil. The coil connections are identified with stickers. Direct Expansion Both the liquid distributor and the suction line extend thru the casing. The expansion valve utilized must be of the external equalizer tube type. The expansion valve bulb must be located on the suction line between the coil and the 1/4" external equalizer tube. Never locate the bulb in a trap. All refrigerant piping practices used should be in accordance with local codes and latest ANSI Standard B9 Safety Code. Hard drawn type L or K copper tubing should be used. Soft tubing where bending is required may be used provided it is protected in accordance with local code restrictions. Good practices should be followed as to pulling adequate vacuum, tubes cleaned of foreign material, etc. Start-Up Make sure all bolts and screws are tight. Remove tagged shipping tie down bolts and spacers from the fan and motor assembly before start-up. Refer to page 5. Check the sheaves to see if they are in alignment and make sure the set screws are tight. Make sure that the dimension across the top is equal on all grooves, otherwise excessive belt wear will result. Check for proper rotation of the blower pulley. Three phase motor rotation can be reversed by exchanging two of the three leads at the motor starter. The rotation of single phase motors can be reversed by exchanging leads inside the motor junction box. Refer to the diagram on the motor. Check the amperage draw of the motor. This should not exceed the nameplate amps shown on the motor serial plate. After approximately two weeks of operation, the belts will have nearly acquired their permanent stretch. After this interval, the belt tension should be checked again and proper adjustment made. Water coils, 3 thru 10 rows, are supplied with a vent and drain connection (1/4" MPT) which extends thru the unit casing. For protection of coils exposed to freezing temperatures, refer to page 7. Coils must be adequately vented in order to prevent air binding. 4
MAINTENANCE The belt tension should be checked at three-month intervals. Re-lubricable bearings mounted inside the fan section have extended lubrication lines which are mounted on the outside of the fan panels. The suggested greasing interval is indicated on a sticker attached to the unit. It is recommended that bearings be lubricated with a high quality lithium base grease at intervals indicated on sticker attached to the unit. Instructions are included on the motor nameplate for lubricating the motor bearings. The filters should be periodically inspected and replaced or cleaned when necessary. Dirty filters reduce the air flow which reduces the capacity of the system. Do not operate system without filters. All CS 2 Units are Internally Isolated Isolators are installed and adjusted at the factory. Brackets and bolts tie down the fan and motor assembly for shipment. Remove tie down bolts before start-up. Refer to page 4 for clarification. Remove the bolt from bracket to motor support base, then loosen bolts to frame and slide bracket to end of slot so bracket is not in contact with the motor support base. The bracket then acts as a snubber on fan start up. END RAIL MOTOR BASE SUPPORT (4) SHIPPING BRACE / SNUBBER (DO NOT DISCARD) Lube inlet vanes and/or damper linkage annually. Check for drain clogging several times a year. Clean coils and drain pans as necessary. Condensate Drain Traps The condensate drain trap piping must be properly designed to insure the removal of condensate. Incorrect trapping can hold water in pan causing overflow. On blow thru units, particularly, system air can escape down the drain with incorrect trapping. ISOLATOR ISOLATOR RAIL CONDENSATE DRAIN TRAP (AIR SEAL) 1¼" PIPE DRAIN CONNECTION A B (a) On draw-thru units (A) shall be equal to or greater than the coil sections negative pressure at operating conditions. (b) On blow-thru units (A) can be as small as 1" but (B) must equal or exceed the total static pressure in the coil section. 5
Section to Section Assembly HEX HEAD BOLT FLAT WASHER MOUNTING BRACKET MOUNTING BRACKET FLAT WASHER HEX NUT DETAIL "A" AHU SECTION AHU SECTION 6
Water Coils Exposed To Freezing Temperatures Water coils exposed to freezing temperatures must be protected from freeze-up by either adding an anti-freeze solution to the coils or by proper draining of the coils. Dunham-Bush coils are circuited to avoid trapped circuits. However, because of the serpentine nature of the circuiting, it is almost impossible to adequately drain the coils by gravity alone. Particularly on longer finned length coils, even a fraction of a degree deviation from a horizontal plane can lead to water being trapped within the serpentine. Water that has failed to drain from a single tube, or even part of a tube, can cause the tube to rupture upon freezing. Draining Coils Using Supplemental Air Blower Ideally, a blower capable of delivering 150 CFM of air at approximately 40-50 inches of water or more should be used. Some small air compressors, while delivering higher pressure, probably will not deliver sufficient volume of air and this is equally as important. 1. Drain the coil by gravity after opening the supply, return, vent and drain connections. 2. Connect the blower to the larger connection that is at the greatest elevation. The small vent or drain connection on the header to which the blower is connected should be closed. Refer to Figure 1 for typical hook-up during the blow-out operation. It is helpful to tap the coil casing along the length of the coil during the draining process. The blower should be operated until no moisture can be detected leaving the coil. Then, shut the blower off and permit the coil to stand for a few minutes. This will permit the moisture that has adhered to the walls to accumulate. Then the blowing out operation should be repeated. Ideally, the coil should be permitted to stand twentyfour (24) hours and then be blown out again. 3. Leave all connections open until coil is put into operation. Installation Of Anti-freeze Solution A second way to prevent a coil freeze-up is to add an anti-freeze to coil such as industrially inhibited glycol. The coil should be valved off so that only the coil would have anti-freeze added to it. The most positive way to assure the mixing of the anti-freeze is to make a runaround loop with a circulating pump. 1. Open all connections and drain the coil as thoroughly as possible. 2. The anti-freeze solution should be added to the coil and circulated through the coil until the solution is thoroughly mixed and all air is purged from the coil. The air vent should be opened during the filling operation and cracked during the pumping operation to accomplish this. When the solution has circulated for 15-20 minutes, the concentration of the solution should be checked with a suitable hydrometer. If the concentration is low, add more glycol and operate the pump again. Refer to Figure 2 for a typical piping diagram. 3. The anti-freeze solution may then be left in the coils or drained and used to flush another coil. The concentration must be checked for each coil flushed. The addition of anti-freeze to a system exposed to freezing conditions may be necessary if the system must be operational at a moment s notice. This affects the chiller and coil performance and must be taken into consideration when selecting components. NOTE: Most anti-freeze solutions will be furnished with a chart for concentration at freezing point. It is also important to be certain that the anti-freeze solution used is not corrosive to the tubing. If this information is not available, consult Dunham-Bush. Figure 1 Blower Supplemented Coil Draining Figure 2 Typical Piping Diagram for Adding Anti-Freeze Solution Horizontal Air Flow Blower *Vent AIR FLOW Out Vent AIR FLOW *Drain Open During Blowing Operation Vertical Air Flow *Vent AIR FLOW GLYCOL SOLUTION Circulating Pump Drain In Open During Blowing Operation Blower *Drain 7
NET WEIGHTS 8 Model Size 12 22 30 40 48 64 80 100 120 150 180 240 270 320 420 480 590 Basic unit: FS Type Horizontal 449 628 733 967 1022 1114 1470 1825 2039 2539 2910 3872 4140 4431 Single Wall Vertical 402 626 698 940 1040 1382 1636 2129 2549 2810 3690 4435 4850 5320 Fan Section 239 402 466 590 592 677 947 1286 1380 1853 2097 2712 2890 3068 Horizontal 466 656 767 1001 1065 1190 1582 1939 2138 2653 3026 4005 4300 4598 Double Wall Vertical 404 663 737 998 1099 1453 1729 2248 2684 2969 3833 4592 5099 5610 Fan Section 249 427 489 610 618 724 1020 1367 1450 1937 2181 2805 2990 3181 Basic unit: AF Type Horizontal 1013 1132 1336 1622 1977 2241 2767 3159 4227 4791 5360 7163 8447 9193 Single Wall Vertical 989 1140 1604 1788 2281 2751 3038 3939 4797 8632 6248 Fan Section 636 692 899 1099 1438 1582 2081 2346 3848 3912 3997 5335 6330 6475 Horizontal 1047 1165 1412 1734 2091 2340 2881 3295 4330 4890 5526 7665 8371 9400 Double Wall Vertical 1045 1199 1675 1881 2400 2886 3197 4082 4954 5700 6547 Fan Section 657 718 946 1172 1519 1652 2165 2430 3143 3632 4109 5709 6543 6621 Accessories Diffuser Sect. 27 91 119 173 202 226 230 295 401 431 588 613 827 1015 1194 1303 1710 1865 Coil Module with Drain Pan (without Coil) Sect. 8 146 209 260 326 364 395 476 481 517 735 844 1011 1102 1194 1303 1710 1865 External Face & Bypass (without Duct) Sect. 20 71 91 93 106 119 146 187 217 233 337 350 628 683 690 820 835 912 Internal Face & Bypass Sect. 17 11 21 26 30 41 53 64 80 96 119 146 189 221 254 321 364 444 Preheat Section Without Coil Sect. 6 57 75 79 92 103 121 161 187 201 294 307 552 570 597 652 721 746 Flat and Bag Filter Section (without Filters) Sect. 10 or 13 171 224 236 277 308 333 402 441 474 587 613 827 857 895 977 1026 1119 Angle Filter Section (without Filters) Sect. 11 & 23 125 164 173 202 225 244 294 323 347 404 423 552 575 597 651 684 746 Combination Mixing & Filter Section (without Filters) Sect. 16C 137 179 251 294 328 364 482 535 574 808 844 1103 1233 1393 1629 2052 2237 Mixing Box Sect. 16 91 119 173 202 225 244 294 401 431 587 613 1011 1100 1194 1303 1710 1864 Section 9 Single Wall 600 682 808 848 1021 1214 1370 1757 2160 2511 3148 3373 3599 4294 5440 6642 Multizone Double Wall 756 860 1009 1060 1338 1542 1712 2196 2705 3139 3934 4216 4499 5.26 6746 8235 ODP T Frame Motor & Adjustable Drive Weights T - Frame 143 145 182 184 213 215 254 256 284 286 324 326 364 365 Motor HP - 1750 RPM 1 1.5 & 2 3 5 7.5 10 15 20 25 30 40 50 60 75 Motor Weight in Lbs. 30 38 56 70 127 141 187 211 263 300 409 460 560 648 Drive Weight in Lbs. 25 27 30 35 45 52 66 74 85 96 108 136 265 354 Water Coil Operating Weights (lbs) - LFA Unit Rows Size 1A 2A 3A 4A 6A 8A 10A 12 32 44 56 68 95 122 149 22 42 58 76 93 131 169 208 30 52 74 99 122 173 224 276 40 69 103 139 173 248 323 398 48 76 113 154 191 275 358 442 64 96 147 202 253 366 478 590 80 110 171 237 298 431 565 698 100 130 206 286 361 525 688 852 120 147 235 327 416 605 794 983 150 173 281 395 503 734 965 1196 180 212 351 495 634 928 1222 1516 240* 266 448 636 818 1200 1582 1965 270* 298 506 721 929 1364 1799 2234 320* 368 610 863 1105 1618 2131 2644 420* 438 737 1048 1347 1978 2608 3239 480* 552 898 1262 1606 2346 3088 3828 590* 656 1064 1488 1896 2764 3632 4501 * = Total of 2 Stacked Coils Steam & Water Coil Connection Sizes & Locations Male Location Iron Pipe Size Steam Water* Supply Return S NFS NFD 1R 2R 3R 4R 5R 6R 8R 10R Steam Type S 1 Row 1.5 1.25 O.E. S.E. # Coils Type S 2 Rows 2.5 1.50 O.E. S.E. # WH 1.5 1.50 S.E. S.E. S.E. S.E. S.E. S.E. WF - 1 & 2 Rows 1.5 1.50 O.E. S.E. Water WF - 3-10 Rows 2.0 2.00 O.E. S.E. O.E. S.E. S.E. S.E. Coils WD 2.5 2.50 S.E. O.E. S.E. O.E. WP 1.5 1.50 S.E. S.E. S.E. S.E. S.E. WQ 2.5 2.50 S.E. S.E. S.E. S.E. #5 NFD coils have (2) supply connections on opposite ends and (1) return connection. *All water coils with 37 tubes in face or more will be stacked, separate coils.
SHIPPING MODULES The CS 2 offers flexibility for splitting the unit into as many (or few) shipment modules as desired. However, sizes 240 and larger are usually too large to allow one piece shipment because unit width exceeds truck width. The CS 2 can be split into modules at as many section to section joints as desired with the following considerations: 1. Wide load shipping costs are required over 102". It is not practical to ship over 144" width. Therefore, the unit must be separated to minimize module length (in direction of air flow) and, therefore, shipping cost. 2. Installation cost is generally proportional to the number of modules. 3. Internal/external connecting brackets are utilized. Therefore, the CS 2 cannot be split between two coil sections, because flanges are not accessible from either direction. The following examples illustrate shipping options and assembled unit length: EXAMPLE: SIZE 320 UNIT ASSEMBLY 3 PIECE SHIPMENT (Maintain 102" maximum module length and standard freight cost) 2 PIECE SHIPMENT (Maintain 144" maximum module length using wide load freight cost) COOL- MIX BOX BAG FILTER COOL- ING MIX BOX BAG FILTER ING COIL COIL HORIZONTAL FAN HORIZONTAL FAN 56.00 36.00 24.00 70.00 56.00 36.00 24.00 70.00 Installed unit length = 186.00 Installed unit length = 186.00 Assembled length = (nominal section lengths + (1.7)"(number of splits) 2 PIECE TRUCK LOADING (Must pay "wide load" premium) Fan & Cooling Coil 109.7 x 151.5 Mix Box & Bag Filter 109.7 x 151.5 CS 2 unit sizes 17 thru 65 can be shipped in one piece. The overall length of the requested sections (i.e. filters, mixing box, access section, etc.) determines if the total unit can be shipped in one piece. Units that exceed twelve (12) feet in direction of airflow will ship in two sections. The design of the CS 2 allows the customer to dictate the number of individual sections of the unit. Consult factory where specific shipping assemblies must be furnished. COMPONENTS & DESIGN SUBJECT TO CHANGE WITHOUT NOTICE. 13
October 2000 101 Burgess Road Harrisonburg, VA 22801 (540) 434-0711, FAX (540) 434-4595 Form 6120A