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Revolution TFX Operation Manual (OMM)

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1. 2 NOTES TERMINAL POINT REMOTE DEVICE BY OTHERS FIGURE 83 FULL VOLTAGE STARTER WITH SINGLE POINT POWER CONNECTION 204195 CONT D FIGURE 84 TRANSFORMER ENCLOSURE WIRING DETAIL SHOWN OPEN SECTION 5 WIRING DIAGRAMS x1 X2 B 2 TO TRANSFORMER 2L3 GND 88 SECTION 5 WIRING DIAGRAMS 2KVA TRANSFORMER SEE TRANSFORMER a CONNECTION DIAGRAMS FOR PROPER 2 FU2 CONNECTIONS LINE LOAD A SERVICE LIGHT SWITCH 5 on G Els B AB A A ZE A FIGURE 85 TRANSFORMER WIRING DIAGRAM 89 SECTION 5 WIRING DIAGRAMS B U B UV LIGHT IN USE 20 B Indicator lamp x 1 D 15 AMP Q B C 30 R1 2 HY M UV LAMPS 40 C 100 L _ INAHU Z N 50 FU1 was 2 AMP 120vac XFM1 60 CLASS II 4 transformer 50va 70 CS 1 80 1 SECOND RESET LATCH A A A a 0 4 2 3 7 90 C 4 5 aa DOOR SWITCHES R1 1 A A IN AHU 100 g O 2 Z 11 14 A1 G A2 lt gt lt gt 100 C 36 100 D e QTY BASED ON DOOR RADIOMETER OPENINGS Sensor 24VAC de e eh _ __ 1 c ind ERN Nue EYE FIGURE 86 UV CONTROL PANEL WIRING 8 AMPS 90 SECTION 5 WIRING DIAGRAMS
2. 31 TABLE OF CONTENTS CONT D NOvelAire Techrnologl68 een EE O OO AE ECP dan PAC Z GE 32 NA su aaa aasan 32 INOMECEETrEJ Gas Heabelart UD uuu io aaa ast 32 Identity Gas Bumer OO mE dede 32 Preliminary Coordinato 33 Recommended ee au u LU 33 Pre UB CHECKIISE Lu ua uu mia AAA kad EW O 33 Checking BUITIGE uu u nA 34 oStar ridgihe BUITIel soie cz satanas 35 MON MANO Mesias unun a hash Saw 43 MEGNANICAL SIANANON zadna e Es os n bus 43 tad 44 slanting The HOA EE EDD T 45 Gal T 47 47 SS TUG SEIS 20 aaa 48 Checking Motors Belts and SH6aVeSu uuu 48 SECTION 3 MAINTENANU GE ullu tussi ctu oum ap qaa qaqa ahua aina 49 General Bedulrermellls 49 ID s D 50 9 D 50 Door Hardware arid Zaa
3. nnne nnne nnn nnn nn ann nnns nana ns 55 FIGURE 42 Motor Base LOWS add adea Due AOR 55 FIGURE 43 Sheave Angular maa o dbac 56 FIGURE 44 Shieave Angular Misalignment u de elon eae kanaa wayua wapus iaa 56 FIGURE 45 56 60 cre 56 FIGURE 46 Bearing with Set Screw Type Locking Device 57 FIGURE 47 Bearing With ECCENNIC LL a a a AE 57 FIGURE 48 Split Bearing Assembled 57 LIST OF FIGURES CONT D FIGURE 49 Optional Lubrication 57 FIGURE 50 Open Drip Proof ODP Motor ccccccccccscsseseeeeeeeeeeeeeaaeaeeeseeeeeeeeesesaaaeeeeeeeeeessaaeasseses 59 FIGURE 51 Totally Enclosed Fan Cooled TEFC 59 Vb 61 FIGURE 53 Installing V Mod Lampa cazzo u re reo a uu deed 61 FIGURE 54 Installing V Ray and V Max Grid Lamps 61 FIGURE 55 V Max Lam OS saa 61 FIGURE 56 gt TypicaliFilekeouuu usuta AO EE Sua a maa ea 62 FIGUHE 57 Installing ANGIE FMES uy uuu re eire
4. 75 Fiter Gaug za asc A 75 UTube 75 DUCLFIESSULES MERERI T NE 76 a utana uay aun Gat 76 76 Total uns BOLA Meee oe es 77 TABLE OF CONTENTS CONT D neJUeSUNGASSISLANCE asa kastan ce dd 77 Adjusting Removing and Installing SheaVves oes a aa 78 Fixed Pitch Sheaves Woods With Sure Grip BUSHINGS 78 Tools and Materials Required uy y n adi tia OC akad 78 Removing Sheave Tm 78 Nate fas a o gt ECC 78 Standard PO 79 dv 79 PCIUSTING SNAVE reisis 79 Adjustable Pitch Sheaves Woods Model JVS 80 Tools and Material Required 80 SINS AY R RO ua aie oe eee 80
5. 35 FIGURE o 36 FIGURE 27 Flue Combustion Temperature and Efficiency Test Port ID 36 FIGURE 26 Damper ACUTO a rovs deeds eee ede 36 FIGURE 29 Typical Wiring 41 FIGURE 30 Minimum Air Velocity Required for Safe Operation aaa 45 FIGURE 31 Pressure Probe Direction a 46 FIGURE 32 Air Flow Switch CONNECTIONS uuu uyu u A TA LEWO 46 FIGURE 33 V Belt Drive l iain abuse 48 FIGUHE 34 Typical Drive Kit Data TOO uu l l ll pao tasas u nu 51 FIGURE 35 Adiustable MOIOFBASOw 51 FIGURE 36 Adjustable Motor Base Top nnn nnns 52 FIGURE 37 Belt Tensioning a 53 FIGURE 36 Belt Tensioning ch see u tec dtc ghee is Su ZS Qu as 53 FIGURE 39 Alignment Using Stramghib Edge oe eoe caso ent etie 54 FIGURE 40 Alignment NA AA Ob Feo aed istae Ur cee IE Ue 54 FIGURE 41 Sheave Angular Misalignment
6. 1 76840 NA 2 ATZAF ATZAF ATZAF w um gt EE N meas 2 270 76 NA mean 3 20 3676 NA meas 3 20 976 NA mean 1 30 492 NA Twas 1 30 404521 NA 2 30 492r NA was 2 so 44521 NA mean 3 30 492r NA was 3 30 404521 NA mean 1 350 5686 NA N A N A N A N A N A N A N A N A N A A 200 00 222 222 222 245 45 245 270 270 20 SECTION 2 START UP AND OPERATION Air Measuring at the Fan Inlets e COMETER is a probe attached to the fan bearing support on Comefri Forward Curve fans from size 7 x 7 up to 18 x 18 The probe is located on the outboard side of the housed fan assembly The probe is piped to the negative port of a factory mounted transducer on the fan wall The positive port is left open to the fan section Wiring is not provided to the transducer PIEZORING PIEZOMETER is a fitting or series of fittings in the inlet cone s of housed fans larger than 18 x 18 and all sizes of Plenum fans that are combined into a single connection piped to the negative port of a factory mounted transducer on the fan wall The positive port is left open to the fan section Wiring is not provided to the transducer The fan manufacturer does not recom mend
7. 66 E E u m EE 67 Inspect Wheel Drive COMmpOnentS a EEE 67 NovelAire Technologl88 25 67 Gleaming tote 67 Adjustng aude Ede Clo eto teo beoe BA PEDAGOG 67 Inspect Wheel Drive GOIIDOrelll Sum y a ede e sorted habun d ose doe hia eee Rie et estere inen 67 How to Measure Assemble and cacka inde Abed cet usw Tee 67 ui T Lc 69 Cleaning The uu u u 69 Adusting dite DS a 69 Thermotech 69 Inspect Wheel 69 P 70 Clearing 70 give LR 70 Inspect Wheel Drive 71 lale zio TECNO sun m 71 SECTION A SERVICE AND REPAIRuu uu uu anam 73 uy uu aku ete bao a naa 73 to let akha unus qaa 74 TOUDIESNOOUNG uu 74 LO T Same eee R 74 Manometer u
8. SECTION 2 START UP AND OPERATION DRAIN DF 15 25 4 DF 30 50 DF 85 200 1 Field Installed Condensate Drain Piping By Others 2 Clean Out Pitch 3 Water Seal Prime Fill 4 Pitch 1 4 Foot 9 Measure the gas supply pressure coming into the gas train as shown in Figure 25 on page 35 Gas pressure can be greater than shown on the burner test report but it must be between the min max values listed in Table 6 on page 39 10 Visually check that the high temperature safety limit is set for a 200 230 F range The limit switch is typically mounted behind the burner control panel 11 Connect a 0 15 inch gas pressure gauge or other suitable instrument to the gas manifold port The gas pressure will be measured when running Refer to Step 4 in Starting the Burner 12 On Powerflame burners the test port is down stream of the main regulator typically on a standard tee fitting in the main gas line 13 On Eclipse burners the test port is located on the backside of the burner below the spark igniter A small valve is provided at this test port 34 SECTION 2 START UP AND OPERATION 14 Connect a manometer or other suitable device to the heat exchanger draft port located on the side of the AHU near the burner The expected draft should read slightly negative about 0 03 inches WC The draft port is typically made of 3 4 in steel pipe and may be plugged Remove plug and add
9. Sc Sa ecm z U t es PR a RR FIGURE 82 FULL VOLTAGE STARTER SECTION 5 WIRING DIAGRAMS NOTES TERMINAL POINT A REMOTE DEVICE BY OTHERS ALTERNATE OL1 USED WITH CT1 2 3 WHEN MOTOR FLA IS GREATERTHAN 80 AMPS FIGURE 82 FULL VOLTAGE STARTER CONT D 85 SECTION 5 WIRING DIAGRAMS DISC 3 PHASE INPUT 208 230 380 460 VAC 50 60 HZ gt NOTE CUSTOMER SUPPLIED DISCONNECT MUST MEET LOCAL CODES O ca 1 L2 L3 2KVA 8 TRANSFORMER 212 213 lt SEE TRANSFORMER CONNECTION DIAGRAMS O m m n m FUA FOR PROPER 2KVA x 1 xi CONNECTIONS lt aa AB L ABD Qi LINE 4 x GFI LOAD SERVICE LIGHT ITCH 5 N B AB A A A K sas E PET MAR P i m sss s s o ME UE ED OFF B RUN TIME AUTO CLOCK OOX 5 qo 1 za lt 4 SAFETIES 4 y A FIRESTAT FREEZESTAT 14 X2 E 11 gal 1 SUPPLY RT ETA Te m am e J J REMOVE JUMPER WHEN CONNECTING SAFETIES RETURN FAN 1 CONTROL 2 CONTROL POWER X2 POWER OPTION B UP TO 4 PANEL O 100VA TRANS ee ee ee ae een OR LOW TEMP RESET 1 20 1 21 Kamilka
10. 75 FIGURE 74 T be Manometer uuu n u umu dup videt eese edel 76 FIGURE 75 slack JUDE Ma omeleru suu huuu hand idu 76 FIGURE 75 Static Pressure AIF SYSIEM y u uuu uuu lu 77 FIGURE 77 Inserting Cap SCreWS ccccccccccccecccseesseeceeeeeeesseaeueeseeeeeeeeseseaeaaseeeeeeeeesseuaaseeeeeeeeessaaaas 78 FIGURE 78 Standard MOUNTING uu uu u uu u ans ear ea EE E Eia 78 FIGURE 79 Reverse MobfPitllig Un un 78 FIGURE 80 Adjustable Pitch Sheave JVS a a nnn nnn nnns 80 FIGURE 81 Adjustable Pitch Sheave FHP cccccceessecceeceeseeeeeeeseeeeeeeeeeseeeeeeeeeesaeaseeeesesaegeeeeseaaas 81 FIGURE 82 Full Voltage ccccccccssssseeeeeeceeeeeeeeeeseeeeeeeeeesseeesaeeeeeeeeeeeeesaeeeeeeeeeeeeeessseesgaeses 84 FIGURE 83 Full Voltage Starter With Single Point Power Connection 204195 86 FIGURE 84 Transformer Enclosure Wiring Detail Shown Open 88 FIGURE 85 Transformer Wiring 89 FIGURE 86 UV Control Panel Wiring 8 amps a nnns 90 FIGURE 87 Gas Heat S
11. 23 FIGURE 9 BIN eli eret ce oh 23 FIGURE 10 2576 Sensing ides E bain A 23 FIGURE AD 2579 79576 SENSING OPIO 23 FIGURE 12 2575 7595 Sensing uh eode o edo YO 24 FIGURE 13 Example of Sweep Balance Results Label On Fan Housing 27 FIGURE 14 2 V elal Spacers hei Boc key 27 FIGURE 15 Vertical Wheel for Quedadas unen sme zd 27 FIGURE 16 Horizontal aa SIE een seat bol eoe ere ERR spas eigo hiya tas eres passe EN IN uy gaa huso 28 FIGURE 17 Energy Recovery Wheel Pulley Side ccccccccccsssseeeeeceeeeeecececeeeececeeeaeeseceeeesseeaeeeessesaageeeessaaas 29 FIGURE 18 Segment RETAIN eax 30 FIGURE 19 Diameter Seal 30 FIGURE 20 Purge Angle 31 FIGURE 21 Purge Angle 32 FIGURE 22 Gas Furnace Condensate Drain Trap 34 FIGURE 23 Open FUSE DISCEOMNECIS e u u sac h skua Im I IL 35 FIGURE 24 Set Id Fan DamipBr a u a Det Lic os id wa Teneo 35 FIGURE 25 Check Main Gas Supply
12. Adjusting Air Seals The Innergy tech energy recovery wheels are equipped WHEEL MEDIA with our AirLoop labyrinth seals facing the media low friction side seals along the depth of the rotor and S type labyrinth peripheral seals along the outer edge of the rotor as shown on the seal general overview drawing below While the side seals and peripheral seals are factory adjusted and don t need further ad justment the AirLoop labyrinth seals should be veri fied prior to start up and adjusted if needed See Figure 68 on page 70 CORRECT d O Start Ch VWHEEL TOLERANCE As illustrated in Figure 67 on page 70 the correct adjustment of our AirLoop labyrinth seal is obtained by allowing it to barely touch the media before tighten ing the screws If an initial gap can be seen between the seal and media the seal is installed too far and should be moved closer until it touches the media On the other hand if any deformation to the lips can be seen it means the seal is installed too close and should be moved back until the lips are straight again ADJUSTMENT PERIPHERAL SEAL AIRLOOP LABYRINTH SEAL AIRLOOP 4 i LABYRINTH SEAL FIGURE 68 ERW SEAL LOCATIONS 70 SECTION MAINTENANCE Inspect Wheel Drive Components Bearings Wheel bearings are greased before ship ping but it is recommended to grease them again be fore start up Proper care and maintenance of the wheel bearing
13. Titus Operation Manual 01 1615 REVOLUTION TFX INDOOR UNIT TUS 605 Shiloh Road Plano Texas 75074 972 212 4800 All rights reserved No part of this work may be reproduced or transmitted in any form or any means electronic or mechanical including photocopying and recording or by any information storage retrieval system without permission in writing from Air Distribution Technologies IMPORTANT READ BEFORE PROCEEDING GENERAL SAFETY GUIDELINES This equipment is a relatively complicated apparatus During installation operation maintenance or service individuals may be exposed to certain components or conditions including but not limited to refrigerants UV materials under pressure rotating components and both high and low voltage Each of these items has the potential if misused or handled improperly to cause bodily injury or death It is the obligation and responsibility of operating service personnel to identify and recognize these inherent hazards protect themselves and proceed safely in completing their tasks Failure to comply with any of these requirements could result in serious damage to the equipment and the property in which it is situated as well as severe personal injury or death to themselves and people at the site This document is intended for use by owner authorized operating service personnel It is expected that these individuals possess independent training that will en
14. UL UL UL UL di MAGOS TABLE 5 NATURAL GAS PRESSURE REQUIREMENTS INCHES WC GAS FEATURE BTUS 38 Note Gas pressure requirements at the inlet to the main manual shutoff cock of the gas train SECTION 2 START UP AND OPERATION TABLE 6 NATURAL GAS PRESSURE REQUIREMENTS INCHES WC w lt lt 0 O O lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt gt z ziziziziziziziziziziziziziz G lt lt 4 4 lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt 22 aa lt z N A N A N A N 1 p 5 N 5 5 8 9 7 KAE KEK ERE ofn ERE lt z lt z lt z lt z lt 2 lt z MINIMUM INLET PRESSURE TO FIRE N A ES EN ES EN na EN ES EN CHI EMI Em ENE lt lt lt lt lt N A lt z lt z lt lt lt s 2 2 2 lt 2 lt ma z lt lt lt 2 2 2 lt m z lt 2 lt 2 lt 2 lt gt 2 lt 2 lt mz z z LO LO r e S SISISISINRIRINIRINININININ 222 z o lt lt lt lt 2 2 2 2 lt lt lt lt 2 2 lt lt z lt
15. 51 Air Louvers Inspection 40 37 Belts Checking Tension 55 40 50 63 Bird Screen Inspection Cabinet Maintenance Cleaning Coils Cleaning Dampers Checking Operation Blade Orientation Cleaning Hardware Check Damper Actuator Installation Direct Coupled Mounting Doors Start Up Inspection Drain Lines Cleaning Freeze Protection Drain Pan Field Testing Freeze Protection Drain Trap Cleaning Freeze Protection 64 Drive Kit Inspection 0 Electric Heat Control Wiring 17 Energy Recovery Wheel Control Wiring Start Up 2 T External Lube Lines 58 Fan Assembly Pre Start Up Inspection Cleaning Maintenance Inspection Fan Bearing Types Lubrication Fan Motor Energizing at Start up Inspection and Maintenance Bearing Lubrication Fan Cleaning Inspection Gas Heat Control Wiring Filters AF FF RF Types Maintenance And Replacement Inserting into Side Load Filter Tracks Motors Check Amperage after Air Balancing Sheaves Replacing after Air Balancing Alignment Start up Start Up Checklist Test and Balance Air Balance Dynamic Balance Variable Frequency Drive VFD Set Up of Non Factory Mounted VFD SECTION 1 GENERAL INFORMATION AND SAFETY INTRODUCTION The Revolution TFX air handling unit AHU is manufac tured to the highest design and construction standards to ensure high performance reliability and adaptability to all types of air handling installations ABO
16. K Tau amen ce OPTION 150VA OR SOOVA TRANSFORMER SEE TRANSFORMER CONNECTION DIAGRAMS r 777 7 FOR PROPER XI CONNECTIONS FIGURE 83 FULL VOLTAGE STARTER WITH SINGLE POINT POWER CONNECTION 204195 SECTION 5 WIRING DIAGRAMS mE 272 gt IT PB SUPPLY FAN OTO 213 gt A USED WHEN FUSES ARE GREATER THAN 60 AMP pisci FU4 M2 OL2 212 3PH RETURN FAN ALTERNATE OL1 USED WITH CT1 2 3 WHEN MOTOR gt ALTERNATE OL1 FLA IS GREATERTHAN 80 AMPS Gai 4 ene apa mpd hei nn me p le ein is em m s YO r L R A M W NE emu em amem em MOTOR PA SUPPLY FAN ALTERNATE OL2 USED WITH CT4 5 6 WHEN MOTOR FLA IS GREATERTHAN 80 AMPS
17. p 3000 zma 1 2 to 1 11 16 500 1500 2000 MN NUN 06 1 15 16 to 2 7 16 Z 2 11 16 to 2 15 16 7 3 7 16 to 3 15 16 1 7 1000 2500 _ NEN A NEC EE ONE AL TABLE 12 FAN BEARING LUBRICATION INTERVALS FOR SPHERICAL ROLLER BEARING SPLIT PILLOW BLOCKS SPEED RPM sw 75 SHAFTDIAMETER N 1 NN NEN 3000 _ sas 1000 15000 2000 2600 Camnews 4 4 m 1 3706345 4 22 w 1 3500 _ ss ss NEN 08 SECTION 3 MAINTENANCE LUBRICATING THE FAN SEGMENT AND MOTOR Keep the motor clean dry and properly lubricated at all times On ODP Open Drip Proof type motors as shown in Figure 50 on page 59 blow dust and dirt out of the windings periodically using low pressure air 50 psig For Totally Enclosed Fan Cooled TEFC motors as shown in Figure 51 on page 59 blow dust and dirt out of the cooling fan as FIGURE 51 TOTALLY ENCLOSED FAN COOLED TEFC MOTOR Checking Condition of Mounting Hardware Adjustable Motor Base and Motor Hardware and Motor Base Check for loose parts and damage If the parts are damaged replace the parts Motor Check the motor for leaky bearing seals damage and dirt dust and debris in the motor housing Checking Electrical Connections Check the following 1 Electrical terminations 2 Conduit fittings and clamps for damage or l
18. z Xx EXE 2 2 ES REN RN 28 NA NA 11 NA NA NA ff NA NA NA NA NA NA NA NA NA EE GASBURNER PIPING AS BURNER TD FURNACE OUTPUT 3 DN 3 3 gt GAS BURNER BURNER lt lt lt lt lt lt lt E e z z ziziziz lt lt lt lt lt lt lt lt lt lt lt lt lt lt LO LO e e MAXIMUM ALLOWABLE INLET PRESSURE FUR NACE OUTPUT a 5 o z 2 GAS FEATURE BTUS Note Gas pressure requirements at the inlet to the main manual shutoff cock of the gas train 39 SECTION 2 START UP AND OPERATION TABLE 7 INLET SIZE NPT GAS BURNER PIPING GAS BURNER TURN DOWN UL 10 EB 1 00 NN 100 A 100 NA NA NA NA NA 100 NA 1 00 1 00 NA NA NA NA NA NA NA NA NA A om UL 25 FURNACE OUTPUT X10K c r w or 1 00 1 00 1 00 em NA A NA x NA NA NA NA NA NA NA 0 NA NA NA 1 00 NA 1 00 1 00 NA NA ONA ONA ONA y 1 00 1 00 1 50 1 50 ia 2 00 Cw pu NA _ NA NA NA 1 00 1 25 1 25 1 25 1 50 y i e o 2 00 2 00 2 00 2 00 2 50 2 50 2 50 2 50 2
19. 39 TABLE 7 Inlet Size NPT uiii usce bea ubasta aids ed 40 TABLES Burner Temperature Rise 42 TABLE 9 Minimum Maintenance Requirements According to ASHRAE 49 TABLE 10 Fan Bearing Lubrication Intervals for Ball Bearing Pillow Blocks 5B TABLE 11 Fan Bearing Lubrication Intervals for Spherical Roller Bearing Solid Pillow Blocks 5B TABLE 12 Fan Bearing Lubrication Intervals for Spherical Roller Bearing Split Pillow Blocks 58 TABLE 13 Motor Bearing Lubrication Intervals a 60 TABLE 14 Motor Bearing Service 60 TABLE 15 Motor Bearing Lubrication Interval Multiplier 60 TABLE 16 Cap Screw Torque Values cccccccccccssseeeeeeececeeeeeeeaeeeeseeeeeeeeeseeeaseeeseeeeeeeeesseaeaeeeeeeeeeeesaaas 79 TABLE 17 Set Screw Torque Values 00 06 cc cccecctecscceseneeeecetesececsseeseesceseseceacedenseeeeteetecccseeesereeeensecas 79 TABLE 18 SI Metric Conversion ce enn ne neo Cross ce zer pee graec ee esee ako oso ieee SERVICE TASK REFERENCE Adjustable Motor Base Operation Air Modulator Start Up
20. Pressure washer that does not exceed 2000 psi oprayer utility garden etc applicator Plastic sheeting and duct tape e Screening Coil cleaner safe commercial disinfecting e Garden hose and spray nozzle Pail and rags e Trash bags Power cords Four inch paint brush Cleaning Procedure 1 Clean dehumidification coils annually or when air pressure drop exceeds 125 of design 2 Cover electrical components such as fan motors damper motors compressors thermostats etc with plastic Care should be taken on interior coil cleaning Remove filters cover fan bearings and any insulation to keep these items free of water damage Condensate drain piping should be screened to allow coil cleaning water to flow freely Screening keeps traps and drain lines from clogging with debris washed from the coils 3 Prior to any application of wet cleaning materials use a wide soft bristle paint brush to dust off any heavy dust leaves bugs or other foreign matter that may be on the coil fin surface 4 Safety glasses should be worn when cleaning coils 5 When possible remove dirt lodged in the depth of the coil by using clean oil free air under pressure Caution should be taken not to use extreme high pressure air as this may cause fin surface damage Direct the air straight at the openings between the fins and never at an angle which may bend the fins against one another Always apply the air from the air leaving s
21. SUPPLY BY OTHERS Q No CR2 1 10 7 MOTOR E O 4 2 OPEN 100 F CRI gt POLO x LOW FIRE START BURNER UMIT SET 14008 Ron w OT INDUCER BURNER J e AT SW ER AGNITION TRANSFORMER 2 PILOT VALVE 9 lt 51 e OD E G 9 BURNER MODULATION MOTOR M9174C W INPUT MODULE Q7230 10 15 T STAT oe 48 24 RELAY COIL W 120V CONTACTS CR1 1 CR1 2 51 gt 52 FAN OVERRIDE HEATER FAN OVERRIDE MUS KEY SHIELDED CABLE RECOMMENDED NOTE JACKSON amp CHURCH WIRING TO BE BURNER PANEL TERMINAL PANEL WIRING R CODED AS FOLLOWS L FIELD WIRING 1 MOTOR WIRING BLACK ciRcum BOARD TERMINAL UNT WIRING 2 CONTROL CIRCUIT RED COMPONENT OUTLINE 3 LOW VOLTAGE YELLOW MODEL RM7895A FIGURE 87 GAS HEAT SINGLE PHASE 1500VA TRANSFORMER WIRING DIAGRAM 91 10 20 30 40 50 60 70 80 90 100 110 120 130 70 AMP 7 4 AWG C1 1 133 FU1 2 AMP CS 1 18 AWG 1 SECOND RESET LATCH 1 133 18 AWG SECTION 5 WIRING DIAGRAMS 18 AWG 18 AWG UV LIGHT IN USE Indicator lamp CB2 14 AWG UV LAMPS IN ie pass g eae AHU L 18 LAMPS I 15 AMP UV LAMPS IN AHU 18 LAMPS MA
22. coil heaters is 100 F and for finned tubular heaters 80 3 Sufficient working space must be provided per paragraph 110 26 of the NEC 4 This electric heater is not designed for or intended to be used for temporary heat prior to system startup balancing Mechanical Installation 1 All heaters will contain an adjustable airflow switch in the heater control panel This switch will be preset to close at a differential pressure of approximately 0 3 W C In all cases the switch will be connected to a pressure probe positioned in the airstream This probe has an arrow stamped on it that is viewable from inside of the control panel When the heater is located upstream of the fan this arrow will point away from the fan When the heater is located on the downstream side of the fan the arrow will again point away from the fan or with airflow If it is incorrectly installed remove the 2 screws holding the pressure probe in place and rotate 180 and reinstall The airflow switch pressure port that is not connected to this pressure probe will be run to the exterior of the air handling unit to source a reference differential pressure In some situations it may be necessary to adjust this switch setting to allow for proper operation Precautions must be made at this time to make sure that the airflow switch does not provide a false indication of airflow Failure to meet this requirement may result in serious dam age or
23. www emerson ept com 08 187037 10 116174 PO P436048 1 KIT 289 24302 201 10 5 RPM 1154 16 7 3 00 TRN OPN TENSION INFO 4 33 LBS 0 25 IN DRIVE S BELT BX56 MOTOR SHEAVE 2VP71X 1 5 8 MOTOR BUSHING NONE REQUIRED Z0 10000 962266 FAN SHEAVE 2BK100X 1 3 8 S FAN BUSHING NONE REQUIRED E Ex 3 2 ES Que 4 REC FIGURE 34 TYPICAL DRIVE DATA TAG a N OPERATING ADJUSTABLE MOTOR BASE SSS 5 Hold Down Bolt Standard Assembly 5 Secure the nut with a wrench placed through the service hole and loosen the bolt Do this to all four hold down bolt assemblies as shown in Figure 35 on page 57 Place Wrench On Nut Through Service Hole 6 Make sure the drive bolt assembly threads are FIGURE 35 ADJUSTABLE MOTOR BASE lightly lubricated 7 Turn both drive bolt assemblies in the same direc tion to move motor for belt installation and tensioning 8 Turn drive bolt assemblies independently to move motor for sheave belt alignment 9 Tighten all four hold down bolt assemblies For belt tensioning instruction refer to Sheave Alignment 51 SECTION 3 MAINTENANCE MOTOR BASE ADJUSTMENT SCREWS DRIVE SIDE STRAIGHT EDG MOTOR S NOTE 2 OTE 3 SHEAVE MOTOR OTOR BASE MOUNTING HARDWARE lt DRIVE SIDE FIG 1 MOTOR BASE PARALLEL MISALIGNMENT PARALLEL ALIGNMENT FIG 4 FIG 5 DRIVE SIDE FIG 2 SUPPORT RAILS
24. 62 FIGURE 58 gt Installing Side Load Filters R u y u te Hit i eee ee es ek 62 FIGURE 59 RMSE SCOMENIS bore tt naue PR 65 FIGURE 60 Diameter Seal 66 FIGURE 61 Airxchange Energy Recovery Wheel With Bearing Support Beam Side 66 FIGURE 62 How to Measure esa ao uu teria Versos eo 68 FIGURE 65 DISSSSembly i uuu uu aun au a oc e Doe 68 FIGURE OG RE cre M 68 FIGURE 65 Installation a 68 FIGURE 66 Loosen Screws Before Adjusting Seals T a a 69 FIGURE 67 Airloop Labyrinth Seal Adjustment 70 FIGURE 68 Seal LOGAUONS uyu a 70 FIGURE 69 Maintenance Requirements r 72 FIGURE 70 Construction of Pitot TUDE estas 74 FIGURE Pilot t u n an Kos eed A maaa bedded board 74 FIGURE 72 Inelined Manotmlelef a RO O 75 FIGURE 73 Minihi lie Fiter GAUGE rd elc aeree
25. Installing 80 AQGJUSUNJ 91 2 E 80 Adjustable Pitch Sheaves Woods Model 81 Toolsand Material Regus 81 REMOVING SINC AV sarees 81 uu u 81 B G 82 SECTION 5 WIRING DIAGRANS 83 uuu u u GRA O SS ak 99 LIST OF FIGURES FIGURE 1 Seismic ISolalOE 14 FIGURE 2 Fan and Motor Isolator Support Frame a aaa nnn nnns 16 FIGURE Spring P 16 FIGURE 4 Counterbalance Locked into Place for Shipping r 17 FIGURE 5 Counterbalance Unlocked for Start Up a a a s 17 FIGURE 6 High And Low Connections For An In Fan Air Monitoring 21 FIGURE 7 Port Locations For Fan Mounted Air Monitoring System 22 FIGURE 8 Ductwork Inlet Lun uuu
26. MOTOR MOUNTING ADJUSTMENT HARDWARE OTOR BASE ADJUSTMENT SCREWS OPP DRIVE SIDE OTOR BASE MOUNTING HARDWARE FIGURE 36 ADUUSTABLE MOTOR BASE TOP MOUNT NOTES 1 THE SHEAVES SHOULD BE CENTERED ON THE SHAFT S KEYWAY SHEAVE CAN BE CLOSER TO THE BEARING AS LONG AS THE SHEAVES HUB IS ABLE TO FULLY ENGAGE WITH THE KEY 2 CHECK FOR PARALLEL MISALIGNMENT BY PLACING A STRAIGHT EDGE ACROSS THE OUTER FACE OF THE SHEAVES FIG 5 STRAIGHT EDGE IS TO BE LONG ENOUGH THAT IT EXTENDS PAST BOTH SHEAVES 3 IF THE SHEAVES ARE MISALIGNED FIG 4 LOOSEN THE MOTOR S MOUNTING HARDWARE AND SLIDE THE MOTOR FORWARD OR BACK TO BRING THE SHEAVES INTO ALIGNMENT FIG 5 THEN RE TIGHTEN HARDWARE SECTION 3 MAINTENANCE Checking Belt Tension Check the belt tension It is normal for belts to loosen after start up or replacement The new belt will run in or take a set by seating slightly deeper into the grooves of the sheaves Recheck tension after one day and again after three days 1 Measure the belt span as shown in Figure 37 on page 53 BELT SPAN FIGURE 37 BELT TENSIONING 2 Position bottom of the large O ring on the span scale at the measured belt span as shown in Figure 38 on page 53 FIGURE 38 BELT TENSIONING GAUGE 3 Set the small O ring on the deflection force scale to zero 4 Place the tension gauge squarely on one belt at the center of the belt span Apply a force on the plunger and p
27. 50 YNA TASTE 50 Fan Segment Supply Return or Exhaust aaa aaa aaa aaa aaaaa aaa aaa nena nnn 50 FICIMOVING ING Faik Duda 50 Operating Adjustable Motor Base nananana aa e a a aa i a E 51 Standard eK PH TM M 51 Ghecking Tensi AA ie stets iet 53 AMONINJ Sea BS Z em EA 53 54 IAG ig RM 54 Belt Replacement Tensioning and Sheave Alignment for Mount 55 er 56 Checking Condition of Extended Lubrication Lines 58 Recommended Lubricant for Bearings 58 Properiinterval angiGOuan ilyu u ec 58 Lubricating the Fan Segment and 59 Checking Condition of Mounting Hardware Adjustable Motor Base and 59 Checking Electrical uu a a iacu au xeu 59 Keep
28. Lock Nut FIGURE 48 SPLIT BEARING ASSEMBLED Fan Bearing Lubrication If the fans will be down for four weeks or more erly apply correct grease and rotate monthly to prevent moisture from damaging bearings Fan bearings on the AHUs are equipped with standard lubrication fittings AHUs under 42 in tall will have either extended lube lines enabling lubrication of both fan bearings from one side of fan as shown in Figure 49 on page 57 or optional external lube lines For AHUs 42 in tall and above extended lube lines and external lube lines are optional Some fans will have permanently lubricated bearings FIGURE 49 OPTIONAL LUBRICATION LINES For specific fan bearing lubrication check the instruc tion packet attached to the fan housing Some forward curved fans are permanently lubricated For best results relubricate the standard pillow block bearings while in operation if it is safe to do so Add grease slowly with the shaft rotating until a slight bead forms at the seals necessary to relubricate while the bearing is station ary refer to the manufacturers data for maximum grease capacity for the size bearing Relubrication is generally accompanied by a tempo rary rise in operating temperature Excess grease will be purged at the seals Wipe away purged grease after several hours of operation 57 SECTION 3 MAINTENANCE Checking Condition of Extended Lubrication free alkali dust rust metal pa
29. Orientation Use the following instructions to orient the damper blades Return Air and Mixing Dampers 1 Position the blades so that they will be open after the actuator is installed which will be the dampers spring return position 2 Note whether the damper shaft is rotated clock wise or counterclockwise SECTION 2 START UP AND OPERATION Outside Air and Exhaust Air Dampers 1 Position the damper blades so that they will be closed with the power off which will be the damp ers spring return position Note if the damper shaft is rotated clockwise or counterclockwise 2 With the actuator shaft clamp tightened to the damper jackshaft and the damper shaft complete ly rotated to its proper position manually operate the actuator to its fully actuated position using the crank arm provided with the actuator 3 Release the spring to allow the damper to go back to its original position which will verify the actuators spring rotation and stroke 4 Set the damper actuators rotation selector switch to the proper rotation required to actuate the damper The damper actuator will always be opposite the spring return rotation 26 SECTION 2 START UP AND OPERATION Energize Fan Motors Use the following instructions to energize the fan mo tors 1 Observe the fan s for smooth operation 2 Check the motor nameplate for the full load amp FLA rating 3 Check the current draw of each leg of each motor
30. SP energy in the continuing ductwork This conversion of velocity energy to SP is called static regain REQUESTING ASSISTANCE When contacting Titus for assistance provide the following information e Titus Order Number e Job Name not contractor Unit Model Number e Customer s Unit ID Design and actual data e Fan RPM Unit SP across fan Unit CFM Pressure drop of water across cooling coil PSIG Air pressure drop across cooling Temperature differential across cooling coil Motor voltage and amperes For fan or motor RPM use a tachometer strobo scope or revolution counter he voltage and amperes can be obtained by using the appropriate multimeter test device A sketch of the duct configuration would assist us in trying to resolve the problem he most important item is to provide a detailed explanation of the problem An orifice is the best method of measuring flow in piping and in the air system 77 ADJUSTING REMOVING AND INSTALLING SHEAVES Fixed Pitch Sheaves T B Woods With Sure Grip Bushings Tools and Materials Required e Standard mechanic s hand tools Medium flat file e Torque wrenches 0 to 250 in lb Hex Allen socket set for torque wrench e Standard 3 8 in or 1 2 in socket set e Hammer Fine Emery cloth Contact cleaner or mineral spirits Removing Sheave 1 Remove the belts 2 Remove the cap screws from bushing sheave as shown in Fi
31. Variable Frequency Drive VFD Titus air modulators are unless otherwise selected provided with start up service NOTE The VFD controlling the speed of the fan s needs to be set up properly so the fan does not run at resonant frequencies This is true whether the VFD is field or factory mounted An option is available when ordering the AHU to select Inverter Drive Balance Sweep Balance When the option is selected the fac tory provides a document or label attached to the fan assembly that lists any values that exceed the peak to peak tolerance See Figure 10 These values are re ferred to as Skip Frequencies Jump or Lockout Fre quencies The technician performing start up of the VFD is to enter these values in the VFD programming according to the manufacturer s instructions This step will prevent continuous operation at the resonant frequencies listed on the label If the option was not selected on the AHU order it is the customers re sponsibility to have the Inverter Drive Balance Sweep Balance performed and enter any detected Skip Fre quencies Jump or Lockout Frequencies in the VFD program This should be done during start up Failure to properly set up the VFD before applying power to the motor will void the fan and motor warranty NOTE SWEEP N RE The values listed below exceed the peak to peak tolerance through the sweep balance When programming the Variable Speed Drive lock out or skip these frequen
32. an external flanged bearing which Inspect Wheel Drive Components Cleaning the Wheel should be greased annually with a petroleum based lu The wheel should be protected by an ASHRAE 30 021811 filter to keep dust and dirt from the heat transfer sur Drive Motor The drive motors should require no face If the wheel becomes dirty it may be cleaned by maintenance If the motor needs to be replaced Re blowing out the unit with compressed air 20 psig placement motors may be purchased from normal mo maximum In cases of severe uncleanliness the tor distributors wheel may be removed from the cassette and washed with flowing water Wheel removal procedures are Drive Belts Wheel belts are multi link belts with in outlined below dividual links constructed of a high performance poly urethane elastomer which is reinforced with multiple 1 Disassemble air handler panels and bulkheads plies of polyester fabric This belt provides strong yet only enough to gain access to front or rear of flexible belting The multi link feature provides quick wheel where necessary or where there are no easy servicing or replacement doors 2 Support the wheel from the bottom How to Measure Assemble and Insta How to Measure Pull belt tight around pulleys to check hand tight length overlapping the last two tabs bearing loosen the allen screws in the bearing with two holes in matching links as shown Count the housing that keeps the shaft affixed i
33. are for 125 and 100 wire sizing If there are more than 3 conductors in a raceway derate these amperages Table 310 15 b 2 a SECTION 2 START UP AND OPERATION 7 When connecting heaters with more than one stage wire stage No 1 so that it is the first stage on and the last stage off 8 The heater must be wired so that it cannot operate unless air is flowing over it This can be accomplished by using a built in airflow switch and a remote interlock See the accompanying wiring diagram for the method used with this heater and provide appropriate interlock wiring as illustrated This diagram will be located inside of the electric heater control panel 9 If not supplied as part of this heater install a line disconnect switch or main circuit breaker in accordance with the National Electrical Code De pending upon the heater s location and accessi bility a built in disconnect switch may meet this requirement 10 All electrical connections in the M heater including both field and factory made connections should be checked for tightness before operating the heater In addition after a short period of operation all connections should again be checked for tightness 11 If heater is wired to a heating cooling thermostat use a thermostat with isolating circuits to prevent possible interconnection of Class 2 outputs 12 If the heating elements are divided into several sections with resistance wire between t
34. be measured For example if a Pitot Tube manometer hook up reads 0 25 inches water the previous equation should be substituted Static Pressure Independent of its velocity air when confined within an enclosure such as a duct or tank will exert itself perpendicularly to the walls of the enclosure This is the compressive pressure existing in a fluid and it is known as the static pressure SP Unlike VP which is always positive SP when it is above atmospheric pressure wil be positive but when below atmospheric pressure it wil be negative The discharge side of a fan in an air system will read a positive pressure the inlet side will read a negative or minus pressure 76 SECTION 4 SERVICE AND REPAIR Total Pressure Static pressure is exerted whether air is at rest or in mo tion The algebraic sum of static pressure and velocity pressure gives the total pressure TP VP TP SP The manometer does not sense the actual VP directly but by using the pitot tube hook up with the static open ing connected to the low pressure side of the gauge and the total pressure opening connected to the high pressure side of the gauge the manometer will read the difference between the two or the VP VP and SP change in the ductwork with every change In the duct configuration but the total pressure on the other hand remains constant As a result as the VP decreases the SP increases and vice versa because the SP is always th
35. be moved so that the outer edge of the seal is always in contact with the main rotor seal 31 FIGURE 21 PURGE ANGLE DETAILLD 7 Grease bearings using Dow Corning Molykote BR2 plus Lithium based high pressure grease Apply the grease to the fitting while turning wheel until a slight amount of grease is purged Remove visible grease residue from the bearing The bear ings are filled with grease prior to shipment This step may be required if the units have been idle on the job site for more than 6 months Put belts back on pulley 8 If the unit is provided with a VFD verify the motor is wired for the correct voltage provided by the VFD NovelAire Technologies Start Up Procedure 1 Does the rotor rotate freely by hand If not re check the seal to determine whether or not it is binding and if so adjust seals following the in structions below 2 15 the motor rotation correct This can be checked by detaching the belts from the drive sheave and bumping the motor The sheave should be rotating in the direction such that the belt will result in rotation per the exterior markings If not rewire the motor 3 Does the air flow orientation match up to design See the identification markings on the cassette 4 Are the belts on correctly and sufficiently tight Belt length is set by the manufacturer Consult NovelAire amp Technologies if the belt appears too loose 5 Is the VFD programmed to control the unit and
36. dirt and debris Check fan base vibration isolators and thrust restraints for damage wear loose parts dirt and debris Check flex connector for damage and wear Check the cleanliness of the filters and replace or clean as required Check filter frames filter tracks for residual contaminates and clean as necessary Verify filter gauge and or switch function properly Check drive kit for damage loose parts wear dirt alignment and belt tension Check belt tension S Lubricate fan bearings Ball Bearing Table 4 2 Roller Bearing Table 4 3 Split Pillow Block Table 4 4 1 See OM Tables check condition or extended libration ines when present T I I x po check adjustable chec fan motor forleaky bearings LOL 0 b Clean condensate arain pan rap arain ine and adjacent wetted faga mate check clean and cabrae ooo check Energy Recovery Wheel clean media adjust seais pce 1 For operating and maintenance requirements listed above refer to appropriate service literature or contact your local Titus Rep Office 2 This procedure must be performed at the specified time interval by a Qualified Technician A record must be maintained should proof of adequate maintenance be required for warranty validation 3 More frequent maintenance may be required depending on actual operating conditions FIGURE 6
37. is grease lubricated as well and does not require any maintenance Life expectancy is in excess of 10 years The drive belt tension does not need any adjustment due to the gravity based mounting base used The B type V belts are installed with a B 437 belt connector manufactured by FLEXCO This connector will even tually wear out and need to be replaced A typical life span is five to 10 years depending on the environmen tal condition 69 SECTION 3 MAINTENANCE INNERGY TECH It should be noted that the AirLoop labyrinth seal is Cleaning the Wheel made of a special material which was specifically In most applications it is not necessary to clean the chosen to make sure it could never damage the media of the wheel because the wheel rotates Incom media While the best seal is obtained when the ing and outgoing airstreams are constantly blowing above steps are followed if installed too close the debris out of the media during operation If cleaning is media will simply use the seal a little more As the needed clean the media with a vacuum cleaner or wheel turns the seal will automatically adjust itself to pressurized air It is not recommended to use any type the wheel s tolerance approximately 1 32 for the of solvent or detergent on the wheel because it may smallest possible air leakage and become a non cause damage to the media or the material used to contact seal that will last throughout the wheel life build the wheel
38. of straight duct is required before enter 100 Sensing option ing the AMS 60 damper 9 25 Sensing Option Min Max 1 equivalent duct diameter d 1 25 w 75 Mixing FIGURE 10 25 SENSING OPTION FIGURE 8 DUCTWORK INLET REQUIREMENTS The 25 Sensing Min Max option arrangement is a dual damper design and used for measuring the mini If one equivalent duct diameter cannot be achieved outside air requirement In this arrangement the during installation the rectangular elbow may be sub 29 damper would be for monitoring airflow through stituted with a radius elbow The outside radius must the first 25 down to 3 75 nominal flow and the 75 have a R W ratio of 0 75 or more damper would have a separate actuator and used for economizer control only This option would be the best low cost option for areas in which economizer cycles are not often seen such as the southeast and are required to constantly operate in at the minimum outside air position e 25 7596 Sensing Option Mixing Box 25 FIGURE 9 DUCTWORK RADIUS Damper Linkage Arrangements The AMS 60 mixing box will ship with independent 75 return air and outside air damper actuators if selected in the MB or FM segments FIGURE 11 25 75 SENSING OPTION 23 The 25 75 Sensing option arrangement 18 similar to the 25 Sensing Min Max option but allows you to measure airflow throughout the economizer cyc
39. or stationary flange of the adjustable sheave with the center flange of the companion sheave 10 Insure the shaft of the motor is parallel to the shaft of the fan 11 Secure the adjustable sheave to the shaft by tight ening the setscrew over the key to the proper torque value 12 Adjust the sheave flange s to the desired pitch diameter Each turn of the flange changes the pitch diameter approximately 0 2 in Six turns are required to adjust the sheave from minimum to maximum for A or B belts and seven turns for 5V belts CAUTION Both flanges of a two groove sheave MUST be adjusted evenly 81 13 Lock the adjustable flange s in position by tight ening the set screw s to the proper torque value 14 To prevent damage to the central sleeve threads the set screws MUST be over one of the flat areas of the central sleeve If the flange is not properly locked the sheave will fail rapidly 15 Install the belts and tighten properly 16 Recheck the alignment and speed SECTION 4 SERVICE AND REPAIR Adjusting Sheave 1 Remove the belts 2 To adjust pitch diameter loosen setscrew s on ad justable flange s of sheave 3 Follow Steps 9 through 12 in nstalling Sheave in this section 82 WARNING WARNING SECTION 5 WIRING DIAGRAMS External wiring unless specified as an optional connection in the manufac turer s product line is not to be connected inside the control panel cabinet
40. placement of the flow measuring probes inside the fan inlet cone in the path of airflow These devices create disturbances and unpredictable perfor mance losses FIGURE 6 HIGH AND LOW CONNECTIONS FOR AN IN FAN AIR MONITORING SYSTEM 21 FIGURE 7 PORT LOCATIONS FOR FAN MOUNT ED AIR MONITORING SYSTEM Air Measuring at Unit Outside Air Inlets e AMS 60 used on Revolution air handlers usually measure outside air This can be provided with one or two pairs of positive or High and negative or Low pressure tube connections Connect amp respectively to the amp ports of the transducer s Wiring amp transducer are not provided unless factory packaged controls were selected SECTION 2 START UP AND OPERATION AMS 60 Damper General The AMS 60 is an airflow monitoring damper which combines the functions of control damper and airflow measurement station into one assembly It is ideally suited for factory installation in Solution air handling units The AMS 60 is tested to AMCA Standard 611 95 and qualifies to bear the AMCA Ratings Seal for Airflow Measurement Performance Damper Operation The AMS 60 airflow monitoring damper design incor porates a low leakage control damper with stationary vertical air monitoring blades and air straightening sec tion into one assembly The control damper utilized for modulating airflow is the ultra low leak Ruskin CD 60 with its standard blade a
41. silicone caulk sealant or caulk sealant containing silicone in or on any air handling equipment BEFORE START UP Perform a general inspection Identify and perform the appropriate the lock out tag out and safety rules Re fer to the AHU Start up Checklist provided with the information package shipped with the AHU For more information about the steps below refer to the Revolution Installation Manual For an AHU equipped with a Variable Frequency Drive VFD refer to the specific VFD literature for additional start up requirements Check for damage to the AHU s interior and ex terior Ensure the terminal screws and wiring connec tions are secure in the control electric and air modulator panels Verify that the Equipment was received as ordered was installed on flat and level surface and with proper clearances Condensate drains are properly trapped All wiring and tubing connections are com plete at shipping splits All field piping connections are completed All shipped loose parts are installed All ductwork is complete and available for full airflow Installer removed all dirt debris hardware mold etc from interior of the AHU and its ducts Filter gauge is set to zero All shipping splits are sealed and secured properly Ensure clean air filters are installed and secure properly e Inspect all field provided wiring c
42. slot and setscrew The setscrew 15 secured with removable locktite to prevent loosening Annually confirm setscrew is secure The wheel drive motor bearings are lubricated and no further lubrication is necessary 5 With the wheel out wash the media carefully with water Once clean allow the media to dry out for several hours or days if necessary 6 Reinstall using the reverse procedure Run the unit It may take several hours for the desiccant to dry out and for the wheel to perform normally The wheel drive belt is a urethane stretch belt de signed to provide constant tension through the life of the belt No adjustment is required Inspect the drive belt annually for proper tracking and ten Adjusting Air Seals sion A properly tensioned belt will turn the wheel immediately after power is applied with no visible slippage during start up The seals are designed to be durable and require no maintenance other than adjustment But if the seals become worn or damaged replace them Clip the seals e If slippage is detected replace wheel drive belt to the cassette or post metal immediately because it likely to become clogged Contact the local Titus Representative to order replacement belt Refer to service manual for belt Bearings Small wheels are equipped with no main replacement instructions tenance inboard bearings which should require no maintenance during the life of the AHU Larger wheels come equipped with
43. started up e Gas lines are purged of air to the equipment valve e Controls are complete Flue stack is correctly installed if parts were shipped loose Recommended Tools Electrical Multimeter with Amprobe e Heating AHU Installation and Operation Instruc tions which are provided with every heating AHU for technical information and troubleshooting Magnehelic Gauge 0 25 in WC Dwyer Series 2000 or Model 1227 Dual Range Manometer for checking pressure over fire draft Control Signal Generator 0 to 20 mA Altek 234 or 334A For 2 to 10 VDC signal add 500 ohms in series with signal generator Magnehelic Gauge 0 15 in WC and 0 to 3 Ib Dwyer series 2000 or Monometer Dwyer 1227 Duel Range Monometer for checking supply gas pressure and manifold gas or pilot gas pressure Honeywell S7800A Test Module for use on Honeywell 7800 Series Relay Module which is available through Airside Parts Flue Gas Analyzer CO and Oz e Stack Thermometer 0 F 1000 F approx Digital Manometer replaces Magnehelic Gauge Digital Manometer Cat 4475 1 FM AVSeries 475 1 Mark III Range 0 to 19 99 In W C from Dwyer Instruments Inc Pre Start Up Checklist o Condensate trap must be installed prior to start up by the installing contractor Refer to Figure 22 on page 34 for installing the gas furnace condensate drain trap Use the following information to check the AHU be fore starting it
44. the belt tension is correct then lower the drive side of the base to remove to remove the belt tension 12 Loosen the mounting hardware on the opposite drive side and raise or lower the base accordingly and repeat Steps 6 10 13 Mark the position of the base s opposite drive side mounting hardware before lowering the base which may help determine where to secure the hardware the next time the belt is replaced 14 Reinstall the belt PLENUM FAN FAN E SHEAVE E FIGURE 42 MOTOR BASE LOWERED 55 SECTION 3 MAINTENANCE STRAIGHT LUBRICATION EDGE Verify the type of bearings before lubricating them as shown below e Sealed not to be relubricated in the field as shown in Figure 45 on page 56 e Standard Pillow Block as shown in Figure 46 on page 57 and Figure 29 on page 41 e Split Pillow Block as shown in Figure 48 page 57 and Figure 31 on page 46 Seal 4 Housing Cap Cap Bolts 2 Locating Ring 2 Lock Nut Lock Washer Tapered Sleeve FIGURE 43 SHEAVE ANGULAR ALIGNMENT Bearing ON O NN Housing Base FIGURE 44 SHEAVE ANGULAR MISALIGNMENT FIGURE 46 SEALED BEARING 56 SECTION 3 MAINTENANCE NE gt E FIGURE 46 BEARING WITH SET SCREW TYPE LOCKING DEVICE 1 Seal 4 6 Lock Washer 2 Housing Cap 7 Tapered Sleeve 3 Cap Bolts 2 8 Bearing 4 Locating Ring 2 9 Housing Base 5
45. thorized service center if grease other than the recommended type is to be used 2 Clean all grease fittings 3 Remove the grease relief plug 99 SECTION 3 MAINTENANCE 4 If motor is stopped add the recommended 6 Clean off any grease from the grease fitting AA 7 Run motor for 15 30 minutes with the relief 5 If the motor is to be greased while running add a plug removed to warm up the grease slightly greater quantity of grease slowly until the new grease appears at the shaft hole in the end plate or relief plug hole 8 Wipe off any grease that was pushed out of the relief plug 9 Reinstall the grease relief plug TABLE 13 MOTOR BEARING LUBRICATION INTERVALS RATED SPEED RPM HOURS FRAME SIZE UP TO 210 INCL 132 2 700 5 500 12 000 18 000 22 000 OVER 210 280 INCL 180 3 600 9 500 15 000 18 000 OVER 280 360 INCL 180 22 200 7 400 12 000 15 000 OVER 360 5800 INCL 180 2200 3 500 74 00 10 500 Lubrication intervals are for ball bearings For roller bearings divide the listed lubrication interval by 2 Relubrication interval for 6205 bear ing is 1550 hrs and for 6806 bearing is 720 hrs Using grease lubrication For 6205 and 6806 bearings For 6807 bearings consult oil mist lubrication MN410 TABLE 14 MOTOR BEARING SERVICE CONDITIONS AMBIENT TEMPERATURE ATMOSPHERIC SEVERITY OF SERVICE TYPE OF BEARING CLEAN
46. with top bottom and side galvanized plate option only 3 Grease both pillow block bearings on the wheel using a NLGI grade 2 consistency mineral oil lithium or lithium complex base grease 4 Before start up make sure the wheel turns by hand and does not bind All contact between the seals and media should be verified and the seals adjusted if needed 5 Visually inspect the wheel to ensure it is centered and does not tilt If there is any indication of a problem call Innergy tech at 1 800 203 9015 6 Does the power supply match the supply required by the electrical equipment If not the electrical equipment or the power supply must be changed The wheel identification tag located near the electrical input gives the proper voltage to use Check the drive motor by bump starting it Check the wheel rotation to ensure it is turning in the correct di rection If the wheel is turning backward reverse the motor rotation 30 SECTION 2 START UP AND OPERATION Thermotech 6 If the unit is supplied with an adjustable purge Start Up Procedure determine the proper purge angle from the ordering 1 Remove the belts from the motor sheave and ro code on the unit nameplate or the specific data for tate the wheel a minimum of one full revolution The seals are non contact If the wheel does not rotate freely it may be due to the wheel being in contact with the seal If the wheel cannot be turned by hand contact Thermo
47. your application However only three 3 are applicable to the AMS 60 function The jumper selections are as follows 0 1 0 5 and 0 25 These are field adjustable To determine the correct jumper setting for your application refer to the equation and examples on page 4 for the Revolution TFX Input Power A 24VAC power supply can be wired into the supply voltage terminals on the Actuator and Transducer CFM Input Signal to Damper Actuator 2 10VDC BELIMO 0 10 VDC JOHNSON CONTOLS CFM Output Signal from Transducer 0 10VDC Sequence Of Operation A 0 10 VDC or 2 10VDC control signal is sent to the AMS 60 damper actuator from the Building Automation oystem BAS The BAS maintains the required cfm by modulating the actuator on the control damper The BAS receives a 0 10 VDC signal back from the transducer confirming the cfm supplied Upon loss of power the AMS 60 actuator returns to a closed posi tion 24 SECTION 2 START UP AND OPERATION AHU Airflow Station Specifications Furnish and install at locations indicated on plans and or schedules an air monitoring station integral with outside air control damper stationary airflow sensing device and air straightening section The integral air monitoring station shall incorporate pressure sensing ports built into the sensing device and shall control the minimum amount of outside air as recommended by ASHRAE 62 The airflow monitoring station must be tested in ac
48. 00 1 50 2 00 2 00 aw 40 SECTION 2 START UP AND OPERATION DISCONNECT SWITCH BY OTHERS A B C D O O O 460V 3PH 60HZ SUPPLY Q ATDR 3 O G N 1 TRANSFORMER 4 115V 9 ORMER SS PILOT AS VALVE 1 2 3 34 LIGHT amp SWITCH CIRCUIT BOARD 35 P2 36 H 1 37 T rog Bw 39 40 Connect Signal 2 41 Generator here for test and start up 42 43 BURNER MODULATING T MODULATION ACTUATOR W SN2 SW CONTROL z is 0 10 VDC OR Sk 4 20 46 3 2 10 47 48 49 LIL Go oTqo ch 14 23 51 Jumper may be 24V RELAY COIL 52 L _ _ _ J lt required here for test 53 and start up 1 1 0 55 FAN OVERRIDE HEATER FAN 500 OHM RESISTOR 56 W 4 20mA ONLY OVERRIDE STATUS KEY CIRCUIT BOARD TERMINAL lt gt FIELD CONNECTION NOTE JACKSON amp CHURCH WIRING TO BE COLOR CODED AS FOLLOWS RNER PAN RMI m FIELD WIRING 1 MOTOR WIRING BLACK SB MAIN PANEL TERMINAL UNIT WIRING 2 CONTROL CIRCUIT RED COMPONENT OUTLINE 3 LOW VOLTAGE YELLOW Luc SMICH TE BAR 4 ELECTRICAL GROUND WHITE MODEL RM7R40I FIGURE 29 TYPICAL WIRING DIAGRAM SECTION 2 START UP AND OPERATION TABLE 8 BURNER TEMPERATURE RISE TABLE 8 BURNER TEMPERATURE RI
49. 1 5 8 MOTOR BUSHING NONE REQUIRED FAN SHEAVE 2BK100X 1 3 8 FAN BUSHING NONE REQUIRED a a A FIGURE 33 V BELT DRIVE KIT LABEL 48 SECTION 3 MAINTENANCE GENERAL REQUIREMENTS The maintenance requirements for Revolution TFX AHUs are shown below The procedure is in the left hand column and the minimum required frequency is marked is described in the right hand column Refer to ANSI ASHRAE Standard 62 1 for start up and maintenance practices related to achieving ac ceptable indoor air quality ANSI ASHRAE Standard 62 1 is under continuous maintenance by a Standing Standard Project Committee SSPC for which the Standards Committee has established a documented program for regular publication of addenda or revisions including procedures for timely documented consensus action on requests for change to any part of the standard as shown in Table 9 on page 49 TABLE 9 MINIMUM MAINTENANCE REQUIREMENTS ACCORDING TO ASHRAE PROCEDURE Maintain filters and air cleaning devices Visually inspect or remotely monitor the outdoor air damp ers and actuators for proper function Clean and maintain humidifiers to limit fouling and microbial growth Visually inspect the dehumidification coils for cleanliness and microbial growth Clean when fouling is observed Visually inspect drain pans and other adjacent surfaces subject to wetting for cleanliness and microbial growth and clean when fouling is observed Veri
50. 11 Cooling Heating Filter O A Damper Return Air Coil Coil FIGURE 16 HORIZONTAL WHEEL When the AHU is operating normally or Many energy recovery wheels are sus temporarily the energy recovery wheel ceptible to damage if the AHU reaches a must rotate to prevent clogging maximum temperature which can occur ifthe heating valve remains open when the CAUTION CAUTION AHU is off The maximum temperatures across energy recovery wheels 1 Thermotech 140 F 2 Innergy Tech 122 F 3 NovelAire Technologies 200 F 4 Airxchange 170 F 28 SECTION 2 START UP AND OPERATION Airxchange 3 With hands and objects away from the moving Start Up Procedure parts activate the AHU and confirm the wheel rotation The wheel rotates clockwise from the 1 With the power off turn the wheel clockwise pulley side as viewed from the pulley side to verify that the u wheel turns freely through a 360 rotation as 4 f the wheel has difficulty starting turn the power shown in Figure 17 on page 29 off and inspect it for excessive interference be tween the wheel surface and each one of the four diameter seals To correct loosen the diameter seal adjusting screws and back adjustable diam eter seals away from surface of the wheel Apply power to confirm the wheel is free to rotate then readjust and tighten hub and diameter seals as shown in Figure 17 on page 29 2 Before applying power to t
51. 13 IH 13 PDOUE TAIS uyu asa 19 Warn aniy UE 13 NE 19 SECTION 2 START UP AND OPERATIONN U u Q 14 POO ll Up M MT A dace 14 INSPECUNG Fan ASSermp yu uushapa iba e rui as 15 Inspecting Belts and SNEAVES ccccccccccccsseececceceaeeeeceeeceueeeeceeeesseeseeceeessaeeeeeeesssaeeeeeeeesseaeeeeeeessageeeeees 16 CMECKIING lt TELE 16 Star U Daa 17 Checking Operation Or u 17 Checking Operation of Dampetrs 17 Back Draft Dampers for Dual 8 5 17 Partlow Control 18 Air Measuring Device Connections uu uu uu 18 Galkulalnd TR ALC Qu 18 Measuring at th Fan wa u 21 Air Measuring at Unit Outside Air 22 PIS 60 uya uy he eae ane aii edi 22 rent ee 22 Damper OperalO ze RE edad 22 NO Calibration A AG
52. 175 200 DROP WC 17 000 18 000 19 000 20 000 21 000 22 000 23 000 24 000 26 000 28 000 30 000 32 000 34 000 KAEN pe pes pa s m ps m Len ww s ATE pe r es se ee e 5 5 ot pe 8 pa s s pe e 4 Las 5 0 57 0 63 0 76 0 82 1 05 1 25 NM NM NEN NM NE uM E NEN 24 000 27 000 30 000 33 000 36 000 39 000 42 000 45 000 48 000 51 000 54 000 58 475 0 337 NN 92 5 EE 0 427 83 3 0 527 75 8 0 637 69 5 0 758 59 5 JEN 1 035 55 6 EH 1 185 52 1 1 35 1 525 395 43 5 325 350 375 400 70 573 42 6 49 2 ojojo h O gt Slo e o gt N IIA Rotating parts and electrical shock haz ards exist Lock out and tag out the fan motor s and heat power disconnects be fore servicing FOLLOW THE LATEST LOCKOUT TAGOUT PROCEDURE Failure to follow proper safety precau tions may resultin serious injury or death Application Information 1 Follow the procedure given in this instruction to find the minimum air velocity for safe operation see Fig 1 At least this minimum velocity must be provided at all points over the heater face area Failure to meet this requirement may result serious damage or nuisance thermal cutout tripping 2 The maximum air inlet temperature for open
53. 6 SECTION 5 WIRING DIAGRAMS AUTOMATIC MANUAL AIRFLOW CUTOUT S CUTOUT S SWITCH E LJ CO THREE w isa VOLTAGE E AR SWITCH CUTOUT S SAFETY p JE CONTACTOR S M ZJ Sees CC AMP RATING 7 MAY VARY ZJ USE COPPER SUPPLY WIRE SUNABLE FOR 7S SOC IN CANADA WIRE EXTERNAL CONTROL GROUT PER CLASS 1 ARTICLE 725 OF NEC AND OR CASS 1 SECTION 16 OF CEC EXCEPT THE CLASS 2 CIRCUIT S SHOWN ABOVE UTILISEZ DU CONDUIT CAPABLE D SUPPORTER 75 90 C AU CANADA CONNECTEZ LE CIRCUIT DE CONTROL EXTERN EN SUIVANT CLASSE 1 ARTICLE 725 DE LA NEC OU ET CLASSE 1 SECTION 16 DE LA CEC EXCEPTION LE CIRCUIT DE CLASSE 2 DEA MENTIONNE AU DESSUS FIGURE 92 TYPICAL WIRING DIAGRAM FOR CONTROL TYPE FULL SCR 97 The following factors can be used to convert from English to the most common SI Metric values TABLE 18 SI METRIC CONVERSION Minute gm Eu Length Inches in Millimeters mm Weight Pounds 155 0 4538 Kilograms kg Velocity Feet Second fps 0 3048 Meters Second m s Feet of Water ft 2 989 Kilopascals kPa Pressure Drop Pounds Square Inch psi 6 895 Kilopascals kPa TEMPERATURE To convert degrees Fahrenheit F to degrees Celsius C subtract 32 and multiply by 5 9 or 0 5556 Example 45 0 F 32 x 0 5556 7 22 C To convert a temperature range i e a range of 10 F f
54. 9 MAINTENANCE REQUIREMENTS 72 gt 5 ip We SECTION 4 SERVICE AND REPAIR Rotating parts and electrical shock haz ards exist Lock out and tag out the fan motor s and heat power disconnects be fore servicing FOLLOW THE LATEST LOCKOUT TAGOUT PROCEDURE Failure to follow proper safety precau tions may result in serious injury or death Refer to general safety guidelines and safety symbols located at the front of this manual Always replace RED metal tab on access doors that provide access to moving parts This mechanical protection from moving parts is required by UL 1995 Always replace RED metal tab on access doors that provide access to pressurized areas This mechanical protection is to prevent accidental release of access doors under positive pressure Do not weld or use torches on the exterior or interior of the AHU housing The housing contains polyurethane insula tion which when under combustion will produce harmful toxic gases resulting in personal injury or death DO NOT PENETRATE WIREWAYS in any manner These sheet metal channels which run along the top panel contain electrical wires and connections Elec trical shock and or damage to the AHU may result Never use silicone caulk sealant or caulk sealant containing silicone in or on any AHU The only exception is when the AHU is provided with hight temperature gas heat venting SERVICE TOOLS AND EQUIPMENT Complete set of Mec
55. AMPER ACTUATOR 36 SECTION 2 START UP AND OPERATION TABLE 4 GAS HEAT SEGMENT MODEL NUMBER NOMENCLATURE DF SIZE AHU HAND CONTROL BURNER CAPACITY DESIGNATION VOLTAGE MOD MBH T STAT sau CONTROL 200 or 208 3 60 277 1 60 as E 380 or 415 3 50 MIS a Ee Lg J sese o Log s yop 0g j J K Jae j j j j Jj pL j jJ Jj j 1001 j Jj j p jJ _ 5 j pg J C j j j j o m poj 2 SB ET A vs sof 200 j j J Jy Jj Jj jJ Jg GAS LP 2 500 BTU CU FT GAS NATURAL 1 000 BTU CU FT Output is approx 8096 of input BTUs 37 SECTION 2 START UP AND OPERATION lt lt lt lt lt lt lt lt lt lt 5 5 lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt s lt 5 5 5 5 22 2 GASBURNER PIPING AS BURNER TD MINIMUM INLET PRESSURE TO FIRE z EEK GEE 5 q N NINININI S S 1 S S S S S 5151 51515 15155 lt 5 SISI IS IS S 5 5 5 zizizizizizizizizizizi2 lt r e 3353 7 X lt lt lt lt lt lt lt lt lt lt lt 2 Z 2 2 2 2 2 2 2 GAS BURNER PIPING GAS BURNER TD MAXIMUM ALLOWABLE INLET PRESSURE FUR NACE OUTPUT a gt 3 2 lt
56. An HVAC air system includes the AHU and the entire air circuitry through which airflows Included are the following parts assemblies Ductwork Fittings and Branch Ducts e Dampers Heat Exchangers Air Filters and Sound Traps Coils e Elbows and Diffusers e Grilles and VAVs Other items through which airflows or which offer obstruction to airflow While differences in temperature and humidity may cause air movement it may be considered very slight compared to the positive circulation required in an air conditioning system To accomplish this air move ment a fan performs two functions Produce sufficient pressure or head to accelerate the mass of air from a state of rest to the required velocity Produce sufficient pressure to overcome any re sistances to the flow of air Determining these pressures is important when trou bleshooting an air conditioning system The generally accepted standard instrument for measuring these unit pressures is the pitot tube as shown in Figure 70 on page 74 and Figure 71 on page 74 The pitot tube is used in conjunction with an inclined manometer magnehelic gauge or a tube manometer SECTION 4 SERVICE AND REPAIR 0 02 in DIAMETER HOLES DRILLED THROUGH OUTSIDE TUBE SOLDER FIGURE 70 CONSTRUCTION OF PITOT TUBE When the pitot tube is used in conjunction with these instruments one is able to read velocity pressure VP static pressure SP and total pres
57. CE AND REPAIR Excessive wedging will split the bushing N Do not tighten the set screw to standard torque values at this time CAUTION Do not use the lubricant on the cap screws Standard Mounting 1 Install the shaft key If a key was furnished with the bushing use that key 2 Install the bushing on the clean shaft flange end first If the bushing will not freely slide onto the shaft insert a screwdriver or similar object into the flange sawcut to act as a wedge to open the bushings bore 3 If using the set screw tighten it enough to prevent the bushing from sliding onto the shaft 4 Slide the sheave into position on the bushing aligning the drill holes in the sheave with the tapped holes in the bushing flange 5 Loosely thread the caps crews with the lock washers into the assembly Reverse Mounting 1 With large end of the out slide the sheave onto the shaft as far as possible Install the shaft key 2 key was furnished with bushing use that key 3 Install the bushing onto the shaft so that the ta pered end will mate with the sheave 4 f using the set screw tighten it enough to prevent the bushing from sliding onto the shaft a Pull the sheave up onto the bushing align the drilled holes in the bushing flange with the tapped holes in the sheave b Loosely thread the cap screws with lock washers into the assembly Using a torque wrench tighten all the cap screws even ly and progres
58. DEEP GROOVE STANDARD 40 C LITTLE CORROSION BALL BEARING MODERATE DIRT SEVERE 50 C BALL THRUST ROLLER CORROSION NS 50 C or SEVERE DIRT CLASS H INSULATION ABRASIVE DUST LOW TEMPERATURE cap ce CORROSION FD Special high temperature grease is recommended Note that high temperature grease may not mix with other grease types Thoroughly clean bearing and cavity before adding grease Special low temperature grease is recommended TABLE 15 MOTOR BEARING LUBRICATION INTERVAL MULTIPLIER SEVERITY OF SERVICE MULTIPLIER EXTREME LOW TEMPERATURE 60 SECTION 3 MAINTENANCE UVC EMITTER LAMPS If purchased the contractor is responsible for install ing the UV lamps and connecting a 120 volt power supply as shown in Figure 52 on page 61 The Titus factory provides the following pre wired parts e Internal wiring with a magnetic door safety switch A lockable disconnect switch with a Press to Test pilot light A latching circuit that has to be manually re ener gized on the AHU s exterior after a door has been opened and closed Use clean cotton rags clean jersey or latex gloves to handle the lamps DO NOT touch UV lamps with bare hands or leather gloves because the oil will damage the lamps UV Light Lamps Installed UV Light Lamps FIGURE 52 UV LAMPS Three Types of Lamps Three different tyoes of UV lamps are used in AHUs V Mod V Ray and V Max Grid V Mod Lamps Install the two p
59. Devices such as relays switches transducers and controls may not be installed inside the control panel No external wiring is allowed to run through the control panel All wiring must be in accordance with Titus published specifications and must be performed only by qualified Titus personnel Titus will not be responsible for damages problems resulting from improper connections to the controls or application of improper control signals Failure to follow this will void the manu facturer s warranty and cause serious damage to property or injury to persons Rotating parts and electrical shock haz ards exist Follow the lates lock out and tag out procedures for the fan motor s and heat power disconnects before ser vicing Failure to follow proper safety precautions may result in serious in jury or death Refer to the general safety guidelines and safety symbols located at the front of this manual Do not penetrate the wireways in any manner These sheet metal channels which run along the top panel con tain electrical wires and connections Electrical shock and or damage to the unit may result The purpose of drawings in this section is to aid in installation start up and trouble shooting Actual wiring configuration may deviate from these drawings and are subject to change without notice Never use silicone caulk sealant or caulk sealant containing silicone in or on any air handling equipment 83 SECTION 5 W
60. Electric Heater Rotating parts and electrical shock haz ards exist Use the latest lock out tag out procedure to the fan motor s and heat power disconnects before servicing Fail ure to follow proper safety precautions may result in serious injury or death Use the following instructions to start up the electrical heater 1 Check all electrical connections in the heater in cluding both field and factory installed connections for tightness before operating the heater After a short period of operation check all connections again for tightness DO NOT operate electric heat below the minimum airflow requirement CAUTION 2 Visually inspect the heater elements prior to us ing the heater If physical damage is evident use a Megohm test to validate that the heater elements are safe to use If a less than 10 megohms 15 achieved replace any damaged elements or ce ramic insulators prior to operation 3 Ensure filters are clean and airflow is at the minimum requirement or greater preferably 100 airflow for this start up procedure 4 Make sure all associated control equipment is turned on 5 Energize main supply disconnect and set control ling thermostat above ambient temperature 6 This heater is equipped with automatic and manual reset temperature limiting controls If it fails to operate make sure the manual resets are operative by pushing reset buttons 45 SECTION 2 START UP AND OPERATION TOP V
61. FIELD SELECTABLE 4 20mA BY OTHERS 46 TRANSFORMER 10 16 24V RELAY COIL W 120V CONTACTS CR1 1 CR1 2 s GP 54 FAN OVERRIDE HEATER FAN OVERRIDE STATUS KEY SHIELDED CABLE RECOMMENDED NOTE JACKSON amp CHURCH WIRING TO BE COLOR CODED AS FOLLOWS BURNER PANEL TERMINAL PANEL WIRING L FIELD WIRING 1 MOTOR WIRING BLACK circum BOARD TERMINAL UNIT WIRING 2 CONTROL CIRCUIT RED COMPONENT OUTLINE 3 LOW VOLTAGE YELLOW Luc SWITCH TIE BAR 4 ELECTRICAL GROUND WHITE MODEL RM7895A FIGURE 89 GAS HEAT THREE PHASE 1000VA TRANSFORMER WIRING DIAGRAM 94 SECTION 5 WIRING DIAGRAMS DISC SW BY OTHERS A B C G O _ SUPPLY BY OTHERS e on U G N On 0 67 BURNER ire SET O1BOF WE OPER SW MICH RSWACH 0 0 60086096509 INDUCER BURNER LJ EK TRANSFORMER VALVE 5 UI e M9174C BURNER MODULATING MOTOR WITH Q7230 INTERFACE MODULE 4 20mA BY OTHERS 47 120V 24V STEPDOWN TRANSFORMER 48 49 50 12 18 51 24V RELAY COIL 52 W 120V CONTACTS 55 CR1 2 54 16 6 io 55 FAN OVERRIDE 56 OVERRIDE Vetus KEY SHIELDED CABLE RECOMMENDED BURNER PANEL TERMINAL PANEL WIRING NOTE JACKSON amp CHURCH WIRING TO BE COLOR CODED AS FOLLOWS Y FIELD WIRING 1 MOTO
62. Feeler Adjusting Screws Gauge FIGURE 60 DIAMETER SEAL ADJUSTMENT Ball Bearings 2 WNN Bearing Support Beam Motor Side GP Drive Motor SECTION 3 MAINTENANCE To adjust diameter seals loosen diameter seal ad justing screws and move diameter seal away from wheel surface e Rotate wheel clockwise until two opposing spokes are hidden behind the bearing support beam as shown in Figure 61 on page 66 Using a folded piece of paper as a feeler gauge position paper between the wheel surface and diameter seals Adjust seals towards wheel surface until a slight friction on the feeler gauge paper is detected when gauge is moved along the length of the spoke e Retighten adjusting screws and recheck clearance with feeler gauge Bearing Support Beam Pulley Side Bearing Access Cover 2 Diameter Seal Adjusting Screws Removable Energy Transfer Segment 8 Drive Pulley FIGURE 61 AIRGXCHANGEG ENERGY RECOVERY WHEEL WITH BEARING SUPPORT BEAM SIDE 66 SECTION 3 MAINTENANCE AIRXCHANGE 4 the unit is equipped with an internal bearing Inspect Wheel Drive Components unbolt the shaft screw on both sides of the shaft Unbolt one post completely and remove post Re move the shaft clips at the face of the hub from both sides of the shaft Remove the shaft Roll the The wheel drive pulley is secured to the drive wheel out carefully motor shaft by a combination of either a key or D
63. IEW OF UNIT POSITIVE PRESSURE AIR BLOWN THROUGH HEATER L HEATER PICK UP TUBE TOWARDS BLOWER ATTACHED TO HIGH PORT OF AIRFLOW SWITCH NEGATIVE PRESSURE AIR DRAWN THROUGH HEATER BLOWER HEATER PICK UP TUBE TOWARDS BLOWER ATTACHED TO LOW PORT OF AIRFLOW SWITCH FIGURE 31 PRESSURE PROBE DIRECTION MOUNTING BRACKET HIGH PORT LOW PORT FIGURE 32 AIR FLOW SWITCH CONNECTIONS 46 SECTION 2 START UP AND OPERATION OPERATION DO NOT penetrate wireways in any man Test And Balance Air Balance ner These sheet metal channels which run along the top panel contain electrical wires and connections Electrical shock and or damage to the AHU may result WARNING Rotating parts and electrical shock haz ards exist Follow the latest lockout tag out procedures to lockout tagout the fan motor s and heat power disconnects before servicing ailure to follow proper safety precautions may result in serious injury or death Refer to general safety guidelines and safety symbols located at the front of this manual WARNING Always replace RED metal tab on access doors that provide access to moving parts This mechanical protection from moving parts is required by UL 1995 WARNING Always replace RED metal tab on access doors that provide access to pressurized areas This mechanical protection is to prevent accidental release of access doors under positive pressure e System air balance s
64. INAL NOMINAL HEIGHT WIDTH 30 to 114 30 to 120 SUPPLY AND RETURN EXHAUST FAN OPTIONS A None B DWDI FC Fan without Motor Controller C DWDI FC Fan with Service Disconnect Only D DWDI FC Fan with Motor Starter E DWDI FC Fan with Variable Frequency Drive VFD F DWDI AF Fan without Motor Controller G DWDI AF Fan with Service Disconnect Only H DWDI AF Fan with Motor Starter J DWDI AF Fan with VFD K SWSI PL Fan without Motor Controller L SWSI PL Fan with Service Disconnect only M SWSI PL Fan with Motor Starter N SWSI PL Fan with VFD P SWSI PL Fan Direct Drive without Motor Controller Q SWSI PL Fan Direct Drive with Service Disconnect Only R SWSI PL Fan Direct Drivee with Motor Starter S SWSI PL Fan Direct Drive with VFD Note The terms skid and section have the same meaning in this document Variable Speed Drive VSD and Variable Frequency Drive VFD do as well 0 FACTORY MOUNTED END DEVICES 0 1 Yes MOTOR HORSEPOWER SUPPLY AND RETURN EXHAUST FAN A 0 B 1 2 TO M H H iH N gt 2 E N N e 46 VOLTAGE CODE 12 120 1 60 17 200 or 208 3 60 27 277 1 60 28 230 or 240 3 60 40 360 3 60 44 440 3 50 46 460 3 60 50 380 or 415 3 50 58 575 3 60 63 220 3 50 DESIGN A Original Unit Design TABLE OF CONTENTS SECTION 1 GENERAL INFORMATION AND SAFETY ene seen asas haha sana
65. IRING DIAGRAMS PDTB T E P U 3 a aon L2 m 785 m L3 m d RE Kaa a a a an a em o ame m gt NOTE CUSTOMER SUPPLIED DISCONNECT MUST MEET LOCAL CODES 212 213 SEE TRANSFORMER 1 CONNECTION DIAGRAMS RR FOR PROPER n 1 X1 CONNECTIONS X2 N SOS SSS mwmw gt em em RUN TIME 6 yis ee o H 4 L H G A FIRESTAT FREEZESTAT OLI 8 14 X2 gc 51 G B AB ae JM aaa OPTIONAL B J J REMOVE JUMPER WHEN CONNECTING SAFETIES CONTROL 2 CONTROL POWER X2 POWER OPTION B 9 UP TO 4 PANEL 100VA TRANS aah ar ar ar I OR LOW TENP RESET 20 M1 21 HH I K WIRED IN YELLOW OPTION 1 1 FU3 DISCI gt Eis L1 U Z 5Z L2 amp D L2 5ko 2 3 D _ Tn sal TF 235 9 585 88 LAR amp m mm 58 plao 5 x Lom OPTIONAL Wd OPTIONAL DISCONNECT FUSED DISCONNECT gt NOTE CUSTOMER SUPPLIED DHI NOTE PUEA LOCAL CODES LOCAL CODES Ba ma came i a i
66. Motor Bealilg LUbrICatedus u each intu mie u amp MI Ii 59 Sessio ER 61 Th e Types ol aD an wu aaa ks GA 61 Maintaining and Replacing Filter Segments nennen nnne nnnm nnne nnn nnn 62 RE 62 TABLE OF CONTENTS CONT D Economizer segment Dampers cta a R EE 63 Cleaning qataqa 63 Hardware re y uuu BGB 63 Coll SEGMENT GISSriifigu u EPAR AAA O ZO EP 63 Tools EQUIDIMERT and Materials uwaa dd Z ES 63 IND sel POC SU Satara ENAR a 63 Condensate Drain Pan Trap and Line Cleaning nnn nnne 64 Tools EGUIDME RE ana sacos edi intei tcv aca at SD banana 64 Schedule and 64 Cleaning miele eU nisu ET 64 md u usuy yum asua qsusa qasa Qaqa 64 65 E a EO C Ete 65 5 65 Gleanngine a 65 118 a n 66 AGIUSUNC Seale uuu aa
67. R WIRING BLACK CIRCUIT BOARD TERMINAL UNIT WIRING 2 CONTROL CIRCUIT RED COMPONENT OUTLINE 3 LOW VOLTAGE YELLOW Q GROUND LUG SWITCH TIE BAR 4 ELECTRICAL GROUND WHITE FLAME CONTROL TERMINALS 2 WIRE TAG DESIGNATIONS 5 MECHANICAL GROUND GREEN MODEL RM7895A FIGURE 90 GAS HEAT THREE PHASE 500VA TRANSFORMER WIRING DIAGRAM 95 SECTION 5 WIRING DIAGRAMS ONTROL INPUT TABLE H Zi 85 0 10 WoC 861 4 20 mA SEE CONTROL INPUT TABLE FOR PROPER CONNECTION INDEECO CONTROLS 208 STEP CONTROLLER mm D Sad dom SEE OPTION CODE 20 21 AND OR 222 FOR WIRE SIZING ee ALE ie LINE Lele paka We N OR WYE TX FUSING 55 2 CLASS Stam EL 2 R SCR STAGE S E sadi lt RE OTH N25 USE COPPER SUPPLY WIRE SUITABLE FOR 75 90 IN CANADA WIRE EXTERNAL CONTROL CIRCUIT PER CLASS 1 ARTICLE 725 OF NEC AND OR 1 SECTION 16 OF CEC EXCEPT THE CLASS 2 CIRCUIT S SHOWN UTIUSEZ DU CONDUIT CAPABLE OE SUPPORTER 75 C 90 C AU CANADA CONNECTEZ LE CIRCUIT DE CONTROL EXTERNE EN SUIVANT CLASSE 1 ARTICLE 725 DE LA NEC OU ET GLASSE 1 SECTION 16 DE LA CEC EXCEPTION LE CIRCUIT DE CLASSE 2 DEJA MENTIONNE AU DESSUS FIGURE 91 TYPICAL WIRING DIAGRAM FOR ELECTRIC HEAT CONTROL TYPE VERMIER 9
68. SE INTERNAL BER TEMPERATURE RISE F PRESSURE DROP WC INTERNAL TEMPERATURE RISE F PRESSURE DF 85 8 500 91 9 000 86 9500 81 10 000 77 10500 74 11 000 70 12000 64 13000 59 14 000 55 Le 15 000 E 4 000 16 000 4 500 5 000 9 900 8 440 32 9 38 4 91 81 77 91 74 87 70 83 76 59 70 55 65 51 61 9 57 17 000 46 54 17 825 52 13 000 14 000 83 77 93 72 87 82 77 61 73 58 55 52 63 50 48 58 46 55 15 000 16 000 N gt gt N N N _DF 125 _89 88 _ 17 000 68 4 500 18000 64 5 000 61 _ 5 500 58 _ 6 000 55 6 500 52 _ 7 000 50 _ 7 500 E 8 000 8 500 9 000 10 725 19 000 20 000 21 000 22 000 23 000 24 000 25000 46 26 315 52 6 000 6 500 7 000 7 900 8 000 9 000 10 000 11 000 12 000 12 900 1 500 2000 2500 3 000 3500 4000 4 500 5248 sss 4000 48500 5000 500 600 _ 6500 7 000 8440 sss 4 500 00 _ 5 500 6 000 6 500 7000 7 800 800 _ 8 500 9 000 10725 EN 6 000 6500 7000 7 500 8 000 900 _ 10000 11 000 12000 12900 SECTION 2 START UP AND OPERATION TABLE 8 BURNER TEMPERATURE RISE CONT D INTERNAL PRES TEMPERATURE RISE F SURE DF DF
69. Shafts should be well supported to prevent distortion and a resulting change in the center distance under load Do not use spring loaded or weighted idlers 53 SECTION 3 MAINTENANCE Using a Straightedge Using a String Place a straightedge against the outer edge of the sheaves Figure 39 on page 54 shows the four points where the straight edge should touch the sheaves The straight edge should cross the sheaves at the widest possible part of the sheave If alignment is different than described refer to Sheave Replacement and Adjustment later in this section Tie a string around either shaft and pull it around and across the outer edge of both sheaves as shown in Fig ure 40 on page 54 shows how the string should touch four points when the drive is properly aligned Straight Edge Touching Sheaves At Points Indicated By Arrows ALIGNMENT USING STRAIGHT EDGE FIGURE 39 ALIGNMENT USING STRAIGHT EDGE Cord Touching Sheaves At points Indicated By Arrows ALIGNMENT USING STRING FIGURE 40 ALIGNMENT USING STRING 54 SECTION MAINTENANCE BELT REPLACEMENT TENSIONING AND SHEAVE ALIGNMENT FOR TOP MOUNT Use the following instructions to align the sheaves on the motor base 1 To remove the old belt loosen the mounting hard ware on the drive side of the motor base The drive side has two adjusting screws Do not increase the left side more than 1 2 in before increasing the right side 2 Remove the tension from th
70. UT THIS MANUAL This manual and any other document supplied with the AHU are the property of Titus which reserves all rights This manual may not be reproduced in whole or in part without prior written authorization from an authorized Titus representative In addition this manual e Includes suggested best working practices and procedures which are issued for guidance only and they do not take precedence over the above stated individual responsibility and or local safety regulations Contains all the information required for correct installation and commissioning of the AHU to gether with operating and maintenance instructions e Should be read thoroughly before attempting to operate or service the AHU e Contains detailed procedures including installation commissioning and maintenance tasks that must only be performed by suitably trained and qualified personnel The manufacturer will not be liable for any injury or damage caused by incorrect installation commission ing operation or maintenance resulting from a failure to follow the procedures and instructions detailed in the manual WARRANTY Titus warrants Revolution TFX AHUs in accordance with the limited warranty engineered systems equipment procedure Titus warrants all equipment and materials against defects in workmanship and materials for a period of 18 months from the date of shipment or 12 months from the date of start up whichever comes first T
71. Verify the AHU was properly started up and that airflow is at the design maximum for the heating cycle Refer to the air balance report e Set the bypass damper if provided Airflow proving switch for main supply fan in stalled and operational Check with the control technician two minute post purge programmed in controller Upon call for unit stop burner cycles off then AHU fan cycles off two minutes later 33 gt FIGURE 22 GAS FURNACE CONDENSATE DRAIN TRAP Checking the Burner 1 Open the fuse disconnects before working on burner as shown in Figure 23 on page 35 2 Check all wire terminations for tightness 3 Check that the incoming voltage s are correct Compare the measured voltages to the burner motor and ID motor nameplates and the burner test report Reset the fuse disconnects 4 Check for the correct rotation of the three phase burner and ID motors 5 Verify that the contractor purged the new gas lines of air up to the manual valve on the gas train 6 Open the valves which were closed for shipping Check that all manual valves operate without leaks 7 The flue stack damper is located at the discharge of the ID blower and was closed for shipping Re lease the locking mechanism and set the damper to match the position indicated by the scribed markings Lock it in place as shown in Figure 24 on page 35 8 Inspect the condensate drain trap to see that it is large enough
72. X UV LAMPS IN AHU 18 LAMPS MAX UV LAMPS IN AHU 18 LAMPS MAX UV LAMPS IN AHU 18 LAMPS MAX 18 AWG XFM1 CLASS transformer 50va 18 AWG D 7 C SW1 DOOR SWITCHES A IN AHU 23 45 65 FIGURE 88 UV CONTROL PANEL WIRING GREATER THAN 8 AMPS 92 SECTION 5 WIRING DIAGRAMS UP TIUNAL RADIUMETER WIRING ae ER 16 SEN Ll iC D Set ts wak RADIOMETER OPTIONAL Cs SENSOR e4VAC 21 L eee L2 L 4 MSENSDR EYE Sequence of Operation Discounnecting Means of UV lighting will be accomplished by CB1 internal to the panel CB1 is cable of being locked out by panel latching mechanism SW1 is a proximity switch with a magnet which will close set of normally open contracts The magnet will engage the SW1 contact when ever it is within 1 2 of the switch TDR1 is one second 1sec time delay relay having normally open contacts When power is initiated its contacts will close for one second then re open To reset power power must be removed from TDR1 C1 is a dpdt 24 vac control relay used to seal in its coil and provide interlocking means to the UV lights If all doors are closed all the SW1 s will allow CT to energize as long as power is available By selecting CS 1 to the on position th
73. a small stop valve and a nipple for a rubber tube 15 Install the Honeywell 7800 Test Module if available 16 Connect the signal generator 0 20mA to ter minals in place of modulation control signal for 2 10 VDC signal add a 500 resistor in series FIGURE 25 CHECK MAIN GAS SUPPLY PRESSURE 17 Visually check that the flue stack is secure and connected properly Typical connections are shown at the end of these instructions Starting the Burner 1 Prior to starting the burner the technician must verify the incoming gas pressure A minimum 19 The system is now ready for start up pressure is listed on the burner test report The maximum pressure is listed as well 18 The burner panel s on off switch should be off 2 Open the manual gas valves on gas supply and pilot line 3 Initiate a call for heat or use jumper to create a call for heat 4 Turn the burner panel on off switch to on 5 Once there is a call for heat a 30 second pre purge period is initiated to remove any gases from the heat exchanger The burner will go through a second purge before ignition 6 The burner will automatically go to low fire at start up After proof of low fire the burner will modulate up to high fire which may take 15 seconds for a Powerflame burner and 90 180 seconds for the Eclipse burner After the burner operates at High Fire use the manometer connected to the Heat Exchanger Draft Port as shown in Figure 26
74. able them to perform their assigned tasks properly and safely It is essential that prior to performing any task on this equipment this individual shall have read and understood this document and any referenced materials This individual shall also be familiar with and comply with al applicable governmental standards regulations pertaining to the task in question SAFETY SYMBOLS The following symbols are used in this document to alert the reader to specific situations Indicates a possible hazardous situation which will result death or serious injury if proper care is not taken DANGER Indicates a potentially hazardous situa tion which will result in possible injuries or damage to equipment if proper care is not taken WARNING Identifies a hazard which could lead to damage to the machine damage to other equipment and or environmental pollu tion if proper care is not taken or instruc CAUTION tions and are not followed Highlights additional information useful to the technician in completing the work being performed properly NOTE External wiring unless specified as an optional connection in the manufacturer s product line is not to be connected inside the control cabinet Devices such as relays switches transducers and controls and any external wiring must not be installed inside the micro panel All wiring must be in accordance with Titus published specifications and must be performed only
75. bs to the inside before installing 2 Determine direction of drive rotation 3 Belt must travel with tabs trailing or following the belt direction arrow g 4 Fit belt in nearest groove of smaller pulley 5 Holl belt onto larger pulley turning the drive slowly Belt may seem very tight this is ok DO NOT JOG MOTOR 6 Check to see all tabs are still in their correct posi tion and are not twisted out of alignment 7 For multiple belt drives work belt from groove to groove On particularly wide drives it may be easier to install half the belts from the inboard side and half from the outboard d x a Belt Direction _ FIGURE 65 INSTALLATION With drive ratios around 1 1 it may be necessary to add back one link to allow belts to be rolled on This does not apply if using the Alternative Installation Method NOTE Alternative Installation Method 1 Set motor to mid position of adjustment range and mark base clearly 2 Determine required belt length as in 3 Push motor forward to minimum centre distance 4 Install belts as in IV 5 Pull motor back to previously marked mid posi tion Retensioning Like all high performance V belts PowerTwist Plus V Belts require the maintenance of correct drive tension to operate efficiently Experience indicates that drive tension should be checked after 24 hours running at full load A retension may be necessary depending on the s
76. by a qualified electrician Titus will NOT be responsible for damage problems resulting from improper connections to the controls or application of improper control signals Failure to follow this warn ing will void the manufacturer s warranty and cause serious damage to property or personal injury OF THIS DOCUMENT In complying with Titus policy for continuous product improvement the information contained in this document is subject to change without notice Titus makes no commitment to update or provide current information automatically to the manual owner Updated manuals if applicable can be obtained by contacting the nearest Titus Representative or accessing the Titus website Operating service personnel maintain responsibility for the applicability of these documents to the equipment If there is any question regarding the applicability of these documents the technician should verify whether the equipment has been modified and if current literature is available from the owner of the equipment prior to performing any work on the unit CHANGE BARS Revisions made to this document are indicated with a line along the left or right hand column in the area the revision was made These revisions are to technical in formation and any other changes in spelling grammar or formatting are not included TFX u MODEL TFX REVOLUTION TFX UNIT MODEL NOMENCLATURE I ndoor 048 x 075 D C M NOM
77. cordance with AMCA Standard 611 95 in an AMCA registered laboratory The airflow monitoring station must bear the AMCA Certified Ratings Seal for Airflow Measurement Performance If airflow station is internally mounted inside air handling unit and incorporates a control damper the control damper must comply with leakage rates of damper specification TABLE 3 EXAMPLE FAN DESIGN UNIT NAME UNIT SIZE FLOW CFM 01 580 21370 RANGE 0 0 TO 0 25 Recommended operating range is 345 2 000 FPM eration outside these parameters is not recommended If ASHRAE 90 1 is referenced also include If airflow station is internally mounted inside air han dling unit and incorporates a control damper the control damper must comply with leakage rates per ASHRAE 90 1 All damper leakage rates must be provided in submittal data on a CFM FT at 1 w g basis AMS 60 Use the following equation to determine the correct jumper setting for your application CFM AREA Ka Pams 1 m where Ka 3213 Pams Range of transmitter and 0 54 B DIM IN AREA AMS 60 SENSING DAMPER AMS A DIMENSIONS 100 SENSING SETPOINT Koa SENSING 25 Locating and Installing Actuators Titus standard actuators are direct coupled on the damper jackshaft Refer to the instructions in the Revolution Installation and Assembly Manual to install the Titus actuators Damper Blade
78. cy ranges during fan start up and shut down If the peak is marked as it was within tolerance and does not need to be locked out or skipped Lock out Skip FIGURE 13 EXAMPLE OF SWEEP BALANCE RESULTS LABEL ON FAN HOUSING Check Doors And Latches Refer to the service manual replacing the doors for adjusting and Doors are shipped with metal shipping spacers glued onto the edges of each door They are located on three edges of each door top latch side amp bottom Figure 14 on page 27 The spacers should be left in place until the AHU is placed in its final location and multiple skid AHUs are fully assembled After AHU in stallation use a channel lock pliers a screwdriver to remove the spacers Do not damage the metal door panel Slight impressions left on the door gasket by the spacers will rebound in approximately a week FIGURE 14 METAL SPACERS ON DOORS Energy Recovery Wheel Configuring the AHU All indoor AHUs will accommodate vertical energy recovery wheel segments in a tiered configuration shown in Figure 15 on page 27 N CAUTION Keep hands away from rotating wheel Contact with the rotating wheel can cause physical injury Filter Energy Wheel FIGURE 15 VERTICAL WHEEL FOR INDOOR AHU as 27 SECTION 2 START UP AND OPERATION Elevation View Exhaust Fan E A Bypass Engery R A Damper Wheel O A Filter Return Air Plan Top View O A Damper m
79. e 24vac control power circuit will be energized As long as all doors with door switches SW1 are closed and upon detection of power to the 1 second time delay realy TDR 1 the TDR 1 normally open contracts will close for one second energizing the contactor C1 will remain energized Should any one door having SW1 mounted were to open C1 will de energize deacti vating the UV lamps Closing all doors will not turn on UV lights CS 1 will be required to be cycled Off then back On to allow the lights to come back on If the power is removed from the UV control panell and re energized such as when power fluctuates off then back on the UV lights will reactivate automatically The IL UV Light In USe indcator lamp will alow the user to know if the lights have been energized FIGURE 88 UV CONTROL PANEL WIRING GREATER THAN 8 AMPS CONT D 93 SECTION 5 WIRING DIAGRAMS DISC SW BY OTHERS A B C G o O SUPPLY BY OTHERS O 4 O Q OPEN 100 F CR1 BURNER L4008A SAFETY L4008E 250 15 LIMIT SET O180F MAN RESET AIR PROVING OPER SW HIGH LIMIT SWITCH CR2 16 O O 4 O 17 gt INDUCER BURNER AIR SW AIR SW s L 5 AGNITION TRANSFORMER PILOT VALVE g M9174C BURNER MODULATING MOTOR WITH Q7230 INTERFACE MODULE amp MODULATION CONTROL 2 10VDC OR
80. e above the damper as shown in Figure 5 on page 17 and then tighten the set screws The counterbalance should be free to rotate FIGURE 4 COUNTERBALANCE LOCKED INTO PLACE FOR SHIPPING FIGURE 5 COUNTERBALANCE UNLOCKED FOR START UP 17 SECTION 2 START UP AND OPERATION Airflow Control Dampers Many combinations of damper sizes are available to control the flow Mixing the return and outside air in the AHU s air inlet section may be supplied as follows e 100 outside air 100 return air e 100 outside air 0 return air e 0 outside air 100 return air e Economizer section 100 outside air 100 return air 10096 exhaust air or mixed air Check the dampers actuators controls and linkage prior to applying power to the operators to make sure nothing will obstruct the operation of the dampers Do not overdrive the damper actuators because this may damage the dampers Exception Actuators with over drive NOTE preset option Return air dampers may be closed for shipping Loosen the actuator or crank arm on the jackshaft open the dampers and retighten the actuator or crank arm The field is responsible for adjustments Air Measuring Device Connections Calculating Flow Rate For a Piezoring k AP AP The differential in static pressure across the fan inches w g k See the table below This assumes a standard air density of 075 16 cubic foot at sea level For a Comete
81. e belt on the lower drive side using the adjustment screws as shown in Figure 41 on page 55 3 After the tension is removed from the belt loosen the mounting hardware on the opposite drive side of the base 4 Continue to lower both ends of the base until the belts can be removed as shown in Figure 42 on page 55 5 After the sheaves are checked for parallel align ment as shown in Sheet 1 place the belts on the sheaves 6 To take the slack out of the belt s start raising the base in 1 2 in increments using the adjustment screws on both ends 7 As the belts start to tighten check for parallel mis alignment by placing a straight edge across the outer face of the sheaves as shown in Figure 43 on page 56 The straight edge should be long enough to extend past both sheaves ANGULAR MISALIGNMENT FIGURE 41 SHEAVE ANGULAR MISALIGNMENT 8 If the sheaves are misaligned as shown in Figure 41 page 57 raise the opposite drive side As the belt tension increases the opposite drive side of the belt will rise Make sure the mounting hardware on the opposite drive side is secure NOTE 9 Continue to tighten the belt s using the drive side the adjusting screws 10 If the sheaves are still misaligned as shown in Figure 42 on page 55 make sure the belt tension is correct then secure the mounting hardware on the drive side 11 If the sheaves are still misaligned as shown in Figure 42 on page 55 make sure
82. e difference between the total pressure and the VP However in an actual duct system the internal friction would cause a loss of total pressure The SP in an exhaust system is always below atmo spheric pressure and it is customary among ventilation engineers to omit the minus sign affecting the static gauge pressure When the unit is designed for connection to a duct system and the installing contractor assembles the ducts elbows registers grilles etc to the outlet and or inlet of the AHU the SP drop through this external ductwork is called external SP as shown in Figure 76 on page 77 The selected fans must be capable of moving the de sired airflow through the entire air moving system including the AHU internal SP and the duct system external SP EXTERNAL STATIC PRESSURE INTERNAL STATIC PRESSURE _ _ FIGURE 76 STATIC PRESSURE AIR SYSTEM At a given flow rate the internal pressure losses plus the external SP losses equal the system SP or the sum mation SP These pressures are important when troubleshooting for issues such as reduced capacity vibration and noise Changes in the cross sectional area of a duct contrac tions or enlargements cause changes in the velocity of the air flowing through the duct When the velocity decreases the VP decreases Some of the velocity energy is lost because where the area changes in the duct Some of the velocity energy is converted into
83. ency last The burner should be running at high fire rate for 30 minutes before efficiency testing is done 15 Efficiency at high fire is pre determined but may be checked by flue gas analysis at the entrance to the ID Blower Housing Test Port At high fire the CO2 should be between 8 1 2 and 10 the 02 should be between 7 1 2 and 4 With these ranges efficiency is 80 plus or minus 2 as shown in Figure 27 on page 36 16 Contact the contractor facilities manager or cus tomer to inform them that the start up was com pleted successfully 17 In the unlikely event that adjustment is required it is done at high fire and must NOT retard low fire light off CAUTION 18 Direct any questions to the local Titus Representative or Product Technical Support before contacting the burner manufacturer Do not change the set up of factory pre set air inlet dampers on the power flame burner SECTION 2 START UP AND OPERATION 19 When operated at low fire for extended periods more condensate is generated and with it deposits of solids in the condensate drainage system 20 Provide the ability to prime the trap During initial and seasonal start up trap inspection and priming is required Condensate in the trap will evaporate during long periods of non use 21 Trap and drainage system should be cleaned annually FIGURE 27 FLUE COMBUSTION TEMPERATURE AND EFFICIENCY TEST PORT ID BLOWER FIGURE 28 D
84. er frame end covers 5 Slide the correct size new filters into tracks SECTION 3 MAINTENANCE 6 On bag filters in FF segments leave banding in place until filters are installed then remove In stall the bag filters so that the pocket dividers are vertical if the filters are over 12 in high 7 Airflow arrows must point downstream in direction of the airflow 8 Install all pleated filters with pleats positioned vertically 9 Reinstall the filter frame end cover Filter Filter Frame End Cover FIGURE 57 INSTALLING ANGLE FILTERS Rigid Pre Filter Filters Filter Frame End Cover FIGURE 58 INSTALLING SIDE LOAD FILTERS 62 SECTION 3 MAINTENANCE ECONOMIZER SEGMENT DAMPERS Prior to occupancy test ventilation sys tem to ensure that outdoor air dampers operate properly in accordance with the system design NOTE Cleaning Procedure Cleaning of dampers should be performed before op eration is hindered in any way Maintenance personnel must determine when cleaning is necessary based on observation and operation CAUTION Do not use lubricants Titus suggests cleaning with contact cleaner or 50 50 H O alcohol solution Consult proper building personnel to ensure above solution will not harm personnel or equipment Hardware Check Make sure all linkage parts actuators and mounting brackets are secure COIL SEGMENT CLEANING Tools Equipment and Materials
85. erpendicular to the belt span until the bottom of the large O ring is even with the top of the next belt or with the bottom of a straight edge laid across the sheaves 5 Remove the tension gauge and read the force ap plied from the bottom of the small O ring on the deflection force scale 6 Compare the force you have applied with the value given on the drive kit data tag as shown in Figure 34 on 51 CAUTION Never use excessive tension because this could result in damaging the bearing motor pulleys or motor base Refer to the drive label on the fan housing for specific details on tension Squealing belts during starting is caused by slipping belts that are not tensioned properly ALIGNING SHEAVES A An incorrectly aligned sheave can sub stantially shorten belt life or overload blower and motor bearings shortening their life expectancy A belt tensioned too tightly can overload the motor electrically causing nuisance tripping of the motor overloads and or motor failure and or shaft failure Sheave alignment and parallelism of shafts is very important Proper alignment helps equalize the load across the entire belt width thereby reducing wear and extending belt life Figure 39 on page 54 shows how to align a synchronous drive properly using a straightedge or shows how to use a piece of string as shown in Figure 40 on page 54 After aligning the sheaves check the rigidity of the supporting framework
86. esed te 22 Duciwork InlebHegulremenls asi uuu Wsad u us 23 Damper Linkage Arrangements a nnns nnn 23 Damper ConnguralollSnacc ha o 23 JUMDEWSEJECHON S 2 24 HT 24 SEQUE CC OCODERANO asi O T n 24 AHU Airtlow Station Specilicalo s od ese eec ec 25 If ASHRAE 90 1 is referenced also include 25 AMS 60 Indoor E 25 kLocaling ana Iristalling u u 26 Damper Blade Ofientallo ask es WAN a Z W AO ela 26 Return Air and Mixing Dampers 26 Outside Air and Exhaust Air DaMpeP ccccccccccseseeeeeeeceeeeeceeseeeeeeeeeeeeseeaeeseeeesseaseeeeesssaaaees 26 Fico Gg ze F an Mor u adt cas OOo qoc 27 Variable Frequency Drive VFD uu uu 27 Check Doors And tenes css usuy a Lm puma akana sh tanesi 27 Energy INCCOVETY WNEBL NITE 27 Conng nng Me kankakun uka aku 27 Sachets E a 29 tell Up PTO CS UB 29 E dE 30 Star UD PROCS CMI uu uu uu 30
87. everity of the drive Any initial belt stretch is then taken up Subsequently belt tension should be checked periodically and adjusted when necessary 68 SECTION MAINTENANCE THERMOTECH Periodic cleaning of the energy recovery wheel will be a function of the operating schedule climate and contaminates in the indoor air being exhausted and outdoor air being supplied to the building Cleaning the Wheel The wheel media does not require any cleaning under normal operating conditions and proper maintenance of the drive systems and main bearings The key is to make sure the wheel is always turning in order to utilize the counter flow airstreams and the purge sector to keep the media clean Over the years there might be some accumulation of dirt on the face of the media but the inside will remain clean The best method to clean the wheel is to brush the surface on the air discharge side with the airflow on or by using a vacuum cleaner A 2 300 psi pressure washer can be used in situations where the media is severely clogged Care should be taken to not damage the media face by the full force of the spray It is recommended that the pressure cleaning method is tested on a small area of the media Adjusting Air Seals The seals are set at the factory and should not require adjustment If the seals are rubbing on the media face due to incorrect installation and other factors adjust the seals 1 Rotate the wheel one ful
88. fy sensors used for dynamic minimum outdoor air con trol accuracy and recalibrate or replace as necessary Measure the minimum quantity of outdoor air in the AHUs except for AHUs under 1000 L s 2000 CFM If measured minimum airflow rates are less than 90 of the minimum outdoor rate in this manual they shall be adjusted or modified to bring them above 90 or shall be evaluated to determine if the measured rates are in conformance with this ASHRAE standard Maintain the floor drains located in plenums or rooms that serve as air plenums to prevent transport of contaminants from the floor drain to the plenum Keep clear the space provided for routine maintenance and inspection around ventilation equipment for equipment component accessibility Investigate and rectify the visible microbial contamination Investigate and rectify the water intrusion or accumulation EVERY 3 EVERY 6 MONTHS ANNUALLY X o EVERY 5 YEARS X X X X X Minimum frequencies may be increased or decreased from what is indicated in this table 49 INSPECT PARTS Inspect the following parts for damage dirt and debris Cabinet Clean the exterior of the AHU with a mild environ mental safe detergent and high pressure water at 2000 psi Door Hardware and Gaskets Inspect the doors handles latches and hinges for proper operation and the door gaskets for damage and if they are properly sealed Secure any loose part
89. gure 77 on page 78 FLANGE KEYWAY sLIT WEB oCcKWASHERS TAPERED SET SCREW not shown TAPER FLANGE BUSHING SHEAVE FIGURE 77 INSERTING CAP SCREWS 3 Separate the sheave from the bushing SECTION 4 SERVICE AND REPAIR 7 Remove or loosen the set screw from the flange of the bushing Inspect it and if necessary replace it 8 Pull the bushing off of the shaft If the bushing will not come off insert a screwdriver into the slit in the bushing 9 Remove the key from the keyway Installing Sheave Do not use lubricants in this installation 1 Bushing and sheave mating surfaces must be clean and oil free CAUTION 1 Inspect the tapered bore of the sheave and the ta pered surface of the bushing Remove any paint dirt oil or grease 2 Select the type of mounting that best suits this ap plication as shown in Figure 78 on page 78 and Figure 79 on page 78 4 am FIGURE 78 STANDARD MOUNTING 4 Standard Mounted Thread the cap screws into the threaded holes in the sheave Hand tighten it against bushing flange 5 Reverse Mounted Thread the cap screws into the threaded holes in bushing Hand tighten it against the sheave web 6 Tighten each cap screw gradually and evenly in rotation to push the sheave off the taper of the bushing Tap lightly with a hammer if necessary Emm mm FIGURE 79 REVERSE MOUNTING 78 SECTION 4 SERVI
90. hanics Hand Tools Observation Mirror e Fin Comb straightener e Heat Gun Straightedge e Tachometer e Manometers capable of 0 01 36 in combined Digital Manometer replaces Magnehelic Gauge Cat 4475 1 FM AV Series 475 1 Mark III with a range of 0 to 19 99 in WC from Dwyer Instruments Inc e Pitot Tube e Duct Hood Velometer and Psychrometer e Combustion Efficiency Analyzer Standard refrigeration gauges manifold Refrigerant reclaimer Refrigerant leak detector e Vacuum pump e Gas torches soldering and or brazing Fire extinguisher Electronic Temperature Meter min 3 leads e Megohm and Phase Meters Capacitor Analyzer e Clamp on Ammeter e Multi Meter or Meters capable of reading the fol lowing e One Thousand Volts AC DC e Amperes e Ohms e Milli volts e Milli amps e Microfarad 73 SERVICE INFORMATION All necessary tags and decals to aid in service or to indicate caution areas are provided Electrical wiring diagrams are attached to the control panel access door Installation operation and maintenance manuals are supplied with each AHU This AHU offers unlimited unit access with complete ly removable panels All of the AHU panels including the top panels can be completely removed Removing the top panels allows the use of overhead cranes and gantries to remove and service the components Fan and filter segments come equipped with doors TROUBLESHOOTING
91. he drive motor confirm that the wheel segments are fully engaged in the wheel frame and the segment retainers are completely fastened as shown in Figure 17 on page 29 Bearing Support Beam Pulley Ball Bearings 2 Side Bearing Access Cover 2 Diameter Seal Adjusting Screws KA ae us NUN Drive Pulley Removable Energy Transfer Segment 8 Drive Motor FIGURE 17 ENERGY RECOVERY WHEEL PULLEY SIDE 29 Segment Retainer Catch Rotate Away From Wheel Rim m c b CSS Spoke E Push Toward Center Wheel Rim CODI Of Wheel FIGURE 18 SEGMENT RETAINER Rotation N To Remove Diameter U To Adjust E pore Diameter Seal Feeler Adjusting Screws Gauge FIGURE 19 DIAMETER SEAL ADJUSTMENT SECTION 2 START UP AND OPERATION Innergy tech Start Up Procedure 1 Make sure all bearing bolts and set screws are tight A special seal lacquer is factory applied This is a visual aid that will warn you if the pillow block bolts or the bearings set screws have loos ened over time or during transport A seal without cracks is the indication that bolts and screws have not loosened 2 Be sure to use all lifting eye bolts when positioning energy recovery wheel into unit or ducting location and that weight is evenly distributed If the eye bolts need to be removed bolts or plugs should replace them in order to avoid any air leakage from these holes required
92. he warranty is limited to parts only replacement and shipping of any faulty part or subassembly which has failed due to defects in workmanship and materials All claims must be supported by evidence that the failure has occurred within the warranty period and that the AHU was operated within the designed parameters specified All warranty claims must specify the AHU model se rial number order number and run hours starts Model and serial number information is printed on the AHU identification plate The AHU warranty will be void if any modification to the AHU is carried out without prior written approval from Titus For warranty purposes the following conditions must be satisfied Only genuine Titus approved spare parts must be used All of the scheduled maintenance operations detailed in this manual must be performed at the specified times by suitably trained and qualified personnel Failure to satisfy any of these conditions will au tomatically void the warranty RESPONSIBILITY FOR SAFETY Every care has been taken in the design and manufacture of the AHU to ensure compliance with the safety requirements However the individual operating or working on any equipment is primarily responsible for Personal safety safety of other personnel and the equipment Correct utilization of the equipment in accordance with the procedures detailed in this manual 13 SECTION 2 START UP AND OPERATION Never use
93. hould be performed as soon as possible after AHU start up Failure to perform air balance may result in dam age to AHU generate noise vibration and conden sation carryover Qualified air balance technician should perform air balance Dynamic Balance Dynamic balance has been performed at the fac tory on the fan assemblies If any changes were made to the fan assembly fan motor sheaves belts isolators support structure a vibration analysis must be performed and the fan assembly trim balanced if needed e Dynamic balance is affected by operation of the VFD If a VFD is provided refer to the caution warnings in the VFD start up instructions in the VFD operators manual Make sure the skip fre quencies jump frequencies are installed prior to operation of the motors for more than 30 minutes Verify conformance with the total outdoor airflow and space supply airflow requirements of ASHRAE Standard 111 SMACNA s HVAC Systems Testing Adjusting and Balancing 2nd edition or equivalent Do not weld or use torches on the exterior or interior of the AHU housing The housing contains polyurethane insula tion which when under combustion will produce harmful toxic gases resulting in personal injury or death WARNING Never use silicone caulk sealant or caulk sealant containing silicone in or on revo lution air handling equipment NOTE Setting Limits Temperature e Cabinet Panels 200 F Standard Mot
94. ide of the coil 6 On heavily soiled coils use a safe commercial grade coil cleaner 7 Follow the safety and mixing instructions as noted on or with the cleaning agent 8 Spray the cleaning agent on both sides of the coil to be cleaned Allow the cleaning agent to remain in contact with the dirty surface for about 5 minutes or as recommended by the agent instructions Then flush the coil with clean water from a hose with spray nozzle or from pressure washer Flush from the air leaving side of the coil Caution should be taken as extreme water pressure may result in fin surface damage Direct the water straight at the openings between the fins and never at an angle which may bend the fins against one another This process will wash away surface dirt on the air entering side of the coil and prevent it from loading within the depth of the coil 63 9 Most cleaners are concentrated detergents and can be diluted with up to 10 parts water Dilute as per cleaning agent instructions and coil condition Re spray both sides of the coil with cleaner Allow to stand five minutes and flush as described previ ously Finish flushing from both sides of the coil 10 Follow the cleaning agent instructions Agent should meet environmental and OSHA standards 11 Some extreme oil and dirt conditions may require steam cleaning Most steam equipment can be adjusted to provide a mixture of water and steam at a moderate pressure Steam alone w
95. ing and binding may occur 6 Align the sheave with the companion sheave 7 If there is a difference of more than 1 8 in between the width of the companion sheave and any adjustable pitch sheave align them using Steps 5 6 8 Alignment procedure for adjustable sheaves 9 Use a square and straight edge to align the center or Stationary flange of the adjustable sheave with the center flange of the companion sheave 10 Insure the shaft of the motor is parallel to the shaft of the fan 11 Tighten the two clamp screws to the following torque values e JVS Model 130 160 in lb or 13 ft lb All other JVS Models 325 in lb or 27 ft lb Be careful not to grasp flanges in such a manner as to cock them while tightening the clamp screws 12 Install the belts and tighten properly 13 Recheck the alignment and speed Adjusting Sheave 1 To adjust the pitch diameter loosen both clamp screws 2 Remove the belts 3 Follow Steps 3 through 8 in nstalling Sheave in this section 80 SECTION 4 SERVICE AND REPAIR Adjustable Pitch Sheaves T B Woods Model FHP Tools and Material Required Standard mechanic s hand tools e Medium flat file e Torque wrench 0 250 in lb Hex Allen socket set for torque wrench e Square and straight edge Fine Emery cloth Removing Sheave 4 Remove the belts 5 Loosen the set screws on the adjustable flange s of the sheave Allen wrench as shown in Figure 81 o
96. ingle Phase 1500Va Transformer Wiring Diagram 91 FIGURE 88 UV Control Panel Wiring greater than 8 amps 92 FIGURE 89 Gas Heat Three Phase 1000Va Transformer Wiring 94 FIGURE 90 Gas Heat Three Phase 500Va Transformer Wiring 95 FIGURE 91 Typical Wiring Diagram for Electric Heat Control Type Vermier 96 FIGURE 92 Typical Wiring Diagram for Control Type Full SCR 97 LIST OF TABLES TABLE 1 Torque for Tightening Set SCreWS ccccccceeccceeeeeeseeeeeeeceeeeeeeeeseeeeeeeeeeeeeesseeeasseeeeeeeeesseaaas 15 TABLE 2 Air Measuring Device nnns 19 TABLE 3 Indoor Unit Example 25 TABLE 4 Gas Heat Segment Model Number Nomenclature 37 TABLE 5 Natural Gas Pressure Requirements Inches Wc 38 TABLE 6 Natural Gas Pressure Requirements Inches Wc
97. ithout the presence of water does not work well with most cleaning agents Cleaning the coils with steam should be done as described previously 12 Comb out any bent or flattened areas of the fin surface 13 Restore the equipment to its operational state SECTION 3 MAINTENANCE Cleaning Procedure 1 Cover any nearby components such as motors control devices or wiring 2 Sweep gather and remove debris from drain pan auxiliary pans and splash guards 3 Scrape loose and substances remove any clinging 4 Cover drain pan outlet with screening to prevent drain clogging 5 Prepare cleaning agent per manufacturer s in structions 6 Apply cleaning agent with spray applicator or brush 7 Apply cleaner to ALL surfaces including un derside of coil header and return bends if in air stream coil supports coil wall or bulkhead auxil iary drain pans splash guards any other surfaces subject to wetting by condensation dripping or CONDENSATE DRAIN PAN TRAP AND LINE i carried by normal airflow drain pan and outlet CLEANING Tools Equipment and Materials 8 Add ample amount of cleaning agent to drain line and trap Toilet bowl brush or similar utility cleaning brush 9 Allow cleaner to stand for time required by manu Cleaning agent safe commercial disinfecting instructions e Rags and trash bags 10 Flush with clean water from pressure washer or Garden hose wi
98. l revolution and determine where the wheel media face is rubbing on the seal 2 Working on one seal quadrant at a time loosen the seal Tek screws as shown in Figure 66 on page 69 3 Move the seal away form the wheel surface until no more rubbing is noticed A typical large diameter wheel will have a flatness variation of 1 16 in from the high to low point of the wheel surface If the seals are adjusted correctly the seal gap will vary that much as the wheel turns but the seal should never touch the wheel surface ING SEALS THERMOTECH Inspect Wheel Drive Components Rotor Bearings The main rotor bearings have been sized for an L 10 life of a minimum of 25 years oper ating 24 hours per day 7 days a week The main reason that a main bearing would fail is lack of lubrication or the existing grease hardens in the bearing due to evapo ration or by penetration of moisture causing corrosion The bearings are filled with grease at the factory or at the time of start up to eliminate a future failure Add a small amount of grease every six months to maintain fresh grease on the inside of the bearing Wipe off any excess purged grease to avoid it getting blown onto the wheel surface All bearings are greased with a Dow Corning Molycote BR2 Plus Grease which is available through most bearing distributors Drive System The motor does not require any main tenance and has permanently lubricated bearings The speed reducer
99. le also In this arrangement the 25 damper would be for monitoring nominal airflow through the first 25 down to 3 75 and the 75 damper would be for monitoring the remaining 75 100 Sensing Option The 100 sensing arrangement is a single damper design used to measure airflow throughout the full range of the outside air damper down to 15 of nominal airflow 100 es See eS O Se FIGURE 12 25 75 SENSING OPTION The 100 sensing option is the lowest cost option but should not be utilized when minimum airflow to be sensed falls below 1596 nominal flow The 2596 Sensing Min Max and 10096 Sensing option arrangements will be the most prevalent The 100 Sensing arrangement with the outside and return air dampers tied to a common actuator will usually be the most common configuration and cost effective solution However areas in which economizer cycles are not often seen and operate primarily in minimum outside air position the 2596 Sensing option should be the preferred option for lowest airflow moni toring and a cost effective solution In each of the available configurations the minimum airflow across the sensing portion of the airflow moni toring station is 300 FPM for the Revolution TFX SECTION 2 START UP AND OPERATION Jumper Selections When selected the AMS 60 factory provided trans ducers technically provides six 6 jumper selections which allow you to select the appropriate range for
100. lled with the directional arrows pointing in the direction of the motor rotation Belt is installed in 6 steps 1 Ask Innergy tech for belt length The length de pends on the wheel diameter 2 If needed remove links by twisting the link tabs sideways and pulling the surplus out of the belt 3 Tape one end of the new belt to wheel and make it turn by hand one complete revolution The wheel should turn freely if belt is removed 4 Pull the belt tightly around the wheel and reducer sheave 5 To connect both free ends of the belt hold belt with tabs pointing outward Place end tab through both links at once Flex belt further and insert second tab through end link by twisting tab with thumb Ensure tab returns to position across belt 6 Reverse belt so tabs turn to the inside of belt 7 Pass the belt over the tensioner idler sheave If there is no tension in the tensioner reduce the length of the belt 71 SECTION 3 MAINTENANCE MAINTENANCE RECOMMENDATIONS FOR SOLUTION AIR HANDLER Includes suggested IAQ minimums for ASHRAE Std 62 2010 Compliance asNeeded PROCEDURE Clean exterior of air handler cabinet Inspect doors handles latches and hinges for proper operation Inspect door gaskets for damage and proper seal Inspect panels for damage Clean fan segment and fan assembly supply return exhaust Check fan housing wheel shaft frame inlet vanes and bearings for damage wear loose parts
101. m the high to the low point of the wheel surface If the seals are adjusted correctly the seal gap will vary that much as the wheel turns but it should never be touching the wheel surface your project Insure proper purge angle setting is correct by visual inspection The minimum purge angle is 1 degree There are 10 adjustment points in one degree increments Purge Adjustment TF Series Wheels The purge angle can be adjusted with each purge set ting hole equal to one degree The bolts that position the purge angle are located on the backside of the purge and are not visible First loosen bolt 2 and 3 Then re move the bolt 1 The whole purge section is then mov able to a new location Re install bolt 1 in the new hole location and re tighten all the bolts Bolt 1 Bolt 2 FIGURE 20 PURGE ANGLE DETAILLD Purge Adjustment TC Series Wheels The purge angle can be adjusted with each purge set ting hole equal to one degree Bolt number 1 positions the purge angle and is located on the front side of the purge Bolt number 2 is the pivot point and is located on the inside of the frame and is not visible First loos en bolt 2 Then remove bolt 1 The purge wiper section is then movable to a new location Re install bolt 1 in the new hole location and re tighten all the bolts Purge angle detail showing bolt locations on front side of purge The purge wiper bolt 2 pivot point is slotted so as the purge wiper is adjusted it can
102. mosphere when one side is open to atmosphere If a U tube is filled to the halfway point with water and air pressure is exerted on one of the columns the fluid will be displaced Thus one leg of water column will rise and the other will fall The difference in height h which is the sum of the readings above and below the halfway point indicated the pressure in inches of the water column 19 PRESSURE 4 4 3 3 2 2 1 1 1 9 2 3 3 4 4 FIGURE 74 U TUBE MANOMETERS The U tube manometer is a primary standard because the difference in height between the two columns is al ways a true indication of the pressure regardless of the variations in the internal diameter of the tubing For use on all air units the manometers should cover at least a 26 in range as shown in Figure 75 on page 76 FIGURE 75 SLACK TUBE MANOMETER SECTION 4 SERVICE AND REPAIR VACUUM DUCT PRESSURES Velocity When air moves at a given velocity V in FPM in a duct it creates a pressure corresponding to the veloc ity which is a measure of the kinetic energy in the fluid and is known as the velocity pressure VP VP is always exerted in the direction of air flow The relationship between the velocity and the VP may be expressed by the following formulas 2 Ja V y 4005 V 40054 VP 4005 0 250 2002 FPM It is a simple matter to determine the velocity FPM of an the air stream so the VP can
103. n bolts are removed from Checking Isolators the four corners of the fan base assembly as shown Check the fan base isolators and thrust restraints for in Figure 2 on page 16 For small AHUs the tie proper adjustment down bolts may only be applied to three corners of the fan base since one corner is not accessible Do not remove the shipping bolts if there 6 are no springs Tie Down Bolts FIGURE 2 FAN AND MOTOR ISOLATOR SUPPORT FRAME Inspecting Belts and Sheaves 1 Verify that the sheaves are properly aligned and tight on the shaft Improper sheave alignment and belt tension are potential causes of excessive noise and vibration and shortened belt and bearing life Refer to SECTION 3 MAINTENANCE in this manual for more information 2 Check the belt tension If not familiar with the process refer to SECTION 3 MAINTENANCE in this manual It is normal for belts to loosen after start up The new belts will run in or take a set by seating slightly deeper into the grooves of the sheaves Recheck the tension after one day and three days 3 Make sure the motor mounting bolts and adjustable motor base bolts are tight e Standard fan isolation consists of spring isolators as shown in Figure 3 on page 16 mounted under the internal fan assembly For thrust restraint adjustment procedures if ap plicable refer to the service manual Prepare the fan isolators for operation using the following instructions 1 Af
104. n page 87 MOUNTING SET SCREW ADJUSTABLE FLANGES SETSCREW KEYWAY CENTRAL SLEEVE STATIONARY FLANGE FIGURE 81 ADJUSTABLE PITCH SHEAVE FHP 6 Screw the adjustable flange s open to expose and loosen the mounting setscrew in the central sleeve over the key 7 Clean and remove any burrs from the shaft from the sheave to end 8 Slide the sheave off of the shaft Installing Sheave 1 Loosen set screws on adjustable flange s of new sheave Allen wrench 2 Screw the adjustable flange s open to expose and loosen the mounting setscrew in the central sleeve over the keyway 3 Inspect the shaft and key for any nicks and burrs Remove same and clean shaft 4 Insert the key into the keyway 5 Slide the new sheave onto the shaft with the mounting setscrew over the key and toward the motor 6 The fan and motor sheaves should be placed on their respective shafts far enough to have the shaft exposed past its chamfer if possible which will facilitate ease of alignment later in this process 7 Align the adjustable sheave s stationary flange with the respective flange of the companion sheave On adjustable sheaves of two or more grooves if there is a difference of more than 1 8 between the width of the companion sheave and any adjustable pitch sheave align using steps 7 through 10 8 Alignment procedure for multiple groove adjustable sheaves 9 Use a square and straight edge to align the center
105. n the hori number of links and remove one link for every 24 of 3L Zontal plane on both bearing front and back Re Z 10 A 4L and B 5L sections and one link for every 20 move the shaft clips at the face of the hub trom of C and D sections This gives the correct installed belt both sides of the shaft Unbolt one post complete length and will ensure optimum belt tension when ly and remove post with bearing completely out running Remove the shaft Roll the wheel carefully out 3 If the unit is equipped with an external flanged 67 FIGURE 62 HOW TO MEASURE Every tenth link is designated with an ar row gt 3L 7 10 4 41 and B SL only For multiple belt drives ensure that each belt has the same number of links NOTE IMPORTANT Turn belt INSIDE OUT as shown to ensure easy assembly and disassembly Disassembly A Hold belt upside down Bend back as far as pos sible hold with one hand Twist one tab 90 parallel with slot B Pull end of link over tab C Rotate belt end with tab 90 D Pull belt end through two links FIGURE 63 DISASSEMBLY Assembly A Hold belt with tabs pointing outward B Place end tab through two links at once C Flex belt further and insert second tab through end link by twisting tab with thumb D Ensure tab returns to position across belt Reverse belt so tabs run inside FIGURE 64 ASSEMBLY SECTION 3 MAINTENANCE Installation 1 Turn belt with ta
106. nd jamb seals used for low leakage Strategically placed stationary and vertical airflow sensing blades measure the airstream velocity pressure Air tubing piping connections are provided to connect the sensing blades to an optional factory mounted transducer The transducer converts the ve locity pressure from the sensing blades to an electrical output signal for the Building Automation System BAS The output signal corresponds directly to flow through the damper The BAS compares this signal to the design CFM setpoint as determined by the particu lar mode of operation of the HVAC system In normal operation this setpoint corresponds to the minimum outside air ventilation required by the system design to meet ASHRAE Standard 62 Based on the difference between the actual CFM reading and the desired setpoint the BAS would send a signal to the optional factory mounted control damper Actuator to position the damper blades as necessary to ensure that the actual outside airflow meets the desired level No Calibration Required The AMS 60 airflow monitoring damper is factory cal ibrated Calibration is not required at the jobsite 22 SECTION 2 START UP AND OPERATION Ductwork Inlet Requirements Damper Configurations When connecting the ductwork to a mixing box with There are possible damper configurations 25 Sens an AMS 60 damper a minimum of one 1 equivalent ing option Min Max 25 75 Sensing option and duct diameter
107. nts of the system parameters should be taken and compared to the measurements recorded on the burner test report to ensure safe and reliable operation Use the following instructions to start an indirect fired gas heat system on an AHU Identify the Gas Burner Type Two types of indirect fired gas burners are used on the AHUs Powerflame and the Eclipse series The Powerflame series offers a turndown modulating ratio of 3 1 or 10 1 The Powerflame is easily identifi able by the motorized gas valve with external linkage connecting the air dampers on the burner air inlet The Eclipse series uses an air gas ratio regulator with no external linkage and has a turndown range of 10 1 to 25 1 sometimes greater A visible external plastic tube is used to transmit gas pressure from the burner to the regulator No external linkage is used 32 SECTION 2 START UP AND OPERATION Both burners utilize a combustion air blower and use an exhaust blower called an induced draft ID blower which keeps the combustion chamber at a slight nega tive pressure Verification of this negative pressure and other system parameters is part of a proper start up procedure Preliminary Coordination Contact the contractor customer who requested start up and do the following e Ensure the AHU and system is capable of design airflow for gas heat start up Ensure reliable power is available Verify the following Verify the AHU was properly
108. nuisance thermal cutout tripping 43 2 A visual inspection of the heater elements should be made prior to use of the heater If physical damage is evident a Megohm test should be used to validate the heater elements are safe for use If a minimum value of 10 megohms is not achieved then any damaged elements or ceramic insulators must be replaced prior to operation Electrical Installation 1 Follow the wiring diagram on the inside of the terminal box 2 Supply connections must be made with copper wiring rated for 75 C minimum 3 If supply connections are for 250 volts or greater all wiring must be insulated for 600 volts 4 When making line connections to heater element terminals FOR FINNED TUBULAR HEATERS ONLY apply a 1 4 wrench to flat section of terminal immediately below threads Otherwise damage to terminal may result 5 Supply conductors for heaters rated less than 50 KW must be sized at 125 of rated load On heat ers rated 50 KW and more the supply conductors may be sized at 100 of rated load if indicated on the wiring diagram The line current for either a single or three phase load is calculated as follows single Phase Line Current KW x 1000 Voltage Three Phase Line Current KW x 1000 Voltage x 1 73 6 The following table shows the maximum current for 75 C copper wire with not more than 3 conductors in a raceway It is based on the National Electrical Code Table 310 16 The amperages shown
109. ompletely Do not remove the functional bolts from the seismic isolators as shown in Figure 1 on page 14 Functional Siesmic Bolt FIGURE 1 SEISMIC ISOLATOR Ensure the damper linkage is tight and is in the correct power off position f the return air dampers are closed loosen the actuator or crank arm on the jackshaft open the dampers and retighten the actuator or crank arm 14 SECTION 2 START UP AND OPERATION Inspecting Fan Assembly TABLE 1 TORQUE FOR TIGHTENING SET Use the following instructions to inspect the fan assem SCREWS bly SETSCREW SIZE MINIMUM RECOMMEND DIAMETER ACROSS ED TORQUE 1 When the AHU is removed from long term stor IN FLATS IN IN LB age purge the moisture laden bearing grease and 66 85 replenish the AHU with fresh grease according to 126 _ 164 the lubrication label are 228 296 190 247 2 Meg the motor to verify that the resistance is at a 7 32 348 452 29 0 35 7 satisfactory level compared to value recorded 504 655 420 546 prior to storage 5 16 1104 1435 92 0 1196 3 Check the torque for bearings and locking collars as shown in Table 1 on page 15 4 Verify that the fan wheel is properly aligned is tight on the shaft and moves freely 5 Make sure the fan bearings are properly lubricat ed Refer to SECTION 3 MAINTENANCE in this manual for more information SECTION 2 START UP AND OPERATION 6 Verify that the tie dow
110. on page 36 observe the reading A pressure of 0 03 inches WC is expected for draft overfire Readings may differ slightly from those shown on the Burner Test Report 7 For valid readings before making any adjustments allow the burner to fire at least 20 minutes to allow the heat exchanger to rise to the operating temperature 8 Observe the gas manifold pressure and compare to the data on the Burner Test Report under both FIGURE 24 SET ID FAN DAMPER high and low fire conditions 35 9 Check the flue stack combustion temperature at the ID blower housing test port Make sure the test probe is inserted halfway into the ID inlet tube as shown in Figure 27 on page 36 Compare the results to the Burner Test Report 10 The ignition transformer is intermittent Pilot continues to burn after ignition transformer is de energized 11 Using the signal generator cycle the burner to check capacity modulation Observe valve damper actuator operation as shown in Figure 28 on page 36 12 Using the standard operating controls cycle the burner several times to assure proper sequencing of start up firing and capacity modulation plus operation of all safety and monitoring controls 13 Test the 180 F high temperature safety by running the burner with the airflow off or diverted The burner will shut down at 180 F Turn the AHU on as quickly as possible to remove the heat from the heat exchanger 14 Test the burner effici
111. ools e Medium flat file e Torque wrenches 0 250 in Ib Hex Allen socket set for torque wrench e Square and straight edge Fine Emery cloth Removing Sheave 1 Remove the belts 2 Loosen both clamp screws with an Allen wrench as shown in Figure 80 on page 80 STATIONARY FLANGE CLAMP SCREW CENTRAL SLEEVE ADJUSTABLE FLANGES FIGURE 80 ADJUSTABLE PITCH SHEAVE JVS 3 Clean and remove any burrs from the shaft from the sheave to the end 4 Slide sheave off shaft If tight insert screwdriver into slit in central sleeve Installing Sheave 1 Loosen the clamp screws on the new sheave 2 Slide the JVS sheave onto the shaft Place the fan and motor sheaves on their respective shafts far enough to have the shaft exposed past its chamfer which will facilitate proper alignment later in the process SECTION 4 SERVICE AND REPAIR 3 The central sleeve of this sheave is split at one end only Install this end first as the split allows the sheave assembly to be secured to the shaft 4 Adjust the sheave to the approximate pitch diameter desired One turn of the adjusting screw will vary the pitch diameter 0 2 in Seven turns are required to adjust the sheave from the minimum to the maximum pitch diameter 5 Put slight finger pressure on the face of the adjust able flanges near the split 180 from the adjusting screw to permit free and equal movement of the flanges during pitch adjustments Otherwise tipp
112. oor air being exhausted and outdoor air being supplied to the building Cleaning the Wheel To clean gain access to the energy recovery wheel and remove the segments as shown in the service manual Brush or vacuum foreign material from the face off the wheel e Wash the segments in a 5 solution of non acid based coil cleaner see material list or alkaline detergent and warm water e Allow segments to soak in solution until grease and tar deposits are loosened An overnight soak may be required to adequately loosen heavy deposits of tar and oil based contaminants Before removing from solution rapidly run finger across surface of segment to separate polymer strips for better cleaning action Hinse dirty solution from segment with clean water and allow excess water to drain prior to remounting segments in the wheel in the service manual as shown in Figure 59 on page 65 A small amount of water remaining in the wheel will be dried out by the airflow FIGURE 59 RINSE SEGMENTS Some staining of the desiccant may re main and is not harmful to performance NOTE Do not use acid based cleaners aromatic solvents steam or temperatures in excess of 170 F damage to wheel may occur 65 AIRXCHANGE Adjusting Air Seals Four adjustable diameter seals are provided on each cassette to minimize transfer of air between the counter flowing airstreams Rotation N To Remove To Adjust 1 E ee Diameter Seal
113. oose ness 3 Operating amperage and compare the number to the number listed on the AHU nameplate Keep Motor Bearing Lubricated Bearing grease will lose its lubricating ability over time because the lubricating ability depends primarily on the type of grease size of the bearing speed at which the bearing operates and the severity of the operating conditions Good results can be obtained if the following recommendations are used in this maintenance program 1 Use a high grade ball or roller bearing grease such as Polyrex EM Exxon Mobile for Baldor Motors only 2 Use lithium petroleum based grease conforming to an NGLI Grade Il consistency for TECO Motors only 3 Maximum operating temperature for standard motors is 166 F 4 Shutdown temperature in case of a malfunction is 175 5 Recommended lubrication intervals are shown in and are based on average use as shown in Table 13 on page 60 and Tables 11 and 12 on page 58 6 Use the following steps to lubricate the motor To avoid damage to the motor bearings keep the grease free of dirt For an tremely dirty environment contact your distributor or an authorized service center for additional information If the is equipped with a grease plug use fol lowing instructions to replace the grease 1 Be sure that the grease you are adding to the motor is compatible with the grease already in the motor Consult a distributor or an au
114. ors with Class B Insulation 104 F e Motors with Class Insulation 140 F Power Wiring 140 F e Controls and Control Wiring 140 F Prefilters 150 F High Efficiency Filters 200 F Variable Speed Drive ABB Mfg 140 F e Damper and Valve Actuators 140 F e Gasketing 200 F Gan Bearings 120 F FC 180 F AF e Foam Flash Point 415 F Energy Recovery Wheels e Thermotech 140 F e Innergy tech 122 F NovelAiree Technologies 200 F Airxchangee 170 F Static Pressure e Maximum design cabinet pressure is 0 5 cfm ft cabinet 4 WC Access doors are double walled Doors are pro vided with adjustable door latches and seals Checking Motors Belts and Sheaves Motors CAUTION Motor amperage should be checked again after the connecting ductwork is installed and an air balance is performed on the air distribution system If the mo tor operates at amperage levels above the nameplate limits discontinue operation and correct the cause or refer to SECTION 3 MAINTENANCE in this manual Do not operate fan motors in overload amperage conditions Motors are designed to operate within the stated Service Factor SF on the motor nameplate SECTION 2 START UP AND OPERATION Belts Check belts for correct tension at start up and again after 24 hours of operation On multiple belt adjust able pulleys check the pitch depth to insure identical belt travel power t
115. osed position The water 64 SECTION 3 MAINTENANCE circulation pumps must keep circulating water through the coils and or auxiliary heat must be maintained inside the AHU cabinet Draining each coil and related piping such as traps and making sure that all low areas also drain e After draining flush the coils with an antifreeze solution such as propylene glycol A solution of 50 glycol and 50 water will protect from freezing to approximately 35 F below zero at sea level Use adequate mixture for the geographic area of the installation Winterizing Drain Traps e During the winter months when the cooling sys tem is turned off and the unit is exposed to freez ing conditions an anti freeze solution which is environmentally friendly and safe for the roof can be poured in the condensate drain trap to prevent freezing and possible damage The condensate drain trap may also be removed as well as heat traced and insulated ENERGY RECOVERY WHEEL This AHU will be equipped with an energy recovery wheel from one of the following vendors Refer to the correct instructions to maintain and clean this AHU e Airxchange NovelAire amp Technologies e Thermowheel Innergy tech AIRXCHANGE Tools and Materials e Brushes Loctite e Screwdriver Acti Klean or alkaline detergent Periodic cleaning of the energy recovery wheel will be a function of the operating schedule climate and contaminates in the ind
116. r CFM k APn AP The differential in static pressure across the fan inches w g k See the table below n See the table below This assumes a standard air density of 075 16 cubic foot at sea level 18 SECTION 2 START UP AND OPERATION TABLE 2 AIR MEASURING DEVICE CONNECTIONS ye caes FANSZE ctass FANSZE n TYPE CLASS TYPE CLASS R ieas 951000 04768 300 506862 NA ATLI ATLI JA EPFN LICICIC EPFN EPFN gt 2 gt 5 19 SECTION 2 START UP AND OPERATION TABLE 2 AIR MEASURING DEVICE CONNECTIONS FAN FAN FAN FAN _ class FANSZE n cass n gt gt gt was 2 12 omo NA 3 12 94492 NA was 3 12 9492 NA 150 120640 NA was 150 120640 NA mean 2 150 120640 NA gt to 120640 NA mean 3 18 120640 NA Twas 3 150 120640 NA mean 165 151058 NA 16 151858 NA wow 2 65 151058 NA was 2 165 151858 NA mean 3 165 151058 NA was 3 16 151858 NA mean 1 182 2192 NA was 1 12 182192 NA mean 2 182 18219 NA Cmos 2 12 12192 NA mean 3 182 1719 NA 182192 NA mean 20 218580 NA
117. ransfer and wear Adjustable motor bases are provided for belt adjustment Sheaves If optional adjustable sheaves are provided replace them with correctly sized fixed sheaves immediately after the system air balance is performed It is not unusual for an adjustable sheave to create damaging vibration in the fan assembly Replacing Sheaves Use the following instructions to replace the sheaves 1 Measure the outside diameter of a belt while it is seated into at least one half the circumference of an adjustable sheave groove which is the sheave pitch diameter 2 Order a good quality pre balanced sheave or sheave and bushing assembly that matches the pitch diameter belt cross section and bore size from your local Titus Representative Provide the following information Drive tag information as shown in Figure 33 on page 48 Label will be located on the fan assembly near the belts New fan RPM Measurement of pitch diameter at which the adjustable sheave is set Job Identification Number from the AHU ID label A new driver motor sheave or sheave and bushing are usually all that is required to directly replace the current adjustable driver sheave IVE KIT M 40 116174 www emerson ept com Cn P436048 1 8 KIT 289 24302 201 MTRHP 105 1154 CD 46 7 3 00 OPN 5 TENSION INFO 4 33 LBS 0 25 IN z DRIVE S BELT BX56 Ra MOTOR 2VP71X
118. rom Fahrenheit to Celsius multiply by 5 9 or 0 5556 Example 10 0 F range x 0 5556 5 6 C range 98
119. ronged lamps into the slotted fixtures as shown in Figure 53 on page 61 then rotate the lamp 90 FIGURE 53 INSTALLING V MOD LAMP V Ray and V Max Grid Lamps Fit the four pronged lamp into the clamp mounted on the UV segment where a pigtail is installed Insert the prongs into the pigtail plug FIGURE 54 INSTALLING V RAY AND V MAX GRID LAMPS FIGURE 55 V MAX GRID LAMPS 61 MAINTAINING AND REPLACING FILTER SEGMENTS A list of filter part numbers sizes and quantities are shown on a label located on each filter segment of each AHU NOTE Every month check the cleanliness of the filters and if necessary replace them Filters should be replaced when the pressure drop measured by a manometer reaches the prescribed limits for the installation Filter Types Flat angle rigid bag are the typical filter types as shown in Figure 56 on page 62 li your has the filter frames bulkheads and segment panels are factory sealed and must remain sealed for NO air bypass DO 4 FIGURE 56 TYPICAL FILTERS Replacing the Filters 1 Check filter sizes and quantities Refer to the filter label located on each filter segment 2 Remove filter frame end cover as shown in Figure 57 on page 62 and Figure 36 on page 52 3 Remove old filters if present 4 Make sure gaskets at both ends of the side load filter tracks are in place The gaskets are normally found on inside of filt
120. rticles or abrasives This Lines light viscosity low torque grease is rust inhibited and water resistant and has a temperature range of 30 F to 200 F with intermittent highs of 250 F Lubricate bearings as required by the severity of required duty Check the lubrication lines as shown in Figure 49 on page 57 for Cracks and brittleness Replace as needed Proper Interval and Quantity e Fittings are tight and lube lines tight on fittings Refer to Table 10 on page 58 and Table 9 on page 49 e Air bubbles in grease Disconnect and purge as for the proper lubrication intervals for the bearings listed necessary earlier in this section Recommended Lubricant for Bearings The bearing on the split pillow blocks is Use a lithium petroleum based grease conforming to 1 3 full when only one side of bearing is an NLGI Grade II consistency The lubricant must be completely full of grease free of any chemical impurities such as free acid or NOTE TABLE 10 FAN BEARING LUBRICATION INTERVALS FOR BALL BEARING PILLOW BLOCKS RE LUBRICATION SCHEDULE MONTHS SPEED RPM 4000 SHAFT DIAMETER IN 500 1000 EN 1 1 1 2 11 16 to 2 15 16 Po sss 3 7 16 to 3 15 16 TABLE 11 FAN BEARING LUBRICATION INTERVALS FOR SPHERICAL ROLLER BEARING SOLID PILLOW BLOCKS 4500 _ p MERE NONE p p SPEED RPM 4000 4500 SHAFT DIAMETER IN NNI NL TE s pa 3500 p 1 1 x L
121. s Panels Inspect the panels for damage If the panels show signs of excessive pressure change they will appear to bulge inward or outward Refer to the Troubleshooting Guide regarding excessive static pressure If the panel needs to be replaced use the instructions later in this section SECTION 3 MAINTENANCE FAN SEGMENT SUPPLY RETURN OR EXHAUST Removing the Fan If necessary remove the fans for cleaning Clean the fan with detergent or solvent that is environmentally safe If water pressure is used do not direct the water stream onto the bearing seals Forward curved fan wheels are more sus ceptible to dirt accumulation than other wheels Dirt and debris on fan wheels and shafts may adversely affect the balance of the fan assembly NOTE Refer to the information later in this section to replace the fan and fan assembly components Checking the Fan Check the following fan parts for damage wear loose parts and debris 1 Fan housing wheel shaft frame and bearings 2 Fan base vibration isolators and optional thrust restraints 3 Flex connector Make sure the fan assembly does not rub the flex material 4 Drive kit which consists of belts sheaves and sheave bushings Check for belt tension The actual data required by design of each fan assembly is listed on the tag affixed to the fan housing near the belts as shown in Figure 84 on page 50 SECTION 3 MAINTENANCE V BELT DRIVE KIT
122. s several advantages over a liquid manom eter Unless extreme accuracy is required this instrument may replace the manometer for average air condition ing work and like the manometer 15 available in va riety of ranges The dial is only two in diameter and has a limited scale several instruments are required to cover the normal ranges encountered in average air conditioning jobs as shown in Figure 73 on page 75 FIGURE 73 MINIHELIC FILTER GAUGE The Minihelic Filter Gauge should be factory installed level The adjust indicator to zero with no airflow or pressure difference across the sensors The adjustment screw is located at the bottom behind the plastic cover When the airflow is initiated the indicator should move to the right If it moves in the opposite direction reverse the tubes U TUBE MANOMETER Pressure is defined as force per unit area The best way to measure air pressure is to balance a column of liquid of known weight against the air pressure and measure the height of liquid columns so balanced The units of measure commonly used are inches of mercury in Hg using mercury as the fluid and inches of water inches wg using water or oil as the fluid Instruments employing this principle are called ma nometers The simplest form is the basic and well known U tube manometers as shown in Figure 74 on page 76 This device indicates the difference between two pressures or between a single pressure and at
123. s should allow it to last up to 20 years Lubrication of bearings and bearing bolts varies de pending on the temperature range in which the wheel will be used For a typical temperature range of 40 130 F 40 54 C recommended lubrication is every six months A NLGI grade 2 consistency mineral oil lithium or lithium complex based grease is recommended to be pumped into the two bearing grease points Check the following parts for tightness before start up and every six months Bearing bolts Bearing set screws two on each side of the wheel Torque them to 13 ft Ib for wheels up to 78 in diameter and 24 ft Ib for wheels from 88 120 in diameter Motor Bolts Check the bolts securing the motor to the base plate periodically for tightness hand wrench tight at start up after one month of operation and annually thereafter INNERGY TECH Drive Belts The belt is a high performance link belt which allows installation or replacement without using special tools Innergy tech recommends checking the belt after a month of operation and every three months through a general maintenance check The inspection should focus on belt wear and correct tension If im proper tension is noticed simply reduce the length of the belt by removing a few links If the belt needs re placement contact Innergy tech for a new belt Innergy tech will need the serial number and the size of the wheel The belt is directional it must be insta
124. sively in rotation to the torque value as shown in Table 16 on page 79 There must be a gap between the bushing flange and sheave hub when in stallation is complete Do not over torque Do not attempt to close i the gap between the bushing flange and the sheave hub CAUTION TABLE 16 CAP SCREW TORQUE VALUES BUSHING CAP SCREW ar JA SH SDS SD 1 4 20 FT LB TO APPLY WITH TORQUE WRENCH 9 9 e ws o The tightening force on the screws is mul tiplied many times by the wedging action of the tapered surface If extreme tight ening force is applied or if a lubricant is CAUTION used bursting pressures will be created the hub of the mating part gt 5 Tighten all set screws according to the values in Table 17 on page 79 TABLE 17 SET SCREW TORQUE VALUES HEX WRENCH MIN RECOMMENDED papel SIZE ACROSS TORQUE FLATS IN LB FT LBS 54 1 8 5 16 1104 1435 92 0 119 6 Adjusting Sheave 1 Before belts are installed check alignment as de scribed in Section 4 2 If adjustment is required measure the space be tween the straight edge and the sheave 3 Follow steps 2 through 5 under Removing Sheave in this section Move the bushing in the proper direction the distance measured 4 Proceed with the instructions in Installing Sheave in this section 79 Adjustable Pitch Sheaves T B Woods Model JVS Tools and Material Required Standard mechanic s hand t
125. sure TP within the system PITOT TUBE STATIC PRESSURE CONNECTION TOTAL C PRESSURE J 13 STATIC PRESSURE U TOTAL PRESSURE 4 bY VELOCITY PRESSURE FIGURE 71 PITOT TUBE PITOT TUBE The pitot tube consists of an impact tube within a larg er static tube When the impact tube is pointed directly into the air stream the small static pressure holes are perpendicular to the air stream and are not affected by air velocity as shown in Figure 71 on page 74 74 SECTION 4 SERVICE AND REPAIR To read velocity pressure the total pressure tap at the end of the pitot tube is connected to one leg of a ma nometer and the static pressure tap at the other leg of the manometer as shown in Figure 72 on page 75 INCLINED MANOMETER This instrument is a simple fool proof device which responds directly to the air pressure exerted against it transmitted from the pitot tube and reads directly in inches of water Ranges vary The technician should have one or more instruments to cover the range of 0 8 inches of water as shown in Figure 72 on page 75 Before using the inclined manometer ensure the in strument is level and then adjust the meniscus to the zero mark The adjustment knob is located at the base of the fluid reservoir FIGURE 72 INCLINED MANOMETER MINIHELIC FILTER GAUGE The Minihelic Filter Gauge a diaphragm operated gauge ha
126. tech Note For TC sizes 14 82 To remove the belt an idler pulley will need to be loosened 2 The side seals should also be checked for clear ance to insure nothing has moved in shipping If the wheel is in contact with the aluminum encasing the side seals the wheel will need to be re centered in the casing This is done by loosening the bearing bolts and by using the bearing adjusting bolts Re center the wheel insuring proper side seal clearance Re tighten bearing bolts as follows 3 8 inch 35 ft Ibs 1 2 inch 45 ft Ibs 3 4 inch 100 ft Ibs 3 Check to insure sheave bushing is not rubbing on the gear box 4 At this point the wheel should rotate freely with no drag or rubbing with the exception of the rivets at the hub cover A slight rub here is acceptable Proper wheel rotation technique Rotate wheel by applying pressure to the rim not the media Care should be taken not to damage the media face 5 The seals are set at the factory and should not re quire adjustment If the seals are rubbing on the media face due to installation or other factors the seals will need to be adjusted First rotate the wheel one full revolution and determine where the wheel media face is rubbing on the seal Working on one seal quadrant at a time loosen the seal tek screws Then move the seal away from the wheel surface until no more rubbing is noticed A typical large diameter wheel will have a flatness variation of 1 16 fro
127. ter removing the tie down bolts from the internal fan assembly check the blower motor frame for the correct height and that the frame is level 2 To adjust the isolators as shown in Figure 3 on page 16 a Loosen the cap screws on top of the ad justment bolt b Turn the adjusting bolt c Check the operational height and level of the frame Repeat this procedure until the height and frame are level d Tighten the cap screws Refer to the ser vice manual for additional instructions Verify the fan is aligned with the AHU discharge Readjust the isolators as necessary FIGURE 3 SPRING ISOLATOR 16 SECTION 2 START UP AND OPERATION START UP CAUTION Do not be operate this AHU until after start up is completed as outlined in these instructions Do not allow the AHU to run on unreliable temporary power which could turn the AHU on off periodically or rapidly and to protect it from irregular voltages and surges It is recommended that the start up technician use the AHU Start up Checklist included with the AHU and record the gathered information in the appropriate fields If there are questions refer to Table 9 on page 49 for inspection requirements Install the provided or temporary filter media prior to Start up to adequately protect the components in the air stream and duct system If the is equipped with an energy recovery wheel rotate the wheel when the AHU is in ser
128. th spray nozzle or power washer garden hose with spray nozzle 11 Apply as much water under pressure as possible to drain outlet to clean trap and drain line Scraper e Screening 12 Remove water from any puddle areas with wet Wet vacuum vacuum Schedule and Conditions 13 Wipe down if necessary to remove any 1 Clean condensate drain pan trap drain line and stubborn material adjacent wetted surfaces at least annually or as often as required to retard growth of microbial substances 14 Restore equipment to operational state Coil Freeze Protection All chilled water hot water and steam coils can be damaged during freezing weather Take the following re cautionary measures to prevent freezing 2 Test Drain Pans To minimize conditions of wa ter stagnation that may result in microbial growth field test drain pans under normal operating con TO e For year round operation glycol and other anti 3 Exception Field testing drain pans is not re quired if units with factory installed drain pans have been certified attested in writing by the manufacturer for proper drainage when installed as recommended freeze solution must be circulated e During winter operation and shutdowns such as power failure night shutdown and weekend shut down the controls must be installed so the valves will go to the full heat position and all fresh air dampers go to the full cl
129. to prevent frost formation If not follow the instruc tions in the manual accompanying the VFD and or consult NovelAire amp Technologies SECTION 2 START UP AND OPERATION Indirect Fired Gas Heat Start Up CAUTION This gas burner has been carefully inspected and tested at the factory however different conditions at the job site including controls that have been added at the time of installation require careful testing and final adjustment for satisfactory operation The Burner Test Report Factory Specification Sheet in each AHU shows the general data recorded during the operation and safety tests at the factory This data should be used as a general guide with final data recorded on the start up form Do not exceed 550 F flue temperature at the ID fan inlet Do not exceed 200 F supply air temperature For your safety this product requires a check test and start up adjustment by a qualified HVAC technician Do not use for temporary heat prior to start up Review the burner control literature including wiring piping cut sheets and drawings before attempting to start this gas heating equipment All factory test start up burner specifications are located on a laminated Burner Test Report Factory Specifi cation Sheet located on the inside of the control panel door Each gas burner has been test run and inspected at the factory Adjustments to the component settings are typically not required However measureme
130. vice to prevent clogging Checking Operation of Fans Check of the operation of the fans by 1 Verifying the correct voltage phase and cycles 2 Energizing the power to the AHU disconnect switch 3 Energizing the fan motor s briefly bump and check for correct fan rotation If the fan rotation is incorrect 1 On three phase equipment reverse any two motor leads at the load side of the last starter component 2 On single phase equipment follow the wiring diagram on the motor housing or on the inside of the motor terminal box 3 Recheck for correct fan rotation Checking Operation of Dampers CAUTION Make sure the AHU will not operate with all dampers closed Most units are shipped with dampers in closed position Release and adjustment is to be done by field technician only Linkage design and or damper linkage is optional Air flow control dampers may be operated with pneumatic or electric actuator controllers Prior to occupancy test the ventilation system to ensure that the outdoor air dampers operate properly in accordance with the system design Back Draft Dampers for Dual Fans The counterbalance is locked into place for shipping as shown in Figure 4 on page 17 Before startup the counterbalance will have to be released To do this loosen the set screws and slide the counterbalance off the end of the shaft Flip the counterbalance and slide it back on the shaft Rotate the counterbalanc
131. wo or more sections maximum KW per sq ft should be calculated as follows Heater nameplate KW Number of heated sections x area of one heated section 44 SECTION 2 START UP AND OPERATION AIR FLOW REQUIREMENTS Calculate KW per square foot of duct area as heater namplate KW duct area Sq Ft 16 T EEE EEE EE EE EEE 12 fi Ff 11110 11117 HHHH AEE HE A 10 11111111141 11111 x lt LL ES SS IS ISI Ei LL nn nn l T mA 2 CONSTRUCTION ILE VLLL LL ILI LL LIA ZL 0 100 20 MINIMUM AIR VELOCITY REQUIRED FEET PER MINUTE see step 12 KW PER SQ FT DUCT AREA E rH H SRE lI ER l lll lll BREED CAREER Hott LLL LLL 14 4 OPEN COIL CONSTRUCTION TTA jl j j j LL LL m LL 1111111111 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 LL N SEI N E NM BE EN a E u MINIMUM AIR VELOCITY REQUIRED FEET PER MINUTE FIGURE 30 MINIMUM AIR VELOCITY REQUIRED FOR SAFE OPERATION Starting The

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