Attachment #7 - City Of Peterborough

Transcript

Attachment #7 Art Gallery of Peterborough Mechanical Upgrades and Interior Alterations Art Gallery of Peterborough Mechanical Upgrades and Interior Alterations Art Gallery of Peterborough Mechanical Upgrades and Interior Alterations Art Gallery of Peterborough Mechanical Upgrades and Interior Alterations Art Gallery of Peterborough Mechanical Upgrades and Interior Alterations T-15-15 – Attachment 3 - Specifications Section 09001 – Room Finish Schedule Addendum 1 Page 1 Part 1 - General 1.1 General Requirements .1 1.2 Conform to Sections of Division 1 as applicable. Related Sections .1 Architectural Woodwork – Section 06400 .2 Resilient Flooring – Section 09650 .3 Painting and Finishing – Section 09900 .4 Resinous High-Build Epoxy Floor Coating – Section 09910 Part 2 - Products 2.1 2.2 2.3 Materials .1 For materials refer to specification sections. .2 Colour selection to be confirmed with successful bidder. Legend .1 EC Epoxy Coating .2 EX Existing .3 GWB Gypsum Wall Board .4 PT Paint .5 RC Rubber Base .6 VCT Vinyl Composite Tile .7 WD Wood Room Finish Schedule The Ventin Group (Toronto) Limited, Architects +VG Job 21498 T-15-15 – Attachment 3 - Specifications Section 09001 – Room Finish Schedule The Ventin Group (Toronto) Limited, Architects Addendum 1 Page 2 +VG Job 21498 T-15-15 – Attachment 3 - Specifications Section 09001 – Room Finish Schedule 2.4 Addendum 1 Page 3 Colour Selection .1 Epoxy Coating; Stonkote GS4 110, 111 & 112; Silver Gray .2 Paint; Dulux/Glidden; 115; Glidden Ultra Interior Latex, Flat White 94500 C01, C02, 110, 111, 112&307; Eggshell Tulle White 50BG72/006 A1996 Ramps; Tulle White, Flat 50BG71/006 A1996 211, 213; Dulux – Eggshell Shasta 60YY 39/654 2.5 .3 Plastic Laminate; Formica Citadel 1097-MC microdot .4 Rubber Base; Johnsonite 20 Charcoal. .5 Vinyl Composite Tile; Flextile, Flexthrough Plus; FT 173, White Cloud. Paint Colour Schedule PT-1; Flat White 94500 PT-2A; Tulle White – flat PT-2B; Tulle White – eggshell PT-3; Ceiling White - flat PT-4; Shasta – eggshell End of Section The Ventin Group (Toronto) Limited, Architects +VG Job 21498 T-15-15 – Attachment 3 - Specifications Section 15258 – Insulation - Ductwork Addendum 1 Page 1 Part 1 - General 1.1 1.2 Work Included .1 Duct thermal insulation .2 Duct acoustic insulation .3 Recovering Quality Assurance .1 1.3 All workers engaged in the application of insulation shall be journeymen, or indentured apprentices working under a journeyman who is on the site. Job Conditions .1 Deliver material to job site in original nonbroken factory packaging, labeled with manufacturer's density and thickness. .2 Perform work at ambient and equipment temperatures as recommended by the adhesive manufacturer. Make good separation of joints or cracking of insulation due to thermal movement or poor workmanship. Part 2 - Products 2.1 2.2 General .1 Adhesives, Insulation, Coatings, Sealers and Recovering Jackets shall have composite fire and smoke hazard ratings not exceeding 25 for flame spread and 50 for smoke developed. .2 Adhesives, coatings and sealers shall be waterproof. Thermal Duct Insulation .1 Insulation shall be precovered, preformed insulation complete with foil or kraft all purpose jacket unless otherwise noted. .2 Use 25 millimeter (1 inch) thick insulation unless otherwise noted .3 Exposed Rectangular Ducts: Rigid fibrous glass insulation, "K" value at 0.24 b.t.u. per inch per square foot per degree Fahrenheit per hour with factory applied reinforced aluminum foil vapour barrier. .4 Round Ducts and Concealed Rectangular Ducts: Flexible fibrous glass insulation, "K" value at 0.26 b.t.u. per inch per square foot per degree Durham Energy Specialist Limited DES Job 13-625 T-15-15 – Attachment 3 - Specifications Section 15258 – Insulation - Ductwork Addendum 1 Page 2 Fahrenheit per hour with factory applied reinforced aluminum foil vapour barrier. 2.3 .5 Recovering Jackets (Interior): U.L.C. listed "Thermo Canvas", treated cotton fabric. .6 Acceptable Manufacturers: .1 Fibreglass Canada .2 Knauf .3 Mason Acoustic Duct Insulation .1 Fiberglass insulation with "K" value at 0.26 b.t.u. per inch per square foot per degree Fahrenheit per hour absolute roughness of exposed surface not to exceed 0.033 millimeters coated to prevent fibre erosion at air velocities up to 400 f.p.m. .2 All substrate material to be non-darkened, contrasting colour from liner layer. .3 Use 25 millimeter (1 inch) thick insulation unless otherwise noted. Part 3 - Execution 3.1 3.2 3.3 Preparation .1 Do not install covering before ductwork and equipment has been tested and approved. .2 Ensure surface is clean and dry prior to installation. Ensure insulation is dry before and during application. Finish with systems at operating conditions. Installation - General .1 In non fire rated surfaces, ensure insulation is continuous through inside walls. Pack around ducts with fireproof self-supporting insulation material properly sealed. .2 Finish insulation neatly at hangers, supports and other protrusions. .3 Locate insulation or cover seams in least visible locations. Thermal Duct Insulation .1 Provide insulation on: Durham Energy Specialist Limited DES Job 13-625 T-15-15 – Attachment 3 - Specifications Section 15258 – Insulation - Ductwork 3.4 .1 All supply air ductwork. .2 Exhaust air ductwork within 2.4 meters (8 feet) of insulated surface penetration .3 Combustion air ductwork in Mechanical Room. .2 Exposed Rectangular Ducts: Secure rigid insulation with 50 percent coverage of adhesive and 12 gauge galvanized impale anchor tabs on 400 millimeter (16 inch) centres. Seal joints with 100 millimeter (4 inch) wide foil tape. .3 Round Ducts and Concealed Rectangular Ducts: Adhere flexible insulation to ductwork with adhesive applied in 150 millimeter (6 inch) wide strips on 400 millimeter (16 inch) centres. Provide 16 gauge annealed tie wire, or polypropylene twine, spiral wound or half hitched at 100 millimeter (4 inch) centres for securing duct insulation until adhesive sets. Butt insulation and seal joints and breaks with 100 millimeter (4 inch) foil tape. Acoustic Duct Insulation .1 3.5 Addendum 1 Page 3 Apply to interior of: .1 First 3 meters (10 feet) of supply and return ducts on inlet and discharge of all air handling units including but not limited to A.H.U., F.C.U., and E.F. .2 Transfer ducts and elbows. .3 As indicated on drawings or as otherwise noted. .2 Secure to ductwork with adhesive using 50 percent coverage and 12 gauge impale anchor tabs on 400 millimeter (16 inch) centres. Cut off excess fastener length and cover with brush coat of sealer. .3 Shop fabrication cuts shall be coated with J.M.’s SuperSeal Duct Butter and Edge Treatment products Canvas Recovering Jacket .1 Provide recovering jackets on exposed insulation throughout including but not limited to Mechanical Rooms. .2 Coat recovering jacket with two coats of waterproof fire retardant coating. End of Section Durham Energy Specialist Limited DES Job 13-625 2146423 Peterborough Art Gallery Reno February 12, 2015 GENERAL Daikin - McQuay Custom Vision air handling unit is ARI certified. CASING Casing is fabricated from 16 gauge nominal channel posts and panels secured with mechanical fasteners. All panels, access doors, and ship sections are sealed with bulb-type gasket. Panel deflection does not exceed L/240 at 125% of design static pressure, minimum +/- 5”. Deflection is measured at the midpoint of the panel height. The casing leakage rate will not exceed 0.5 cfm per square foot of cabinet area at 6 inches of negative static pressure or 5 inches of positive static pressure Panels and access doors are constructed as a 2-inch (50-mm) nominal thick, thermal broke double wall assembly, injected with foam insulation for an Rvalue of not less than R-13. The inner liner shall be constructed of G90 galvanized (AHU-1&2) solid stainless steel (in cooling and humidification sections). Exterior casing and structure is fabricated from G60 galvanized steel, phosphatized and painted with baked on enamel. Access doors are flush mounted to the cabinetry and secured with heavyduty stainless steel hinges. The door latch handle assembly is provided with a full-size grip handle and roller pall for smooth operation. The assembly is gasketed and sealed to prevent thermal bridging. . All access doors open against pressure. Inspection windows are on each fan access door. Lights are provided in all fan access sections. Drain pans are constructed from stainless steel with cross break and pitch to drain connection. Drain pans are provided under cooling coil section and humidifier section. Unit has a factory installed 4 (AHU-2) and 8 (AHU-1) inch high formed galvanized channel base rail. Floor plate is constructed from aluminum tread plate .125 inch thick. COILS Access to coils is from connection side of unit for service and cleaning. Coil headers and return bends are fully enclosed within unit casing. Coil connections, vents and drains are fabricated to extend beyond unit casing. Grommets are provided for an airtight casing. Coils are removable through side panels and/or top panels of unit without removal and disassembly of entire section. Drain pan is located underneath and extending downstream of the coil and intermediate drain pans. The pan is stainless steel. Coil performance is as per schedule and data is certified in accordance with ARI Standard 410, where applicable. Coil construction is: Tubes: Fins: Headers: Casing: Copper Aluminum mechanically bonded to tubes Seamless copper with vent and drain connections 16 gauge, galvanized steel (Heating) stainless steel (cooling) Water cooling and heating coils are circuited drainable with a vent connection at the highest point and a drain connection at the lowest point. Coil headers are copper with steel male pipe connections. Refrigerant cooling coils are designed for use with Refrigerant R-410A. Sweat type copper suction connections are located at the bottom of the suction headers for gravity oil drainage. Multiple circuited coils are interlaced. DX coils are matched to their respective condensing units. FILTERS Filter box section has filter guides, hinged and latching access doors onone side for side loading of filters. Filter media is UL 900 listed, Class I or Class II. Filter is Flat arrangement with: 2” MERV 8 Prefliter - Pleated 2” Carbon Filters 4” MERV 15 Cartridge. FANS Fans are forward curved or air foil, as scheduled. They are dynamically balanced before and after installation in fan cabinet section. RPM is below the first critical speed of the fan. ACCESS Access sections as shown. Access doors are constructed from galvanized steel for flush mounting, with gasket, latch and handle assembly. Ball or roller bearings are self-aligning, grease lubricated, with extended copper lubrication lines located on the access side of unit. Grease fittings are attached to fan base assembly near access door. HUMIDIFIER SECTION – AHU-1 Only Units are supplied with a cabinet section with stainless steel drain pan. Humdidifier grid is field installed in supply duct above unit. Fan and motor are located internally on a steel base. The motor is factory mounted on a slide base that can be slid out of the unit. Motor, drive and bearings are accessible through hinged access doors. Fan and motor assembly ismounted on 2" deflection spring vibration isolators inside cabinet. UNIT ELECTRICAL Units are supplied with a factory mounted and wired junction boxes for each fan motor. Lights are provided in all fan access sections. Lights are wired to an ONBEARINGS & DRIVES Bearing load rating is computed in accordance with AFBMA - ANSI Standards. Bearings are rated for L-50 life at 400,000 hours and are heavyduty pillow block type with self-aligning, grease-lubricated ball bearings. Shaft is ground and polished, constructed from solid hot rolled steel and protectively coated with lubricating oil. All motors 7 1/2 HP and lower use variable pitch sheaves. Larger motors utilize constant pitch sheaves with V-belt drive for a service factor of 1.25. Motors are open drip proof premium efficiency. OFF switch mounted on the outside of the cabinet. Interconnecting wiring between split sections must be completed on site by the installing contractor. WARRANTY The warranty period commences at the date of initial startup and continues for a period of one (1) year not to exceed eighteen (18) months from shipment. Manufacturer's warranty includes parts only. Manufacturer's warranty does not include maintenance during the warranty period. Proper preventative maintenance is required. HTS Oshawa 2001 Thickson Rd, South Unit #11 Whitby, ON L1N 6J3 T 905.579.6700 F 905.597.5290 ontario.htseng.com SUBMITTAL DATA APPROVAL REQUIRED AIR HANDLING UNIT AHU-1 – GALLERY, VAULT AND STORAGE TECHNICAL INFORMATION AND DRAWINGS NOTES: 1.) Fan motor requires a 208/3/60 electrical feed. Motors are VFD rated. VFD is by others. 2.) Light in fan section requires a 120/1/60 electrical feed. 3.) Unit is sectioned to allow installation into mechanical room. 4.) Carbon filters are not shipped with unit, and will be provided separately and installed at the time of start up. HTS. Delivering Real Success.® Custom Air Handling Unit Job Information Technical Data Sheet Job Name Date Submitted By Software Version Unit Tag 2146423 Peterborough ArtGallery Reno February 12 2015 DR 10.32 AHU-1 Gallery-Storage and Vault Unit Overview Supply Air Volume Model Number Static Pressure External Total cfm CAH014GBDM 5725 Height External Dimensions Width inWc inWc in in in 1.25 4.47 50* 60* 154 Length *Not including base rails, coil connectors, drain connectors and control boxes. Unit Model Number: Approval: Outer Panel: Liner: Insulation: Unit Configuration: Base: Tread Plate Floor Liner: Parts Warranty: Plenum Section CAH014GBDM ETL Listed / ETL Listed to Canadian Safety Standards (ETL Label / ETLc Label) Painted heavy-gauge G60 Galvanized Steel Galvanized Steel (unless noted per section) R-13 Injected Foam Drive (Handling) Location: Right Inline horizontal Wall Thickness: 2 in 8" formed channel Tread plate installed (unless Altitude: 0 ft noted per section) Standard One Year Component: 1 Length: 20 in Shipping Section: 1 Air Pressure Drop 0.04 inWc Custom Openings Custom Opening Location Width Height Rainhood w/Screen 1 2 3 Top Top End 36 in 10 in 16 in 16 in 16 in 16 in None None None Door Location Width Opening Drive side 16 in Outward Page 1 of 7 www.DaikinApplied.com Custom Air Handling Unit Panel Filter Component: 2 Type Pleated Length: 14 in Efficiency Face Velocity Face Area MERV 8 412 ft/min 13.9 ft² Clean Air Air Pressure Drop Mean Air Dirty Air 0.19 inWc 0.59 inWc 1.00 inWc Shipping Section: 2 Air Volume Filter Loading 5725 cfm Side Number of Filters Height Width Depth 2 2 24 in 20 in 24 in 24 in 4 in 4 in Door Location Width Opening Drive side 10 in Outward Special Options Special Text Extra filters 1 set(s) Intersept Antimicrobial treatment Manual Component Component: 3 Length: 16 in Shipping Section: 3 Pressure Drop 0.00 inWc Door Location Width Opening Drive side 12 in Outward Page 2 of 7 www.DaikinApplied.com Custom Air Handling Unit Supply Fan Component: 4 Length: 34 in Shipping Section: 4 Fan Performance Air Volume External Static Pressure Total Cabinet Brake Horsepower 5725 cfm 1.25 inWc 4.47 inWc 0.00 inWc Fan Type Blade Type / Class Quantity of Fans Centrifugal Plenum Airfoil / 2 1 Speed Outlet Velocity Operating Maximum 6.54 BHP 2536 rpm 2930 rpm Wheel Diameter Material Type Number of Blades Discharge Motor Location 18.25 in Aluminium 9 Axial To Side of Fan 0 ft/min Fan Data Motor Data Power Electrical Supply Speed Efficiency Enclosure Frame Size Supplier Number of Poles Lock Rotor Current Full Load Current 7.5 HP 200/60/3 1750 rpm Premium ODP 213 T frame Generic 4 162.4 A 22.2 A V/Hz/Phase Fan Options Wheel Guard: Inlet Screen: Provided Provided Belt Guard: Isolator Type: Provided Spring Drive Package Data* Fan Sheave Motor Sheave Belt Number of Belts Actual Drive S.F. Bearing Type AK59H AK84H A66 1 1.13 Extended - L50 (400K) *Daikin Applied reserves the right to provide a different but equivalent drive package VFD/Starter/Disconnect Data Selection Type: Voltage: Mounting: External J-Box 200 V Door Side Vendor: Height x Width x Depth: Enclosure: Factory Standard 4.00 in x 6.00 in x 6.00 in NEMA 1 Door Location Width Opening Window Type Light Drive side 18 in Outward Round Marine light kit and switch only Manual Component Component: 5 Length: 12 in Shipping Section: 5 Pressure Drop 0.00 inWc Door Location Width Opening Drive side 8 in Outward Page 3 of 7 www.DaikinApplied.com Custom Air Handling Unit Combination Filter Component: 6 Access Side Portion Pre-Filter Filter Type Length: 14 in Face Velocity Face Area 412 ft/min 13.9 ft² Clean Air Air Pressure Drop Mean Air Dirty Air CARBON 0.29 inWc 0.65 inWc 1.00 inWc Varicel II MH MERV 15 cartridge 0.60 inWc 1.05 inWc 1.50 inWc Carbon Filter Shipping Section: 6 Efficiency Air Volume 5725 cfm Number of Filters Height Width Depth 2 2 2 2 24 in 20 in 24 in 20 in 24 in 24 in 24 in 24 in 2 in 2 in 4 in 4 in Door Location Drive side Width Opening 10 in Outward Special Options Special Text Page 4 of 7 www.DaikinApplied.com Custom Air Handling Unit Combination Coil Component: 7 Length: 24 in Shipping Section: 7 Direct Expansion Coil Coil Model Total Capacity 5EJ1006B 222276 Btu/hr Air Volume Sensible Capacity Number of Coils 143509 Btu/hr 1 Number of Rows 6 Air Temperature 5725 cfm Entering Dry Bulb Wet Bulb Leaving Dry Bulb Wet Bulb 78.0 °F 55.1 °F 66.5 °F 0.72 inWc Suction Temp. Refrigerant Sub-Cooled Refrigerant Liquid Temp. 46.0 °F R410a 110.0 °F Type Liquid OD Sweat 2-0.88 in Connection Quantity Suction Size 2 2-1.63 in Tube Diameter Tube Spacing (Face x Row) 0.625 in 1.50 in x 1.299 in 10 Coil Air Pressure Drop 53.8 °F Fluid Fins per Inch Finned Height Finned Length Face Area Face Velocity 39 in 47 in 12.73 ft² 450 ft/min Suction Vapor Superheat Temp. at Coil Outlet Design Saturated Condensing Temp. 8.0 °F 110.0 °F Location Material Min. Fin Surface Temp. Min. Tube Wall Surface Temp. Drive side Copper tube 32.0 °F 32.0 °F Material Fin Tube Header Case Aluminum .0075 in Copper .020 in Copper Stainless steel Drain Pan Drain Side Stainless steel Drive side Component performance shown is based on the component air volume shown. Static pressure shown is based on the component air volume shown. AHRI 410 Certification Coil is NOT certified by AHRI Reheat Hot Water Coil Coil Model Total Capacity Number of Coils Number of Rows Fins per Inch Tube Diameter Tube Spacing (Face x Row) 5WB0701B 82354 Btu/hr 1 1 7 0.625 in 3.00 in x 1.299 in Air Volume Air Temperature Entering Leaving Dry Bulb Dry Bulb 5725 cfm 57.0 °F Water Entering Leaving 160.0 °F 139.8 °F Coil Air Pressure Drop Finned Height Finned Length Face Area Face Velocity 0.07 inWc 39 in 44 in 11.92 ft² 480 ft/min 70.2 °F Flow Rate Pressure Drop Velocity Volume 8.10 gpm 0.40 ftHd 1.20 ft/s 2.0 gal Type Quantity Connection Size Threaded 2 1.50 in Location Drive side Weight 24.00 lb Min. Tube Wall Surface Temp. Fouling Factor Material Min. Fin Surface Temp. Carbon steel 139.8 °F 139.8 °F 0.000 Material Fin Tube Header Case Aluminum .0075 in Copper .020 in Copper Galvanized track Component performance shown is based on the component air volume shown. Static pressure shown is based on the component air volume shown. AHRI 410 Certification Certified in accordance with the AHRI Forced-Circulation Air-Cooling and Air-Heating Coils Certification Program which is based on AHRI Standard 410 within the Range of Standard Rating Conditions listed in Table 1 of the Standard. Certified units may be found in the AHRI Directory at www.ahridirectory.org Special Options Liner Stainless Steel Page 5 of 7 www.DaikinApplied.com Custom Air Handling Unit Plenum Section Component: 8 Length: 20 in Drip Pan Stainless steel drip pan Shipping Section: 8 Drip Side Air Pressure Drop Drive side 0.10 inWc Custom Openings Custom Opening Location Width Height Rainhood w/Screen 1 Top 40 in 16 in None Door Location Width Opening Drive side 16 in Outward Special Options Liner Stainless Steel Unit Sound Power (dB) Type Radiated: Unit Discharge: Unit Return: 63 Hz 125 Hz 250 Hz 500 Hz 1000 Hz 2000 Hz 4000 Hz 8000 Hz 76 81 78 76 76 76 71 75 80 80 80 93 68 73 75 59 68 74 47 60 73 39 50 67 Shipping Section Details Section Length in Weight lb P1 Corner Weights (lb) P2 P3 1 2 3 4 5 6 7 8 20 14 16 34 12 14 24 20 343 289 264 948 236 311 762 306 86 72 66 326 59 78 217 77 86 72 66 226 59 78 192 77 Entire Unit 154 3459 897 791 P4 XX Center of Gravity (in) YY ZZ 86 72 66 162 59 78 166 77 86 72 66 234 59 78 187 77 10 7 8 14 6 7 11 10 30 30 30 25 30 30 28 30 29 29 29 26 29 29 29 29 831 942 79 28 28 NOTE: Special components aren't included in the corner weights and center of gravity data. Page 6 of 7 www.DaikinApplied.com Custom Air Handling Unit AHRI Certification Supply fan performance is certified in accordance with the Central Station Air-Handling Unit Certification Program, which is based on AHRI Standard 430. Notes Standard 1. As a standalone component, unit meets or exceeds requirements of ASHRAE 90.1 - 2007. The approving authority is responsible for compliance of multi-component building systems. Page 7 of 7 www.DaikinApplied.com HTS Oshawa 2001 Thickson Rd, South Unit #11 Whitby, ON L1N 6J3 T 905.579.6700 F 905.597.5290 ontario.htseng.com SUBMITTAL DATA APPROVAL REQUIRED AIR HANDLING UNIT AHU-2 – HOUSE TECHNICAL INFORMATION AND DRAWINGS NOTES: 1.) Fan motor requires a 208/3/60 electrical feed. Motors are VFD rated. VFD is by others. 2.) Light in fan section requires a 120/1/60 electrical feed. 3.) Unit is sectioned to allow installation into mechanical room. HTS. Delivering Real Success.® Custom Air Handling Unit Job Information Technical Data Sheet Job Name Date Submitted By Software Version Unit Tag 2146423 Peterborough ArtGallery Reno February 12 2015 DR 10.32 AHU-2 House Unit Overview Supply Air Volume Model Number cfm CAH008GDAC 3500 Static Pressure External Total Height External Dimensions Width inWc inWc in in in 1.00 2.64 34* 58* 64** Length *Not including base rails, coil connectors, drain connectors and control boxes. **Total lower deck length. Unit Model Number: Approval: Outer Panel: Liner: Insulation: Unit Configuration: Base: Tread Plate Floor Liner: Parts Warranty: Plenum Section CAH008GDAC ETL Listed / ETL Listed to Canadian Safety Standards (ETL Label / ETLc Label) Painted heavy-gauge G60 Galvanized Steel Galvanized Steel (unless noted per section) R-13 Injected Foam Drive (Handling) Location: Right Stacked / vertical Wall Thickness: 2 in 4" formed channel Tread plate installed (unless Altitude: 0 ft noted per section) Standard One Year Component: 1 Length: 14 in Shipping Section: 1 Opening Location Opening Size Air Pressure Drop Top 10.00" x 54.00" 0.05 inWc Location Width Opening Drive side 10 in Outward Door Page 1 of 4 www.DaikinApplied.com Custom Air Handling Unit Panel Filter Component: 2 Type Pleated Length: 12 in Efficiency Face Velocity Face Area MERV 8 397 ft/min 8.8 ft² Clean Air Air Pressure Drop Mean Air Dirty Air 0.28 inWc 0.64 inWc 1.00 inWc Shipping Section: 1 Air Volume Filter Loading 3500 cfm Side Number of Filters Height Width Depth 1 1 1 24 in 24 in 24 in 24 in 20 in 12 in 2 in 2 in 2 in Door Location Width Opening Drive side 8 in Outward Special Options Special Text Extra filters 1 set(s) Intersept Antimicrobial treatment Direct Expansion Coil Component: 3 Coil Model Total Capacity 5EJ1106B 141804 Btu/hr Air Volume 3500 cfm Length: 20 in Sensible Capacity Number of Coils 95054 Btu/hr 1 Number of Rows Entering Dry Bulb Wet Bulb Leaving Dry Bulb Wet Bulb 80.0 °F 55.2 °F Fluid Fins per Inch 6 Air Temperature 67.0 °F Shipping Section: 2 53.8 °F Tube Diameter Tube Spacing (Face x Row) 0.625 in 1.50 in x 1.299 in 11 Coil Air Pressure Drop Finned Height Finned Length Face Area Face Velocity 0.81 insWg 24 in 45 in 7.50 ft² 467 ft/min Suction Temp. Refrigerant Sub-Cooled Refrigerant Liquid Temp. Suction Vapor Superheat Temp. at Coil Outlet Design Saturated Condensing Temp. 46.0 °F R410a 110.0 °F 8.0 °F 110.0 °F Type Liquid OD Sweat 2-0.88 in Connection Quantity Suction Size 2 2-1.63 in Location Material Min. Fin Surface Temp. Min. Tube Wall Surface Temp. Drive side Copper tube 32.0 °F 32.0 °F Material Fin Tube Header Case Aluminum .0075 in Copper .020 in Copper Stainless steel Drain Pan Drain Side Stainless steel Drive side AHRI 410 Certification Coil is NOT certified by AHRI Special Options Liner Stainless Steel Access Section Component: 4 Length: 16 in Shipping Section: 3 Air Pressure Drop 0.00 inWc Door Location Width Opening Drive side 12 in Outward Special Options Liner Stainless Steel Page 2 of 4 www.DaikinApplied.com Custom Air Handling Unit Access Section Component: 5 Length: 16 in Shipping Section: 4 Air Pressure Drop 0.00 inWc Door Location Width Opening Drive side 12 in Outward Supply Fan Component: 6 Length: 36 in Shipping Section: 5 Fan Performance Air Volume 3500 cfm External Static Pressure Total Cabinet Brake Horsepower 1.00 inWc 2.64 inWc 0.00 inWc Speed 3.53 BHP Outlet Velocity Operating Maximum 1813 rpm 2518 rpm 3333 ft/min Fan Data Fan Type Blade Type / Class Quantity of Fans Wheel Diameter Number of Blades Discharge Motor Location 1 10.62 in N/A Top horizontal To Side of Fan Centrifugal DWDI Forward Curved / 2 Motor Data Power Electrical Supply Speed Efficiency Enclosure Frame Size Supplier Number of Poles Lock Rotor Current Full Load Current 5.0 HP 200/60/3 1750 rpm Premium ODP 184 T frame Generic 4 122.7 A 15 A V/Hz/Phase Fan Options Isolator Type: Spring Drive Package Data* Fan Sheave Motor Sheave Belt Number of Belts Actual Drive S.F. Bearing Type AK59H AK61H A30 1 1.12 Extended - L50 (500K) *Daikin Applied reserves the right to provide a different but equivalent drive package VFD/Starter/Disconnect Data Selection Type: Voltage: Mounting: External J-Box 200 V Door Side Vendor: Height x Width x Depth: Enclosure: Factory Standard 4.00 in x 6.00 in x 6.00 in NEMA 1 Door Location Width Opening Window Type Light Drive side 20 in Outward Round Marine light kit and switch only Plenum Section Component: 7 Length: 12 in Shipping Section: 6 Opening Location Opening Size Air Pressure Drop End upper 8.00" x 54.00" 0.01 inWc Location Width Opening Drive side 8 in Outward Door Unit Sound Power (dB) Type Radiated: Unit Discharge: Unit Return: 63 Hz 125 Hz 250 Hz 500 Hz 1000 Hz 2000 Hz 4000 Hz 8000 Hz 73 80 78 81 83 81 68 77 73 64 76 72 63 76 71 57 76 71 44 73 66 40 70 61 Page 3 of 4 www.DaikinApplied.com Custom Air Handling Unit Shipping Section Details Section 1 2 3 4 5 6 Entire Unit Length in Weight lb P1 Corner Weights (lb) P2 P3 26 20 16 16 36 12 286 418 177 226 639 208 68 111 44 57 182 52 68 98 44 57 136 52 64 1954 n/a n/a P4 XX Center of Gravity (in) YY ZZ 75 98 44 57 137 52 75 111 44 57 183 52 14 10 8 8 18 6 29 27 29 29 25 29 19 19 19 19 17 19 n/a n/a n/a n/a n/a Lower level only NOTE: Special components aren't included in the corner weights and center of gravity data. AHRI Certification Supply fan performance is certified in accordance with the Central Station Air-Handling Unit Certification Program, which is based on AHRI Standard 430. Notes Standard 1. As a standalone component, unit meets or exceeds requirements of ASHRAE 90.1 - 2007. The approving authority is responsible for compliance of multi-component building systems. Page 4 of 4 www.DaikinApplied.com HTS Oshawa 2001 Thickson Rd, South Unit #11 Whitby, ON L1N 6J3 T 905.579.6700 F 905.597.5290 ontario.htseng.com SUBMITTAL DATA APPROVAL REQUIRED AIR HANDLING UNIT INSTALLATION AND OPERATIONS MANUALS NOTES: HTS. Delivering Real Success.® Installation and Maintenance Manual IM 672-10 Group: Applied Air Systems Part Number: IM 672 Date: March 2014 Vision™ Air Handler Models CAC/CAH 003—090 C TABLE OF CONTENTS TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 37 Receiving and Handling . . . . . . . . . . . . . . . . . . . . . . . 3 Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Unit Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . 5 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Service Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Service and Warranty Procedure . . . . . . . . . . . . . . . 48 Unit Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Assembling Sections . . . . . . . . . . . . . . . . . . . . . . . . . 8 Warranty Return Material Procedure . . . . . . . . . . . . 48 Panels, Frame Channels, and Doors . . . . . . . . . . . . 13 Check, Test, and Start Procedure Form . . . . . . . . . 49 Multizone Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 16 Quality Assurance Survey Report . . . . . . . . . . . . . . 51 Duct Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Piping and Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Internal Isolation Assembly Adjustment . . . . . . . . . . 23 OSHPD Seismic Anchoring/Mounting . . . . . . . . . . . . 26 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . 27 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Startup Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 VFD Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Fan Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Fan Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . 29 Fan Array. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Optional Piezometer Ring $LUÀRZ0HDVXUHPHQW'HYLFH . . . . . . . . . . . . . . . . . . 34 Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Fan Vibration Levels . . . . . . . . . . . . . . . . . . . . . . . . . 36 IM 672-10 • VISION AIR HANDLING UNIT  ZZZ'DLNLQ$SSOLHGFRP INTRODUCTION INTRODUCTION General Information Receiving and Handling Vision®LQGRRUDLUKDQGOHUVDUHQRWGHVLJQHGWREHZHDWKHU 1. Carefully check items against the bills of lading to verify all crates and cartons have been received. Carefully inspect all units for shipping damage. Report damage LPPHGLDWHO\WRWKHFDUULHUDQG¿OHDFODLP resistant. Do not install them outdoors. 7KHV\VWHPGHVLJQDQGLQVWDOODWLRQPXVWIROORZDFFHSWHG industry practice as described in the ASHRAE Handbook, the National Electric Code, and other applicable standards. This HTXLSPHQWPXVWEHLQVWDOOHGLQDFFRUGDQFHZLWKUHJXODWLRQVRI authorities having jurisdiction and all applicable codes. 2. Vision air handler units are constructed of galvanized or painted steel and are inspected thoroughly before leaving the factory. Take care during installation to prevent damage to units. ,QVWDOODWLRQDQGPDLQWHQDQFHPXVWEHSHUIRUPHGE\TXDOL¿HG SHUVRQQHOIDPLOLDUZLWKDSSOLFDEOHFRGHVDQGUHJXODWLRQVDQG H[SHULHQFHGZLWKWKLVW\SHRIHTXLSPHQW6KHHWPHWDOSDUWV VHOIWDSSLQJVFUHZVFOLSVDQGVXFKLWHPVLQKHUHQWO\KDYH sharp edges; the installer should exercise caution. 3. 7DNHVSHFLDOFDUHZKHQKDQGOLQJWKHEORZHUVHFWLRQ$OO fans are dynamically balanced before leaving the factory. Rough handling can cause misalignment or a damaged bearings or shaft. Carefully inspect fans and shaft before unit installation to verify this has not happened. CAUTION 4. +DQGOHWKH]RQHGDPSHURIWKHPXOWL]RQHXQLWVZLWK special care. Zone dampers are set and inspected before leaving the factory, but should be checked on arrival to the job to verify the bell arm and connecting rod set VFUHZVGLGQRWEHFRPHORRVHLQVKLSPHQW Sharp edges and coil surfaces are a potential injury hazard. $YRLGFRQWDFWZLWKWKHP Nomenclature CAH 003 G D A C Model CAH = Custom modular air handler CAC = Custom modular component Unit cross section C = Standard unit cross section M = Custom size cross section Nominal unit size (cataloged size—nominal square foot of coil) 003, 004, 006, 008, 010, 012, 014, 017, 021, 025, 030, 035, 040, 050, 065, 080, 085, 090 Vintage Motor location A = Motor along side of fan housing ' 0RWRUGRZQVWUHDPRIEHOWGULYHSOHQXPIDQ F = Motor on inline fan * 0RWRUGRZQVWUHDPRIGLUHFWGULYHSOHQXPIDQ + 0RWRUGRZQVWUHDPRIIDQDUUD\ 7 0RWRUEHKLQGWZLQIDQKRXVLQJ Unit type/coil position % %ORZWKURXJKFRROLQJFRLOORFDWLRQ ' 'UDZWKURXJKFRROLQJFRLOORFDWLRQ H = Heating only V = Vent only M = Multizone ZZZ'DLNLQ$SSOLHGFRP  ,0‡9,6,21$,5+$1'/,1*81,7 INTRODUCTION Unit Storage • 6WRUHRQDOHYHOVXUIDFHLQDFOHDQGU\ORFDWLRQZKHUH temperature can be controlled if possible. Belt-Driven fans • Reduce belt tension by at least 50% or remove the belts. 5HPRYHEHOWVLIWKH\ZLOOEHVXEMHFWHGWRWHPSHUDWXUHV exceeding 85° F to avoid deterioration. • Pack fan and motor bearings (unless motor bearings are VHDOHG ZLWKFRPSDWLEOHJUHDVHZLWKWKHVKDIWVWDWLRQDU\ After grease has been installed, rotate shaft about 10 rotations. • 5HPRYHEHOWJXDUGZKHQDGMXVWLQJEHOWV • Isolate unit from shock and vibration. • Reduce belt tension prior to removing or installing belts. • Once a month, rotate shaft a minimum of 10 revolutions. Insure the stopped position is different than the original position. • Removing or installing tensioned belts may cause personal injury and damage to the sheaves, belts, bearings or shafts. • &RDWVKDIWVZLWKOXEULFDQWDVQHHGHGWRSUHYHQWFRUURVLRQ • $GMXVWDEOHVKHDYHVVKRXOGEHRSHQHGDVZLGHDV possible and the adjustment threads lubricated so they do not corrode. Be careful not to put lubricant on the belt running surface • A descant bag may be hung in the interior of the unit to minimize corrosion in humid storage environments. Do QRWFOHDQJDOYDQL]HGVWHHOVXUIDFHVZLWKRLOGLVVROYLQJ chemicals. This may remove the protective coating and accelerate corrosion. Prior to start up • 6HWVFUHZVRQEHDULQJVIDQZKHHOVDQGVKHDYHVQHHGWR be checked for proper torque. Also check bolt torque for DQ\WDSHUORFNKXEVHLWKHURQWKHZKHHORUVKHDYHV • 'RQRWDOORZFRYHULQJVWRWUDSPRLVWXUHRQJDOYDQL]HG surfaces. • &KHFNVKHDYHVIRUFRUURVLRQ6LJQL¿FDQWFRUURVLRQFDQ cause belt or sheave failure. • 3XUJHROGJUHDVHIURPIDQEHDULQJVZKLOHURWDWLQJWKH VKDIWWRGLVWULEXWHWKHQHZJUHDVHHYHQO\DQGSUHYHQW bearing seal failure. • Correctly align and tension belts. See General Rules of Tensioning on page 42. IM 672-10 • VISION AIR HANDLING UNIT  ZZZ'DLNLQ$SSOLHGFRP MECHANICAL INSTALLATION MECHANICAL INSTALLATION Service Clearances Figure 1: Servicing Space Requirements In addition to providing adequate space around the unit for piping coils and drains, access to at least one side of the unit LVDOZD\VUHTXLUHGWRDOORZIRUUHJXODUVHUYLFHDQGURXWLQH PDLQWHQDQFHZKLFKLQFOXGHV¿OWHUUHSODFHPHQWGUDLQSDQ inspection and cleaning, fan bearing lubrication, and belt DGMXVWPHQW3URYLGHVXI¿FLHQWVSDFH²DWOHDVWHTXDOWRWKH length of the coil—on the side of the unit for shaft removal and coil removal. Space, at least equal to the length of the side coil, is required for coil removal. Space, at least equal to the ¿QKHLJKWLVUHTXLUHGIRUWRSFRLOUHPRYDO6HHFigure 1 for servicing space requirements. 4 .0 0 " b a s e r a il e x te n s io n W id th 3 0 .0 0 " W id th o f c o il s e c tio n 4 .0 0 " W id th o f fa n s e c tio n For routine maintenance purposes, access normally is obtained WKURXJKWKHDFFHVVGRRUVRUE\UHPRYLQJSDQHOV)DQDQG¿OWHU VHFWLRQVDUHDOZD\VSURYLGHGZLWKDVHUYLFHGRRURQRQHVLGHRI the unit. If requested, doors can be provided on both sides of the unit. Optional service doors are available for most section types and are provided based on customer request. If component replacement is required, the top panel also can be removed. If necessary, the unit can be disassembled. 0DLQWDLQDWOHDVWRIFOHDUDQFHLQIURQWRIHOHFWULFDOSRZHU GHYLFHVVWDUWHUV9)'VGLVFRQQHFWVZLWFKHVDQGFRPELQDWLRQ GHYLFHV (OHFWULFDOSRZHUGHYLFHVWKDWDUHPRXQWHGRQWKHVLGH of the unit typically are up to 12" deep (Figure 2). Fan sections ZLWKPXOWLSOHIDQVKDYHPRWRUFRQWUROER[HVXSWRGHHS ZKHQVXSSOLHGZLWK9)'V 3 0 .0 0 " H e ig h t Figure 2: Service Clearance for Electrical Power Devices 1 2 " 5 4 " ZZZ'DLNLQ$SSOLHGFRP  ,0‡9,6,21$,5+$1'/,1*81,7 MECHANICAL INSTALLATION Rigging WARNING Figure 4: Units on Skids Use all lifting points. Improper lifting can cause severe personal injury and property damage. CAUTION Lifting points may not be symmetrical to the center of gravity of the unit. Ballast or unequal cable lengths maybe required. DANGER DO NOT LIFT FROM 2" HOLES AT ENDS OF UNIT. Failure to comply may result in personal injury or death. Vision air handlers ship as separate sections, completely assembled, or in modules of assembled sections. The unit must be rigged as it ships from the factory. Do not rig units DIWHUDVVHPEO\:KHQDXQLWLVSURYLGHGZLWKDIDFWRU\LQVWDOOHG base rail, it can be lifted using the 2" diameter lifting holes located in the corners of each shipping section (Figure 3). If a unit does not have a base rail, rig it using straps or a sling. )DVWHQWKHVWUDSSLQJXQGHUWKHVNLGWKDWVKLSVZLWKWKHVHFWLRQ (Figure 4). To prevent damage to the unit cabinetry, use spreader bars. Position spreader bars to prevent cables from rubbing the frame or panels. Before hoisting into position, test lift for stability and EDODQFH$YRLGWZLVWLQJRUXQHYHQOLIWLQJRIWKHXQLW A fan array or coil section might have a tall, thin aspect ratio. The center of balance on these sections can be high and make the section prone to tipping during the lift. Care should be WDNHQZKHQOLIWLQJXQLWVZLWKDWDOOWKLQDVSHFWUDWLR )DQVHFWLRQVJUHDWHUWKDQZLGHWKDWDUHVWDFNHG on another section that are not Class II plenum fans are FRQVWUXFWHGZLWKLQWHUQDOIDQVXSSRUWIUDPHVWKDWKDYHLQWHJUDO lifting brackets (Figure 5). After the fan section is placed in position, remove and discard the lifting brackets. Install the VPDOOSDQHOVSURYLGHGWRFRPSOHWHWKHXQLWFDELQHWDUHDVZKHUH WKHOLIWLQJEUDFNHWVZHUHORFDWHG Figure 5: Large Fan Sections Stacked on Top of a Lower Section Figure 3: Units on Base Rails R e m o v e liftin g b ra c k e ts (4 ) In s ta ll p a n e ls ( 4 ) IM 672-10 • VISION AIR HANDLING UNIT  ZZZ'DLNLQ$SSOLHGFRP MECHANICAL INSTALLATION Class II plenum fans that are stacked on another section may EHOLIWHGXVLQJWKHPHWKRGVVKRZQLQWKHIROORZLQJ¿JXUHV7KH shipping brackets must remain in place and be tight in order to lift using this method. Figure 6VKRZVDEHOWGULYHIDQZLWK¿HOG VXSSOLHGH\HEROWVWKDWDUHVFUHZHGLQWRIDFWRU\LQVWDOOHGKH[ AVK fasteners in the main channels supporting the fan. Figure 7VKRZVDGLUHFWGULYHIDQZLWK¿HOGVXSSOLHGH\HEROWVRQWKH motor end and straps around the spring bracket on the inlet end. When factory installed hex AVK fasteners are installed, they should be used for lifting. When they are not installed, it is acceptable to lift from the shipping brackets on the fan. Figure 8VKRZVGXDOIDQVEHLQJOLIWHGLQDVLPLODUPDQQHUDVWKHVLQJOH direct-drive fan. An eight point lift must be used for dual fans to make sure both fans are supported properly and the cabinet structure does not become overloaded along the center. Figure 7: Direct-Drive Class II Plenum Fan Stacked Unit If the fan section is connected to another section such as a plenum or access section, then DO NOT attempt to lift both sections using just the fan section. The other section(s) must be supported separately using straps. Figure 6: Belt-Drive Class II Plenum Fan Stacked Unit Figure 8: Direct-Drive Class II Dual Plenum Fan Stacked Unit ZZZ'DLNLQ$SSOLHGFRP  ,0‡9,6,21$,5+$1'/,1*81,7 MECHANICAL INSTALLATION Unit Leveling Assembling Sections 3ODFHWKHHTXLSPHQWRQDÀDWDQGOHYHOVXUIDFH:KHUHWKH surface irregularities could cause the equipment to distort, use a shim so the base of the unit is a straight line. Uneven RUGLVWRUWHGVHFWLRQVFDXVHPLV¿WRUELQGLQJRIWKHGRRUVDQG panels and improper draining of drain pans. Units that are over ZLGHPXVWUHVWRQDÀDWVXUIDFHIRUWKHHQWLUHZLGWKRIWKH base rails or must be shimmed at one or more points along the length of the rails to prevent distortion or sagging of the support rails (Figure 9). Figure 9: Leveling the Unit External Section-to-Section Mounting Vision air handling units can ship fully assembled or as VHSDUDWHVKLSSLQJVHFWLRQV5LJXQLWVWKDWUHTXLUH¿HOG DVVHPEO\RIVKLSSLQJVHFWLRQVLQWRSRVLWLRQ¿UVW6KLSSLQJ VHFWLRQVDUHSURYLGHGZLWKDFRQQHFWLRQVSOLFHMRLQWDWWDFKHGRQ the leaving air side of the shipping section. The splice joint is LQVXODWHGDQGSURYLGHVDQDLUWLJKWVHDOEHWZHHQWZRVHFWLRQV RQFHWKH\DUHDVVHPEOHGWRJHWKHU,IWKHVSOLFHMRLQWZDVEHQW during shipping or rigging, restore it to its original position. (Figure 19 on page 12). +RUL]RQWDO$LUÀRZ6HFWLRQ0RXQWLQJ 1. Rig the unit into position and lineup shipping sections in WKHGLUHFWLRQRIDLUÀRZ3XOOVHFWLRQVWRJHWKHUWRIDVWHQ Use a furniture clamp or straps and a ratchet to help pull the sections together securely (Figure 10). 2. ,IWKHXQLWKDVDIDFWRU\LQVWDOOHGEDVHUDLO¿UVWIDVWHQ base rails together using the 3/8"-16 × 5" bolts located in WKHVSOLFHNLWSURYLGHGZLWKWKHXQLW a. 7RIDVWHQWZRVKLSSLQJVHFWLRQVWRJHWKHUIRXUEROWV DUHQHHGHGWZRRQHDFKVLGHRIWKHXQLW 7KH bolts are run from one base rail into the other and IDVWHQHGZLWKDQXW&RPSOHWHHDFKVHFWLRQERWWRP and top before attaching additional sections. S h im s e c tio n s u n til th e y a r e s tr a ig h t a n d le v e l 3. If no base rail is provided, fasten the unit in the same manner on the bottom and top frame channels. S h im to p r e v e n t d is to r tio n if w id th is o v e r 1 0 8 " 4. Once the sections are positioned together, remove the fastener in each of the channel corners (on the mating edges in the channel piece). 5. 3ODFHDÀDWVHFWLRQMRLQLQJSODWHIRXQGLQWKHVSOLFHNLW  RYHUWKHWZRFRQHGKROHVLQWKHFKDQQHOVVRWKDWWKH SODWHVSDQVWKHWZRVHFWLRQV 6. Replace the fasteners in their original position, through the joining plate. 7. For certain Custom Air Handler units, use the provided section joining plates to fasten sections together. Space WKHPDVVKRZQLQFigure 11. Using the provided ¼"-14 x VHOIWDSSLQJVFUHZVGULOOVFUHZWKHMRLQLQJSODWHVLQWR the frame channel on each section, keeping unit sections WLJKWWRJHWKHU)ROORZLQVWUXFWLRQGUDZLQJLQFOXGHGLQWKH assembly kit. IM 672-10 • VISION AIR HANDLING UNIT  ZZZ'DLNLQ$SSOLHGFRP MECHANICAL INSTALLATION 9HUWLFDO,QYHUWHG$LUÀRZ6HFWLRQ Mounting Figure 10: Horizontal Joining Sections T o p For vertical or inverted arrangements, before lifting any top mounting sections into place, rig into place and fasten together the bottom tier of sections. Once bottom level sections are in place and secured, lift stacked components and fasten using WKHIROORZLQJSURFHGXUH NOTE: See Face and Bypass Section Mounting on page 14 for the exception to this procedure. B o tto m 1. The vertical/inverted section has a splice joint extending RXWWKHWRSRIWKHERWWRPMRLQLQJVHFWLRQ/RZHUWKH section that is to be positioned over the opening over WKHVSOLFHMRLQWWRVHDOWKHFRQQHFWLRQEHWZHHQWKHWZR sections. w ith b a s e r a il 2. 7KHWZRVHFWLRQVDUHIDVWHQHGWRJHWKHUDWWKHIRXU bottom corners of the mating edge. To fasten the corners ORFDWHGRQWKHHQGRIWKHXQLWZKHUHERWWRPVHFWLRQDQG WRSVHFWLRQZDOOVDUHÀXVKZLWKHDFKRWKHU UHPRYHWKH ÀDWKHDGIDVWHQHUVLQWKHFRUQHUVRIERWKVHFWLRQV 3. &RYHUWKHFRQHGKROHVZLWKDÀDWMRLQLQJSODWHDQG UHSODFHWKHÀDWKHDGIDVWHQHUVLQWKHKROHVWRVHFXUHWKH joining plate to both sections (Figure 12). 4. When one section is deeper than the other, secure the WZRVHFWLRQVXVLQJDQ/VKDSHGMRLQLQJSODWH7RVHFXUH WKH/VKDSHGEUDFNHWUHPRYHWKHÀDWKHDGIDVWHQHU from the corner, position the bracket over the hole, and UHSODFHWKHÀDWKHDGIDVWHQHUZLWKDîEROW Once the bolt is in place, secure the bracket to the DGMRLQLQJVHFWLRQZLWKDîGULOOVFUHZ5HSHDWWKH same procedure on both corners of the unit (Figure 12). Figure 11: Frame Channel Stiffener Plates (Custom Air Handler Units Only) Figure 12: Vertical/Inverted Joining Sections .2 5 x 1 0 0 d r ill s c r e w .3 1 2 -1 8 x 1 0 0 b o lt B B A A R e p la c e m e n t s c r e w ZZZ'DLNLQ$SSOLHGFRP  ,0‡9,6,21$,5+$1'/,1*81,7 MECHANICAL INSTALLATION Extended Coil Section Mounting 6LGHE\6LGH+HDWZKHHO6HFWLRQ-RLQLQJ 7KHH[WHQGHGFRLOVHFWLRQLVZLGHUWKDQDOORWKHUVHFWLRQVRI WKHVDPHXQLWVL]H7KHH[WHQVLRQLVDOZD\VORFDWHGRQWKHFRLO connection side of the unit. Because the extended coil section LVZLGHUWKDQRWKHUVHFWLRQVLWDOZD\VVKLSVDVDVHSDUDWH shipping section, and must be joined to other sections in the ¿HOG7RMRLQDQH[WHQGHGFRLOVHFWLRQWRRWKHUFRPSRQHQWV¿UVW IROORZWKH+RUL]RQWDO$LUÀRZ6HFWLRQ0RXQWLQJÃSDJHVWHSVWR secure the opposite connection side. To fasten the connection VLGHXVHWKHIROORZLQJSURFHGXUH 7KHVLGHE\VLGHKHDWZKHHOZLOOKDYHWZRLQGLYLGXDOVHFWLRQV SDUDOOHOLQWKHGLUHFWLRQRIDLUÀRZWREHDWWDFKHGWRHLWKHUVLGH (DFKVHFWLRQZLOODWWDFKWRWKHKHDWZKHHOVHFWLRQDQGWKHQWR the other parallel section. 1. If the unit has a factory-installed base rail, the extended FRLOVHFWLRQEDVHUDLOLVDOVRZLGHUWKDQWKHDGMRLQLQJ base rail. Extended coil section base rails on the connection side are fastened together using the 3/8"-16 E\EROWVORFDWHGLQVSOLFHNLWSURYLGHGZLWKWKHXQLW (Figure 13). 1. Rig the unit into position and line shipping sections up in GLUHFWLRQRIDLUÀRZ6HFWLRQVPXVWEHSXOOHGWRJHWKHUWR fasten using a furniture clamp or straps. a. ,IWKHKHDWZKHHOVHFWLRQZLGWKLVJUHDWHUWKDQ WKHQULJWKHVHFWLRQLQWRSRVLWLRQXVLQJWKHWZR removable lifting channels. After section is properly placed, remove cotter pin and bolts from lifting channel and discard as seen in Figure 14 Figure 14: Cotter Pin and Bolt Detail 2. If no base rail is provided, the section is fastened in the same manner on the bottom and top. Once the sections are positioned together, remove the fastener in the corner of the channel piece of the section mating to the extended coil section (Figure 13). 3. Place an L-shaped section joining plate (located in the splice kit) over the coned hole in the channel. 4. 5HSODFHWKHÀDWKHDGIDVWHQHURULJLQDOO\XVHGLQWKH FRUQHUZLWKDEROWDQGIDVWHQLWWKURXJKWKH L-shaped joining plate. 5. Position the L-shaped joining plate so it butts up against the extended coil section frame channel. To secure WKHSODWHWRWKHH[WHQGHGFRLOVHFWLRQUXQWZRî GULOOVFUHZVWKURXJKWKHMRLQLQJSODWHDQGLQWRWKHIUDPH channel. 2. If included, remove center base plates that are attached to the base channels and save for Step 4. Figure 13: Extended Coil Section Joining 3. If the unit has a factory installed base rail, fasten the base rails together using the 3/8"-16 × 5" bolts located in WKHVSOLFHNLWSURYLGHGZLWKWKHXQLW T o p V ie w A a. 7RIDVWHQWZRVKLSSLQJVHFWLRQVWRJHWKHUWZR bolts are required on the one side. The bolts are run from one base rail into the other and fastened ZLWKDQXW&RPSOHWHHDFKVHFWLRQERWWRPDQGWRS before attaching additional sections. (2 ) 1 /4 x 1 D r ill S c r e w s B o tto m w ith b a s e r a il 4. $VVHPEOHWKHFHQWHUEDVHSODWHVDVVKRZLQFigure 15, OHDYLQJDVSDFHEHWZHHQHDFKSODWHWRVOLGHRQWR VHFWLRQEDVHFKDQQHOVWRFHQWHUSRLQWRIVHFWLRQZLGWK A 5. Once the sections are positioned together, remove the fastener in each of the channel corners (on the mating edges in the channel piece). 6. 3ODFHDÀDWVHFWLRQMRLQLQJSODWHIRXQGLQWKHVSOLFHNLW  RYHUWKHWZRFRQHGKROHVLQWKHFKDQQHOVVRWKHSODWH VSDQVWKHWZRVHFWLRQV IM 672-10 • VISION AIR HANDLING UNIT 10 ZZZ'DLNLQ$SSOLHGFRP MECHANICAL INSTALLATION Figure 17: Frame Channel Detail Figure 15: Base Plate Detail Internal Section-to-Section Mounting 7. Replace the fasteners in their original position, through the joining plate. If desired, shipping sections can be fastened together LQWHUQDOO\7RIDVWHQLQWHUQDOO\UXQ¿HOGSURYLGHGVKHHW PHWDOVFUHZVRUGULOOVFUHZVORQJPD[LPXP WKURXJKWKH interior frame channel of one unit into the splice joint of the neighboring section. 8. Assemble the next section parallel to the assembled VHFWLRQE\IROORZLQJ6WHSV±DERYH 9. 8VLQJWKHîEROWVSURYLGHGIDVWHQWKHWZR parallel sections’ bases together as seen in Figure 16. 10. Using appropriate safety equipment if necessary, remove the fastener in each of the channel corners on the top EHWZHHQWKHWZRSDUDOOHOVHFWLRQVDQGGLVFDUG 11. 8VHWKHîKROHGVSOLFHSODWHZLWKîî VFUHZVDQGîóGULOOVFUHZV7KHîî VFUHZVZLOOJRLQWRWKHIUDPHFKDQQHOKROHVDQGWKHî óGULOOVFUHZVZLOOJRLQWRWKHKHDWZKHHOIUDPHFKDQQHO DVVKRZLQFigure 17. For Custom Air Handler units, ensure that the D-gasket is attached to the entering air side frame channel (Figure 18). If it has dislodged during shipping, restore to original location. Figure 18: D-Gasket Placement Detail (Custom Air Handler Units only) Figure 16: Base Section Detail ZZZ'DLNLQ$SSOLHGFRP 7KHVHFWLRQWRVHFWLRQVSOLFHMRLQWLVDOZD\VSURYLGHGRQWKH leaving air side of a shipping section and seals against the frame channel on the entering-air side of the adjoining section. Align the splice joint to seat into the mating gasket to provide an DLUVHDO,IWKHVSOLFHMRLQWZDVEHQWGXULQJVKLSSLQJRUULJJLQJ restore it to its original position (Figure 19).  IM 672-10 • VISION AIR HANDLING UNIT MECHANICAL INSTALLATION Figure 19: Internal Fastening Ceiling Hung Using Angle Iron Channel ,QVWDOO¿HOGSURYLGHGDQJOHLURQRUFKDQQHOVSHU60$&1$ guidelines. When a unit is unitized (ships in one piece), channel VXSSRUWHDFKFRPSRQHQWXQGHUWKHXQLWZLGWKFigure 21). NOTE: The supporting angle iron must fully support the 2" frame channel at each section joint. When a unit is sectionalized (ships in multiple sections), FKDQQHOVXSSRUWHDFKFRPSRQHQWXQGHUWKHXQLWZLGWKDQG provide support under the full length of the unit base (Figure 22 /RFDWHKDQJHUURGVVRWKH\GRQRWLQWHUIHUHZLWKDFFHVV into the unit. Ceiling suspension using the unit base rails is limited WRXQLWFDELQHWZLGWKVOHVVWKDQ".6XSSRUWXQLWVZLWK FDELQHWVZLGHDQGJUHDWHUZLWKVWUXFWXUDOPHPEHUV designed to support the unit at the ends and at intermediate points along the base rails. Ceiling Hung Figure 21: Ceiling Suspended w/o Base Rail— Unitized Construction :KHQDXQLWLVFHLOLQJKXQJVXSSRUWLWZLWKDEDVHUDLODQJOH iron, or channel. The Vision air handler is not designed to be suspended from the top of the unit. Before hanging, rig and completely assemble the unit. See Assembling Sections on page 8. Ceiling Hung Using Base Rail The optional base rail provided by the factory has 5/8" diameter holes in each corner to run hanger rods through. To properly support the unit and maintain unit integrity, support each VKLSSLQJVHFWLRQZLWKKDQJHUURGVLQHDFKFRUQHUFigure 20). Figure 20: Ceiling Suspended with Base Rail Figure 22: Ceiling Suspended w/o Base Rail— Modular Construction IM 672-10 • VISION AIR HANDLING UNIT 12 ZZZ'DLNLQ$SSOLHGFRP MECHANICAL INSTALLATION Panels, Frame Channels, and Doors Panel Removal Fan Section Doors 7RUHPRYHDVLGHRUWRSSDQHOUHPRYHWKHÀDWKHDG7RU[ fasteners along the sides of the panel. Lift off the panel after removing all fasteners. CAUTION Sharp edges and coil surfaces are a potential injury hazard. $YRLGFRQWDFWZLWKWKHP Frame Channel Removal Frame channels that run the length of the unit along the top FDQEHUHPRYHGWRDOORZDFFHVVWRERWKWKHVLGHDQGWRSRI WKHXQLW7RUHPRYHWKHIUDPHFKDQQHO¿UVWUHPRYHWKHVLGH SDQHOV 2QFHWKHVLGHSDQHOLVRIIUHPRYHWKHÀDWKHDG7RU[ 30 fasteners in the corner of the frame channels. Then pull the IUDPHFKDQQHORXWWKHVLGH5HPRYHDQ\SDQHOVFUHZVWKDWDUH ZLWKLQRQHLQFKRIWKHRIWKHIUDPHVLQFHWKH\DUHHQJDJHGLQWR WKHJDVNHWHGÀDQJHRIWKHIUDPHFigure 23). NOTE: Opening fan section doors requires using a 1/2" VRFNHWZUHQFKFigure 24 ZKLFKVDWLV¿HV$16, standards and other codes that require the “use of tools” to access compartments containing moving SDUWVRUHOHFWULFDOZLULQJ Figure 24: Opening Fan Section Door Figure 23: Removing Panel Screws R e m o v e a n y p a n e l s c re w s th a t e n g a g e fra m e R e m o v e p a n e l to re m o v e fra m e ZZZ'DLNLQ$SSOLHGFRP  IM 672-10 • VISION AIR HANDLING UNIT MECHANICAL INSTALLATION Injected-Foam Insulated Panels 9LVLRQDLUKDQGOHUVDUHIXUQLVKHGZLWKGRXEOHZDOOLQMHFWHG foam insulated panels. Foam panels are stronger, more rigid, DQGOLJKWHUWKDQSDQHOVZLWK¿EHUJODVVLQVXODWLRQ7KHLQVXODWLRQ 5YDOXHLVLPSURYHGWR+RZHYHUIRDPLQVXODWLRQFDQEXUQ ZKHQH[SRVHGWRÀDPHRURWKHULJQLWLRQVRXUFHVDQGUHOHDVH WR[LFIXPHV7DNHFDUHLQFXWWLQJDQGVHDOLQJDOO¿HOGFXW openings in these panels. Panel Cutting Procedure WARNING Flame and smoke can cause equipment damage, severe personal injury, or death. Before operating unit, seal all piping and ZLULQJKROHVRQERWKLQQHUDQGRXWHUSDQHOV ZLWKDQLQGXVWULDOJUDGHVLOLFRQHVHDODQWRU duct seal compound. Do not use a cutting WRUFK RU H[SRVH SDQHO WR ¿UH Panel damage can occur. 1. Determine the number and location of holes required for HOHFWULFDOFRQGXLWSLSLQJDQGFRQWUROZLULQJDVIROORZV (also refer to Figure 25): )LHOG0RXQWLQJ-XQFWLRQ%R[HVDQG Other Components )RU¿HOGPRXQWLQJîRUVPDOOHUMXQFWLRQER[HVWRWKH standard panel exterior, use a minimum quantity of four, 3/16" GLDPHWHUSRSULYHWV'2127XVHVHOIWDSSLQJGULOOVFUHZV 7KH\ZLOOQRWWLJKWHQQRUVHFXUHSURSHUO\DQGSDQHOGDPDJH can occur. If larger, heavier components require mounting on unit panels, XVHWKURXJKEROWVZLWKÀDWZDVKHUVWKURXJKERWKRXWHUDQG LQQHUSDQHOV7RPDLQWDLQSDQHOLQWHJULW\VHDOERWKHQGVZLWK an industrial/commercial grade silicone sealant or duct seal compound. The unit frame channel is another excellent location for VHFXULQJKHDYLHUFRPSRQHQWVVHOIWDSSLQJVFUHZVDUHQRW acceptable. Ensure that the location permits the full operation RIDOODFFHVVGRRUVDQGSDQHOVDQGGRHVQRWLQWHUIHUHZLWK other vital components. Face and Bypass Section Mounting Internal face and bypass, and external face and bypass for sizes 003 to 035 are mounted together using the instructions for horizontal components and do not require additional instruction. a. Check that adequate space is available inside the unit for conduit or pipe routing. For all size units that bypass directly into a vertical fan section DQGIRUVL]HVWRZLWKH[WHUQDOIDFHDQGE\SDVVXVHWKH IROORZLQJLQVWUXFWLRQV b. Do not locate holes in a panel that provides access WRNH\PDLQWHQDQFHFRPSRQHQWVVXFKDV¿OWHUV and fan assemblies. Figure 26: Assembly of Fan Coil Sections Joining collar c. 'RQRWORFDWHZKHUHWKHFRQGXLWRUSLSLQJEORFNV DLUÀRZRUREVWUXFWVKLQJHGDFFHVVGRRUV 2. Once a proper location is determined, drill a small pilot hole completely through the panel. Then use a sharp KROHVDZRUDVDEHUVDZDQGFXWIURPHDFKVLGHRIWKH panel. 3. 6HDOWKHGRXEOHZDOOSDQHORQHDFKVLGHZLWKDQ industrial/ commercial grade silicone sealant or duct seal compound. It is extremely important to seal each panel hole or penetration securely so that it is airtight, ZDWHUWLJKWDQGWKDWWKHUHLVQRH[SRVHGIRDPLQVXODWLRQ Figure 25: Cutting/Sealing Injected-Foam Insulated panels Seal completely with silicone sealant or duct seal compound Cut hole from both sides of panel Prop 65—Substances in fuel or from fuel combustion can cause personal injury or death, and are known to the State of California to cause cancer, birth defects or other reproductive harm. IM 672-10 • VISION AIR HANDLING UNIT 14 ZZZ'DLNLQ$SSOLHGFRP MECHANICAL INSTALLATION Bypass Into a Vertical Fan Section 9HUWLFDOFRLOVHFWLRQVDQGWKHWRSPRXQWHGIDQVHFWLRQDOZD\V ship separately and must be mounted together at the job site. The vertical coil section and the bypass duct each has a joining collar mounted on the leaving air side of the section and duct, respectively (Figure 26 7KHPRXQWLQJFROODU¿WVLQWRWKHVLGH (bypass) and bottom (vertical coil section) openings in the fan section. To correctly position the collars in the fan openings, DVVHPEOHWKHIDQDQGFRLOVHFWLRQ¿UVW8VHWKHVWHSVEHORZIRU assembly. 1. Place the vertical coil section in position. If an access VHFWLRQLVSRVLWLRQHGGRZQVWUHDPIURPWKHFRLOVHFWLRQ and not already assembled to the coil section, secure the WZRVHFWLRQVWRJHWKHU 2. Lift the fan section on top of the vertical coil section, taking care to line up the joining collar in the bottom of the fan section. 3. For sizes 003 to 035, the bypass duct is integral to the unit construction and does not require attachment to the bypass section. For sizes 040 to 090, position and assemble the bypass duct to the bypass section before joining to the fan. External Face and Bypass Duct Assembly (Sizes 040 to 090) :KHQXQLWVL]HVWRDUHRUGHUHGZLWKH[WHUQDOIDFH and bypass, the bypass duct ships separately and must be DWWDFKHGWRWKHXQLWLQWKH¿HOG7KHMRLQLQJRIWKHE\SDVVGXFW to the unit must be done after the unit is assembled. Also, if the bypass duct is over 90" long, the duct does not ship in one SLHFHDQGPXVWEH¿HOGDVVHPEOHG7KH¿HOGDVVHPEO\RIWKH E\SDVVGXFWWRWKHXQLWUHTXLUHVWKHIROORZLQJVWHSVDOVRUHIHU to Figure 27). 1. Position the unit shipping sections together and assemble in the equipment room. 2. After the unit is assembled, lift the duct into position over the unit. Joining collars are shipped factory assembled to the unit and duct. There is a joining collar located in the top of the bypass opening and in the leaving air side of the bypass duct. These joining collars are used to SURYLGHDLUVHDOV/LQHXSWKHGXFWZLWKWKHWRSRSHQLQJV in the unit. 3. If the bypass duct is longer than 90", the duct ships in PRUHWKDQRQHSLHFHDQGPXVWEH¿HOGDVVHPEOHG3ODFH the piece of duct that has the joining collar on the bottom RQWRSRIWKHXQLW¿UVW2QFHLWLVLQSODFHSRVLWLRQWKH RWKHUSLHFHRIGXFW7DNHFDUHWR¿WWKHVSOLFHFROODULQWR WKH¿UVWSLHFHRIGXFWDQGWKHQORZHUWKHRWKHUHQGLQWR the bypass opening. 4. Once the fan is positioned on top of the vertical coil section and the bypass duct and bypass section are DVVHPEOHGSRVLWLRQWKHWZRDVVHPEOLHVDQGOLQHXSWKH MRLQLQJFROODUVZLWKWKHRSHQLQJVLQWKHIDQDQGYHUWLFDO coil section. 4. Once the duct is positioned correctly, fasten the duct SLHFHVWRJHWKHUZLWKWKHMRLQLQJSODWHSURYLGHG7RGR this, remove the fasteners in the corners of the duct assemblies, place the plate over the holes in the corners, and then replace the fasteners (Figure 10 on page 9). 5. Once the sections are lined up and in position, secure the unit together by fastening joining plates to the unit. Figure 27: Assembly of Bypass Duct to Unit ZZZ'DLNLQ$SSOLHGFRP  IM 672-10 • VISION AIR HANDLING UNIT MECHANICAL INSTALLATION Multizone Assembly The multizone section may ship completely assembled or it may ship in numerous pieces. Whether the section ships in a single piece or multiple pieces depends on customer requirements and the unit size. When a multizone section is RYHUKLJKRUZLGHVSOLWLWLQWRVHFWLRQVIRUVKLSSLQJ The unit may ship in 1, 2, 3, 4, or 5 separate pieces, see Figure 29. Typically, the multizone damper assembly ships separately (see Multizone Damper Assembly and Figure 29) and must be attached at the job site. Attach the damper after the other FRPSRQHQWVDUHDVVHPEOHG8VHWKHLQVWUXFWLRQVEHORZIRU assembling the multizone section (also refer to Figure 29). Multizone Damper Assembly :KHQDPXOWL]RQHXQLWLVRUGHUHGZLWKGDPSHUVGHSHQGLQJ RQWKHPXOWL]RQHFRQ¿JXUDWLRQDQGVL]HWKHGDPSHUDVVHPEO\ PD\VKLSVHSDUDWHO\DOOKRUL]RQWDODQGXQLWVZLWKDWRWDOKHLJKW over 90"). When the dampers are not factory assembled to the unit, they VKLSWRWKHMREVLWHRQDVNLG$QDVVHPEO\NLWZLWKVFUHZVDQG DQLQVWUXFWLRQGUDZLQJDUHLQFOXGHGZLWKWKHGDPSHUIRU¿HOG assembly to the unit. To assemble: 1. If the diffuser and the cold deck section ship separately, MRLQWKHPWRJHWKHU¿UVW7KHMRLQLQJFROODUPRXQWHGLQWKH GLIIXVHU¿WVLQWRWKHHQWHULQJDLUVLGHRIWKHFRLOVHFWLRQ /LQHXSWKHWZRVHFWLRQVDQGIDVWHQWRJHWKHU 1. First remove the side plate that encloses insulation from both sides of the damper assembly. 2. Lift the damper assembly into position (Figure 29). 3. )DVWHQWKHDVVHPEO\WRWKHIUDPHFKDQQHOVZLWKLQWKH multizone openings. 2. Once the diffuser and cold deck sections are joined, lift the hot deck and bypass sections in place on top of the diffuser/ cold deck section. If possible, assemble the hot deck and bypass section (if there is one) together EHIRUHOLIWLQJRQWRS7KHUHDOZD\VLVDMRLQLQJFROODULQ WKHGLIIXVHU7KHMRLQLQJFROODUSURYLGHVWKHVHDOEHWZHHQ WKHVHFWLRQVMRLQWV,WLVLPSRUWDQWWROLQHXSDQG¿WWKH collar in the hot deck and bypass section. For vertical applications, the cold deck also has a joining collar in the GLVFKDUJHRSHQLQJ7KLVFROODU¿WVLQWKHERWWRPRIWKH vertical bypass section. 3. $IWHUWKHFRPSRQHQWVLQWKHPXOWL]RQHDUH¿WWHGWRJHWKHU fasten the joining plates to the corners in the unit exterior. 4. Use caulking to seal up the areas around the unit frame channel to prevent any air leakage. 5. After caulking, put the side plates back in place and secure. Damper shaft extensions are provided on both ends of the damper assembly for actuation. The dampers are linked together by a linkage bar on both ends of the damper. The linkage bar is cut at the time of installation to divide the damper into the required number of zones (refer to Multizone Damper Adjustment on page 17). Figure 29: Multizone Damper Assembly 4. ,IDGDPSHUZDVRUGHUHGDVVHPEOHLWWRWKHVHFWLRQVHH Multizone Damper Assembly and Figure 29). D a m p b ro k e s h o w b a la n b e h in A ir flo w R ig h t h a n d c o il NOTE: Verify that the joining collars are aligned to seat into the gasket. Straighten any collars distorted from shipping or from rigging. e r b la n o u t a ir flo c e p la d th e m d e s to w te s . Figure 28: Multizone Sections Assembly Zone damper assembly Upper unit—heating (and optional bypass) Joining collars R e in c o to m o s u la v e r a llo v e a s s e tio n p a fro m d a w c a u lk m n e m in b ly l p e r g . D r ill s c r e w c a b in e t fr a w ith # 1 0 A d r ill s c r e w . If a ir flo w b a re p re s e n d a m p e rs s p la te s a r e o f e a c h z o in to m e B x .5 0 S e a l w ith c a u lk o n b o th s id e s . Diffuser a la n c e p t, th e n in o th a t th e o n th e b o n e . la te s s ta ll b a la n c e tto m 1 /4 A B x .5 0 O p e n d a m p e r b la d e s to a llo w fa s te n in g . Cooling coil IM 672-10 • VISION AIR HANDLING UNIT 16 ZZZ'DLNLQ$SSOLHGFRP MECHANICAL INSTALLATION Duct Connections 8VHÀH[LEOHFRQQHFWRUVRQWKHRXWOHWDQGLQOHWGXFWFRQQHFWLRQV of all units. Each zone divider has a W-shaped duct clip. Insert GXFWZRUNLQWRWKLVFOLSFigure 30). Figure 31: Bell Arms at 45° Angle to Vertical Center Z o n e d a m p e r lin k a g e C o n n . lin k 4 5 ° 4 5 ° Figure 30: Duct Connectors D u c t w o rk D u c t c lip B e ll a r m In s ta lla tio n m o d ific a tio n fo r m u ltip le z o n e s 4 5 ° 4 5 ° Z o n e d iv id e r NOTE: %HIRUHFRQQHFWLQJWRGXFWZRUNUHIHUWR0XOWL]RQH 'DPSHU$GMXVWPHQWEHORZ Multizone Damper Adjustment B e ll a r m The installer must clear the damper assemblies of construction dirt and debris. These materials result in higher torque requirements and may bend or damage damper components. Before you begin: 1. Verify that dampers are square and operating smoothly before ducting. 7RGLYLGHWKHGDPSHUVHFWLRQLQWRPXOWLSOH]RQHVFXWDQGUHPRYHVXI¿FLHQWFRQQHFWLQJOLQNWR DOORZDGMDFHQW]RQHVWRRSHUDWHLQGHSHQGHQWO\ NOTE: 7KHGDPSHUEODGHVRQWZRGHFNGDPSHUVVHDOWKURXJKVHYHUDOGHJUHHVRIVKDIW rotation.The damper blades can rotate 360° and do not engage a stop.The hot deck blades are mounted at a 90° to the cold deck blades. Beforeinstalling the zone duct, set up linkages and dampers and adjust. If adjustmentis required and access to the blades is restricted, observe the cold deck bladeposition by removing the cabinet panel on the coil section. 2. ,QVWDOOGXFWDFFHVVSDQHOVRQWKHGRZQVWUHDPGDPSHUIRU inspection and maintenance. If multizone dampers do not close properly, adjust the blades DVIROORZV 1. /RRVHQVHWVFUHZVLQEHOODUPVIRUDOO]RQHV 2. Close all cold deck dampers tightly. 3. Move bell arms so they are at a 45° angle to the vertical FHQWHUZKHQYLHZLQJWKH]RQHGDPSHUVIURPWKHFROG deck end of the damper section (Figure 31). a. 7ZRGHFN]RQHGDPSHUV²7KHFROGGHFNFORVHV ZKHQWKHEHOODUPVDUHƒIURPWKHYHUWLFDOFHQWHU 7KHKRWGHFNFORVHVZKHQWKHEHOODUPVDUHƒ FORFNZLVHIURPWKHYHUWLFDOFHQWHU b. Three-deck zone dampers—The cold deck closes ZKHQWKHEHOODUPVDUHƒFORFNZLVHIURPWKH YHUWLFDOFHQWHU7KHKRWGHFNFORVHVZKHQWKHEHOO DUPVDUHƒFRXQWHUFORFNZLVHIURPWKHYHUWLFDO center. 4. 7LJKWHQVHWVFUHZVRQEHOODUPVZKLOHKROGLQJWKH dampers closed. 5. All zone damper blades should close properly. If one or a IHZ]RQHVGRQRWFORVHFRPSOHWHO\UHSHDWWKHSURFHGXUH for these zones. ZZZ'DLNLQ$SSOLHGFRP  IM 672-10 • VISION AIR HANDLING UNIT MECHANICAL INSTALLATION Multizone, Mixing Box and Economizer Damper Torque Requirements On multizone units, the actuator must drive the connection link for proper damper actuation. Do not activate multiple dampers must from the shaft extension opposite the connection link. Mounting Actuators CAUTION Maximum damper rotation is 70°. Maximum shaft torque is 205 inches/pound. Greater rotation or torque can cause equipment damage. The installing contractor is responsible for the mounting of DOO¿HOGLQVWDOOHGDFWXDWRUV1RSURYLVLRQVDUHPDGHIRUWKH location of these actuators due to the number of options and DUUDQJHPHQWVDYDLODEOHDQGWKHYDULHW\RIVSHFL¿FDSSOLFDWLRQV Typically, actuators are mounted inside the cabinet. Provide proper support for the actuator to avoid excessive stress in the cabinet, linkage, or damper shafts. Fresh air and return air dampers can be linked together and driven from the same actuator if the dampers are the same size. If the dampers are different sizes, they must be driven by separate actuators and controlled appropriately. Exhaust GDPSHUVDUHDOZD\VGULYHQE\DVHSDUDWHDFWXDWRU A typical rotary electric actuator can handle up to 40 sq. ft. of GDPSHU)RUSQHXPDWLFDFWXDWRUVDOORZLQOESHUVTXDUHIRRW of damper area. Face Bypass Damper Torque Requirements Face and bypass dampers may or may not be linked together. When dampers are placed before a single bank of coils, they DOZD\VDUHOLQNHGWRJHWKHUDQGUHTXLUHDVLQJOHDFWXDWRU:KHQ dampers bypass a stacked or staggered coil, the dampers are not linked and require multiple actuators. Unit sizes 040 to 090 SURYLGHGZLWKH[WHUQDOIDFHDQGE\SDVVUHTXLUHWKUHHDFWXDWRUV 2WKHUDUUDQJHPHQWVZLWKVWDFNHGRUVWDJJHUHGFRLOVUHTXLUHWZR actuators. A damper shaft extension is provided. Normally, the shaft extension is located on the drive side of the unit, but it can be moved to the other side. Face and bypass dampers have a torque requirement of 10 in-lbs per square foot of damper face area. Isolation Dampers for Multiple Fans Optional isolation dampers can be provided on multiple fans WRSUHYHQWEDFNÀRZWKURXJKDIDQWKDWLVWXUQHGRIIIRUVHUYLFH These isolation dampers are not intended to be used to control ÀRZWKURXJKWKHIDQ7KHLVRODWLRQGDPSHUIRUDIDQWKDWLV going to be started must be positioned in the full open position EHIRUHWKHIDQLVVWDUWHG'RQRWVWDUWDIDQZLWKWKHGDPSHU ORFDWHGDWWKHLQOHWZLWKWKHGDPSHUIXOO\RUSDUWLDOO\FORVHG 7KLVFDQFDXVHDLUÀRZYLEUDWLRQDQGVRXQGSUREOHPVWKDWFDQ lead to failure. ,VRODWLRQGDPSHUVFDQEHSURYLGHGZLWKDFWXDWRUVWKDWDUH mounted in the airstream. Actuator sizing for the isolation dampers should be based on 9 in-lb per square foot of damper. IM 672-10 • VISION AIR HANDLING UNIT 18 ZZZ'DLNLQ$SSOLHGFRP MECHANICAL INSTALLATION Piping and Coils When designing and installing piping: Steam Coils • )ROORZDSSOLFDEOHSLSLQJGHVLJQVL]LQJDQGLQVWDOODWLRQ information in ASHRAE handbooks. Piping (see Figure 32) • $OOVWHDPFRLOVLQXQLWVDUHSLWFKHGWRZDUGUHWXUQ connection. • Observe all local codes and industry standards. • Do not apply undue stress at the connection to coil headers; DOZD\VXVHDEDFNXSSLSHZUHQFK • Steam supply and steam return connections typically are male NPT iron pipe and are labeled on the end panel of coil section. Connections extend through the coil section end panel. • 6XSSRUWSLSHZRUNLQGHSHQGHQWO\RIWKHFRLOV Water Cooling Coils • When installing couplings, do not apply undue stress to the connection extending through unit panel. Use DEDFNXSSLSHZUHQFKWRDYRLGEUHDNLQJWKHZHOG EHWZHHQFRLOFRQQHFWLRQDQGKHDGHU • :DWHUVXSSO\ZDWHUUHWXUQGUDLQDQGYHQWFRQQHFWLRQV extend through the end panel of the coil section. All connections are labeled on the end panel. • :DWHUVXSSO\DQGZDWHUUHWXUQFRQQHFWLRQVDUHW\SLFDOO\ male NPT iron pipe. • Support piping independently of coils and provide DGHTXDWHSLSLQJÀH[LELOLW\6WUHVVHVUHVXOWLQJIURP expansion of closely coupled piping can cause serious damage. • When installing couplings, do not apply undue stress to the connection extending through unit panel. Use DEDFNXSSLSHZUHQFKWRDYRLGEUHDNLQJWKHZHOG EHWZHHQFRLOFRQQHFWLRQDQGKHDGHU • Do not reduce pipe size at the coil return connection. Carry return connection size through the dirt pocket, making the reduction at the branch leading to the trap. • )ROORZUHFRPPHQGDWLRQVRIWKHFRQWUROPDQXIDFWXUHU regarding types, sizing, and installation of controls. Coils Direct Expansion Coils • The coil distributor and suction connection extend through the end panel of the coil section. • Check nozzle in distributor for proper tonnage. • :KHQD¿HOGVXSSOLHGWKHUPRVWDWLFH[SDQVLRQYDOYHLV used, it is located outside the unit and connected directly to the distributor. Do not apply heat to the body of the expansion valve. • The thermostatic expansion valve must be of the external equalizer tube type. Connect the 1/4" diameter external equalizer tube provided on the coil to connection on expansion valve. • Install vacuum breakers on all application to prevent retaining condensate in the coil. Generally, the vacuum EUHDNHULVFRQQHFWHGEHWZHHQWKHFRLOLQOHWDQGWKH return main. The vacuum breaker should be open to the DWPRVSKHUHDQGWKHWUDSGHVLJQVKRXOGDOORZYHQWLQJRI large quantities of air. • Do not drip supply mains through the coil. • 'RQRWDWWHPSWWROLIWFRQGHQVDWHZKHQXVLQJPRGXODWLQJ or on/off control. • 8VHFDUHZKHQSLSLQJWKHV\VWHPWRVHHWKDWDOOMRLQWVDUH tight and all lines are dry and free of foreign material. For typical refrigerant piping, see condensing unit product manual. ZZZ'DLNLQ$SSOLHGFRP  IM 672-10 • VISION AIR HANDLING UNIT MECHANICAL INSTALLATION Traps Valves • 6L]HWUDSVLQDFFRUGDQFHZLWKWKHPDQXIDFWXUHUV¶ recommendations. Make sure that the required pressure GLIIHUHQWLDOLVDOZD\VDYDLODEOH'RQRWXQGHUVL]H • Do not use modulating steam valves on high pressure systems. • 8VHÀRDWDQGWKHUPRVWDWLFRUEXFNHWWUDSVIRUORZ pressure steam. On high pressure steam, use bucket traps. Use thermostatic traps only for air venting. • )UHH]LQJFRQGLWLRQVHQWHULQJDLUWHPSHUDWXUHVEHORZ 35°F). • Properly size modulating valves. Do not undersize. • Use bucket traps for on/off control only. • Daikin strongly recommends 5JA, 8JA, 5RA and 8RA coils. • /RFDWHWUDSVDWOHDVWLQFKHVEHORZWKHFRLOUHWXUQ connection. • Supply 5 psi steam to coils at all times. • Do not use modulating valves. Provide control by face and bypass dampers. • Multiple coil installation • Individually trap each coil or group of coils that is controlled individually trapped. • &RQVLGHUXVLQJWZRRUWKUHHFRLOVLQVHULHVZLWKWZR position steam control valves on the coil or coils that handle 35°F or colder air. Use a modulating valve on the GRZQVWUHDPFRLOWRSURYLGHWKHGHVLUHGGHJUHHRIFRQWURO • Coils in series—use separate traps for each coil, or bank of coils. • Coils in parallel—a single trap can be used, but an individual trap for each coil is preferred. • Thoroughly mix fresh air and return air before it enters the coil. Also, to obtain true air mixture temperatures, properly locate temperature control elements. • 'RQRWDWWHPSWWROLIWFRQGHQVDWHZKHQXVLQJPRGXODWLQJ or on/off control. • As additional protection against freeze-up, install the WUDSVXI¿FLHQWO\EHORZWKHFRLOWRSURYLGHDQDGHTXDWH hydrostatic head to remove condensate during an interruption in the steam pressure. Estimate three feet for each 1 psi of trap differential required. • :LWKFRLOVDUUDQJHGIRUVHULHVDLUÀRZXVHDVHSDUDWH FRQWURORQHDFKEDQNRUFRLOLQWKHGLUHFWLRQRIDLUÀRZ • On startup, admit steam to coil ten minutes before admitting outdoor air. • Close fresh air dampers if steam supply pressure falls EHORZWKHPLQLPXPVSHFL¿HG IM 672-10 • VISION AIR HANDLING UNIT 20 ZZZ'DLNLQ$SSOLHGFRP MECHANICAL INSTALLATION Figure 32: Piping Arrangements Float and thermostatic trap Check Valve Strainer Gate Valve Control valve modulating two position High Pressure (over 25 psi) 5TA, 8TA, or 5HA coils. Condensate is lifted to overhead return main 5GA or 8GA coils. Note that the addition of a vacuum breaker to permit the coil to drain during shutdown. Low Pressure (to 25 psi) 5J, 5G, 8J or 8G coils. 5JA or 8JA coil. Installed in series. Note that each coil must have a separate control valve and trap. 5RA, 8RA, or 5SA coils. Banked two high, individual trapping of each coil as shown is preferred. 5RA, 8RA, or 5SA coils. Installed ZZZ'DLNLQ$SSOLHGFRP  IM 672-10 • VISION AIR HANDLING UNIT MECHANICAL INSTALLATION Water Heating Coils CAUTION ,PSURSHU LQVWDOODWLRQ XVH RU PDLQWHQDQFH RI ZDWHU KHDWLQJ FRLOV FDQ FDXVH HTXLSPHQW GDPDJH 5HDG DQG IROORZ instructions carefully. • :DWHUVXSSO\DQGZDWHUUHWXUQFRQQHFWLRQVH[WHQG through the end panel of the coil section. All connections are labeled on the end panel. Drain Pan Traps Run drain lines and traps full size from the drain pan FRQQHFWLRQ,QVWDOOGUDLQSDQWUDSWRDOORZFRQGHQVDWHWRGUDLQ IUHHO\2QERWKEORZWKURXJKDQGGUDZWKURXJKXQLWVWKHWUDS GHSWKDQGWKHGLVWDQFHEHWZHHQWKHWUDSRXWOHWDQGWKHGUDLQ SDQRXWOHWPXVWEHWZLFHWKHVWDWLFSUHVVXUHLQWKHGUDLQSDQ section under normal operation so the trap remains sealed (Figure 33). Figure 33: Allow Adequate Distance Between Trap Outlet and Drain Pan Outlet • :DWHUVXSSO\DQGZDWHUUHWXUQFRQQHFWLRQVDUHPDOH137 iron pipe. Pressure (P) at the drain pan • When installing couplings, do not apply undue stress to the connection extending through unit panel. Use a EDFNXSSLSHZUHQFKWRDYRLGEUHDNLQJWKHZHOGEHWZHHQ the coil connection and header. 2P • )ROORZUHFRPPHQGDWLRQVRIWKHFRQWUROPDQXIDFWXUHU regarding types, sizes, and installation of controls. 2P • 'RQRWXVHKRWZDWHUFRLOVZLWKHQWHULQJDLUEHORZƒ) • ,IIUHVKDLUDQGUHWXUQDLUDUHWREHKHDWHGE\DKRWZDWHU coil, carefully design the system to provide thorough mixing before air enters the coil. • 7RSUHSDUHFRLOVIRUZLQWHURSHUDWLRQVHHWinterizing Water Coils on page 44. IM 672-10 • VISION AIR HANDLING UNIT 22 ZZZ'DLNLQ$SSOLHGFRP MECHANICAL INSTALLATION Internal Isolation Assembly Adjustment 2QXQLWVZLWKLQWHUQDOO\LVRODWHGIDQDQGPRWRUDVVHPEOLHVWKH assemblies are secured for shipment. Before Operating the Unit 5HPRYHWKHVKLSSLQJEUDFNHWVDQGWLHGRZQEROWVUHIHUWR Figure 35, Figure 36 and ) and discard. The shipping brackets ORFDWHGRQWKHRSSRVLWHGULYHVLGHRIWKHXQLWDUHGLI¿FXOWWR access from the drive side of the unit. Either remove them before the unit is assembled, or remove the panel on the opposite drive side to gain access. The spring isolators under the four corners of the fan and PRWRUDVVHPEO\DUHIDFWRU\DGMXVWHGZKLOHWKHIDQZDVQRW running. With the unit operating at normal cfm and static pressure, all the isolators should be at the same height opening (Table 1 through Table 5). If adjustments are required, ORRVHQWKHFDSVFUHZRQWRSRIWKHLVRODWRUDQGWXUQ WKHDGMXVWLQJEROWWRORZHURUUDLVHWKHIDQDQGPRWRUEDVH 5HWLJKWHQWKHFDSVFUHZZKHQDGMXVWPHQWVDUHFRPSOHWHG Table 1: Motor Beside Fan Spring Mount Adjustments Spring Mount Adjustment at Rest Isolator Position Top or Bottom Horizontal H 'RZQEODVW+ )RUPRGHOVWKURXJKZLWKKRXVHGIDQVWKHLVRODWRUV should be at equal height (6") during fan operation. Center the fan outlet in the outlet panel opening. If adjustment is required, loosen the bolt on top of the isolator assembly ( . Turn the DGMXVWPHQWQXWEHORZWKHIDQIUDPHWRORZHURUUDLVHWKHIDQ motor and frame assembly. Retighten the bolt on top of the isolator assembly. Table 3: Class II Belt-Drive Plenum Fan Spring Height Fan Size Isolator Type Operating Height (in.) ± 6WDQGDUG'HÀHFWLRQ 4.5 ± 6WDQGDUG'HÀHFWLRQ 4.0 ± Seismic 4.0 ± All 6.75 Table 4: Class III Plenum Fan Spring Height Cabinet Width (in.) Isolator Type Width < 108 All Operating Height (in.) 4.0 :LGWK• All 6.75 Table 5: Class II Direct-Drive Plenum Fan Spring Height Upblast H Unit Sizes 003 – 035 1 3.75 3.75 4.25 2 4.25 3.75 4.25 3 4.25 3.75 4.25 4 3.75 3.75 4.25 1 6.00 6.00 6.50 2 6.50 6.00 6.50 3 6.50 6.00 6.50 4 6.00 6.00 6.50 Fan Size Isolator Type ± All Operating Height (in.) 4.0 ± All 6.75 Figure 34: Adjusting Large Spring Mount Assembly Unit Sizes 040 – 090 Table 2: Motor Behind Fan Spring Mount Adjustments Spring Mount Adjustment at Rest Isolator Position Top or Bottom Horizontal H 1 6.75 6.75 6.75 2 6.75 6.75 6.75 3 6.75 6.75 6.75 4 6.75 6.75 6.75 'RZQEODVW+ Upblast H Unit Sizes 003 – 035 Unit Sizes 040 – 090 1 6.75 6.75 6.75 2 6.75 6.75 6.75 3 6.75 6.75 6.75 4 6.75 6.75 6.75 ZZZ'DLNLQ$SSOLHGFRP  IM 672-10 • VISION AIR HANDLING UNIT MECHANICAL INSTALLATION Figure 35: Removing “Motor Behind” Shipping Brackets IM 672-10 • VISION AIR HANDLING UNIT Figure 36: Removing “Motor Beside” Shipping Brackets 24 ZZZ'DLNLQ$SSOLHGFRP MECHANICAL INSTALLATION Figure 37: Plenum Fan Typical Shipping Brackets Shipping hold-down nut and bolt Remove and discard - 4 places Shipping bracket Remove and discard - 4 places ZZZ'DLNLQ$SSOLHGFRP  IM 672-10 • VISION AIR HANDLING UNIT MECHANICAL INSTALLATION OSHPD Seismic Anchoring/Mounting For seismic stability of the unit, additional anchoring and mounting procedures are required. The anchoring options and corresponding spectral response acceleration are given in Table 6+ROHVLQWKH9LVLRQ6N\OLQHEDVHIUDPHDUHWREH¿HOG GULOOHG$Q\PRXQWLQJKDUGZDUHLVWREH¿HOGVXSSOLHG Figure 39: Unit with Base Frame Welded Table 6: OSHPD Mounting Attachment Method SDS Bolted attachment to steel (Figure 38) Welded attachment to steel (Figure 39) Bolted attachment to Concrete (Figure 40) Attachment System (by Others) Spacing System 1.93 48 5/8" DIA SAE Grade 5 1.84 48 3/16" Weld Leg and ZHOGHGOHQJWK 1.68 24 Hilti HAD-P M16 × 190/40 ZLWKHPEHGPHQW Figure 38: Unit with Base Frame Mounted on Steel Figure 40: Unit with Base Frame Mounted on Concrete IM 672-10 • VISION AIR HANDLING UNIT 26 ZZZ'DLNLQ$SSOLHGFRP ELECTRICAL INSTALLATION ELECTRICAL INSTALLATION Wiring DANGER Capacitor Hazardous Voltage!)DLOXUHWRGLVFRQQHFWSRZHU DQGGLVFKDUJHFDSDFLWRUVEHIRUHVHUYLFLQJZLOOUHVXOWLQVHULRXV injury or death. 'LVFRQQHFW DOO HOHFWULF SRZHU LQFOXGLQJ UHPRWH GLVFRQQHFWV before servicing. Perform lockout/tagout procedures to ensure WKDW SRZHU FDQ QRW EH HQHUJL]HG )RU YDULDEOH IUHTXHQF\ drives,or other energy storing components that have been furnished and mounted by either Daikin, or by others, refer WRWKHVSHFL¿FPDQXIDFWXUHU¶VOLWHUDWXUHIRUDOORZDEOHZDLWLQJ periods For discharge of capacitors. Verify capacitors have been discharged using an appropriate voltmeter. CAUTION Use copper conductors only! Failure to use copper conductors can result equipment damage. • Electrical service to each fan must correspond to the rated voltage on the motor or electrical panel nameplate and conform to the National Electric Code and local restrictions. • Connect each fan section metal frame to the building electrical ground. • A door electrical interlock is not provided as standard. • Thermal motor protection is external to the unit. Unless WKHXQLWLVSURYLGHGZLWKDYDULDEOHIUHTXHQF\GULYH (VFD) or a unit mounted starter, thermal protection and DGLVFRQQHFWVZLWFKSURYLVLRQSHUHOHFWULFFRGHVDUH provided by others. • :KHQWKHXQLWLVIDFWRU\SURYLGHGZLWKDGLVFRQQHFW VZLWFKVWDUWHURUDYDULDEOHIUHTXHQF\GULYH9)' WKH components are mounted on the outside of the unit FDELQHW)DFWRU\ZLULQJLVSURYLGHGIURPWKHGHYLFHWRWKH unit internal motor. • :KHQWKHXQLWLVSURYLGHGZLWKD9)'RQO\UHIHUWRWKH 9)'PDQXDOIRUZLUHVL]HDQGWRUTXHUHTXLUHPHQWV)RU LQVWDQFHVZKHUHPXOWLSOHPRWRUVDUHEHLQJGULYHQE\D VLQJOH9)'EHVXUHWRVHWXSWKH9)'DQGVL]HWKHZLULQJ DFFRUGLQJWRWKHSRZHUUHTXLUHPHQWVRIDOOPRWRUVWKDW are being driven by that VFD. • When not being serviced, close and secure electrical panel doors to prevent ingress of moisture and airborne contaminants. Control Wiring • Access to the VFD is through the fan cabinet access door for single fans. Provide shielded cable only as described LQWKHSURYLGHG9)'PDQXDO5RXWHZLUHWKURXJK WKHSDQHOVRWKDWLWGRHVQRWLQWHUIHUHZLWKDQRWKHU components or access doors. Do not drill through drip pans or drain pans. Refer to the provided VFD installation PDQXDOIRUGHWDLOHGFRQWUROZLULQJLQVWUXFWLRQV • For multiple fans in parallel, the VFD(s) are mounted LQVLGHRIWKHHOHFWULFDOHQFORVXUHZKLFKLVPRXQWHGRQ the exterior of the fan section. When multiple fan sections DUHSURYLGHGZLWKPXOWLSOH9)'VWKH\PXVWEHVHWXS VRWKDWWKHIDQVDOZD\VVWDUWVLPXOWDQHRXVO\DQGDUHVHW WRUDPSXSDQGGRZQWRJHWKHU'RQRWDWWHPSWWRUXQ fans in parallel at different speeds as this can result in XQHYHQDLUÀRZWKDWFDQFDXVHSHUIRUPDQFHVRXQGDQG vibration problems that can lead to failure. Provided that the fan is capable of running fast enough and the motor is sized appropriately, VFDs may be operated up to a maximum recommended frequency of 90 Hertz for 1800 530DQGVORZHUPRWRUV0RWRUVWKDWDUH530PD\ be operated up to a maximum speed of 4000 RPM or 66.7 Hertz provided the fan is rated that high. Operation above 4000 RPM can damage motor bearings and is not recommended. • All electrical components must be grounded to the EXLOGLQJFHQWUDOJURXQG6XLWDEOHJURXQGZLUHVDQGRU (bonding) lugs are provided for all motors, disconnect VZLWFKHVVWDUWHUVDQGYDULDEOHIUHTXHQF\GULYHV3URYLGH dedicated ground (bonding) copper conductors in DFFRUGDQFHZLWKORFDODQGQDWLRQDOFRGHV • )RUXQLWVSURYLGHGZLWKDPRWRURQO\RUZLWKDQH[WHUQDO MXQFWLRQER[ZLUHFRQQHFWLRQVDUHPDGHZLWKVXLWDEOH ZLUHQXWVRUFRQQHFWRUVIRUWKHJDXJHZLUHVSURYLGHG • )RUXQLWVSURYLGHGZLWKDGLVFRQQHFWVZLWFKRUVWDUWHU¿HOG ZLULQJZLOOEHWHUPLQDWHGWROXJV:LUHVL]HDQGOXJWRUTXH UHTXLUHPHQWVDUHVKRZQRQWKHXQLWHOHFWULFDOVFKHPDWLF SURYLGHGLQWKHFRPSRQHQWSULQWSRFNHW$OOSRZHUVXSSO\ ZLUHFRQQHFWLRQVPXVWEHWRUTXHGDVVKRZQ ZZZ'DLNLQ$SSOLHGFRP  IM 672-10 • VISION AIR HANDLING UNIT OPERATION OPERATION Startup Checks :KHQSHUIRUPLQJVWDUWXSDQGVHUYLFHDOZD\VWDNHWKRURXJK safety precautions. Only trained, experienced personnel should perform these functions. WARNING ROTATING FAN Can cause severe injury or death. Before servicing fans,lockout DQGWDJRXWSRZHU Before Starting the Unit CAUTION Equipment damage due to loose fasteners represents improper start-up and equipment abuse. It is not covered by WKHZDUUDQW\ %HIRUHHQWHULQJIDQVHFWLRQPDNHVXUHWKDWIDQHOHFWULFDOSRZHU source is disconnected and locked in the OFF position. 1. Check that the unit is completely and properly installed ZLWKGXFWZRUNFRQQHFWHG WARNING FIRE/ELECTRIC SHOCK HAZARD 2. &KHFNWKDWDOOFRQVWUXWLRQGHEULVLVUHPRYHGDQG¿OWHUV are clean. Can cause property damage, personal injury or death. Wire IDQSRZHUVXSSO\DQGJURXQGPRWRUIUDPHLQDFFRUGDQFHZLWK local electric codes. 3. &KHFNWKDWDOOHOHFWULFDOZRUNLVFRPSOHWHDQGSURSHUO\ terminated. WARNING 4. Check that all electrical connections are tight and that the proper voltage is connected. Phase imbalance must not exceed 2%. Fan motor requires overload protection. Failure to provide motor overload protection can result in ¿UHSURSHUW\ GDPDJH HOHFWULF VKRFN SHUVRQDO LQMXU\ RU death. Connect motor to an overload protective device rated LQFRPSOLDQFHZLWKORFDOHOHFWULFFRGHV 5. Do not grease ball bearings on the fan shaft and motor before startup. They are prelubricated. 6. &KHFNWLJKWQHVVRIFUHZVLQEHDULQJVDQGIDQZKHHOV  ,IUHWLJKWHQLQJLVQHHGHGSRVLWLRQWKHIDQZKHHOV SHU Table 7, page 29 through Table 9, page 30 and Table 10 through Table 12, page 31. Torque set VFUHZVSHUTable 13 and , page 31. CAUTION DO NOT OVERHEAT FAN MOTOR High air temperatures in the fan section can cause the fan PRWRUWREXUQRXW2QGUDZWKURXJKDLUKDQGOHUVRUDLUKDQGOHUV ZLWK WKH IDQ VHFWLRQ GRZQ WKH DLU VWUHDP IURP WKH KHDWLQJ section, the discharge air temperature of the heating section must not exceed 104°F (40°C). 7. Check alignment of fan and motor sheaves and belt tension. Adjust if necessary. Check tightness of sheave VHWVFUHZVDQGRUFDSVFUHZVUHIHUWR, page 31). 8. Leak test the thermal system to verify that connections are tight. 9. Check that the condensate drain is trapped. 10. Rotate the shaft by hand to be sure it is free. 11. ,IPXOWLSOHIDQVDUHVXSSOLHGZLWKDEORFNRIISODWHDQGLWLV installed on one of the fans, make sure to only start the IDQVZLWKRXWWKHEORFNRIISODWH'RQRWVWDUWDQ\IDQWKDW has the block off plate installed on it. 12. ,IPXOWLSOHIDQVDUHVXSSOLHGZLWKLVRODWLRQGDPSHUVPDNH sure the isolation dampers are fully open before starting the fans. IM 672-10 • VISION AIR HANDLING UNIT 28 ZZZ'DLNLQ$SSOLHGFRP OPERATION VFD Setup Fan Wheel Alignment )DQVRUGHUHGZLWK9)'VWKDWZHUHIDFWRU\LQVWDOOHGDUHVHWXS and tested prior to shipment. Prior to starting the fan(s), double check the VFD settings according to the recommendations in the VFD manual. Figure 41: Wheel-to-Inlet Funnel Relationship— Fan Wheels (Housed) 2QFHWKHFRUUHFW9)'VHWWLQJVDUHYHUL¿HGWKHIDQVVKRXOGEH UXQWKURXJKDVZHHSRIWKHIXOOUDQJHRIRSHUDWLQJVSHHGVWKDW are expected to check for any vibration issues. If any areas of concern are located, it is recommended to lock out those frequencies using the VFD (see lock out frequencies or skip IUHTXHQFLHVLQWKH9)'PDQXDO 7KLVZLOOHQVXUHWKDWWKHIDQV ZLOOQHYHURSHUDWHFRQWLQXRXVO\DWWKRVHSRLQWVEXWZLOOUDWKHU pass through them to get to the desired points of operation. B A E q u a l s p a c in g a ll a r o u n d A Table 7: Wheel-to-Inlet Funnel Relationship— Fan Wheels(Housed) Fan Startup Airfoil1 (in.) Unit sizes 003 to 035 Start and run fan. See on page 30 for proper fan rotation. 2EVHUYHWKHURWDWLRQ,IWKHIDQRSHUDWHVEDFNZDUGUHYHUVHWZR OHJVRIWKHWKUHHSKDVHVXSSO\SRZHU Unit sizes 040 to 090 Diameter A2 (mm) B3 (mm) Diameter A2 (mm) B3 (mm) 13.22 4.56 (116) 0.21 (5.33) 20.00 7.19 (183) 0.31 (7.87) 14.56 5.06 (129) 0.21 (5.33) 22.25 7.69 (195) 0.33 (8.38) 16.18 5.62 (143) 0.21 (5.33) 24.50 8.56 (217) 0.31 (7.87) 17.69 6.90 (175) 0.22 (5.59) 27.00 9.47 (241) 0.63 (16.00) 21.56 7.59 (193) 0.24 (6.10) 30.00 10.47 (266) 0.39 (9.91) 24.00 8.45 (215) 0.23 (5.84) 33.00 11.75 (298) 0.38 (9.65) — — — — — — 36.50 40.25 325 (12.78) 0.38 (9.65) 363 (14.31) 0.50 (12.70) NOTE: Variable pitch fan drives usually are provided for operation in the mid-speed adjustment range. +RZHYHUWKHGULYHVXVXDOO\VKLSZLWKWKHDGMXVWPHQW opened up for minimum fan speed. Adjust the drives IRUWKHSURSHUDLUÀRZ6HHFan Drive Adjustments on page 38. Note: After 48 Hours of Operation 1To obtain rated air performance, dimensional relationship must be held. 27RREWDLQGLPHQVLRQ$ORRVHQVHWVFUHZVLQZKHHOKXEV VKLIWLQJZKHHOV D[LDODVQHHGHGUHWLJKWHQLQJ VHWVFUHZV 37RREWDLQGLPHQVLRQ%ORRVHQVFUHZDQGZDVKHUIDVWHQHUVDURXQGSHULSKHU\RIIXQQHOV VKLIWLQJIXQQHOUDGLally as required, re-torquing fasteners. WARNING ROTATING FAN Can cause severe injury or death. Before servicing fans,lockout DQGWDJRXWSRZHU Figure 42: Wheel-to-Inlet Funnel Relationship— Forward Curved Fan Wheels C 1. 'LVFRQQHFWDQGORFNHOHFWULFDOSRZHUVRXUFH W h e e l C 2. &KHFNWLJKWQHVVRIDOOEHDULQJZKHHODQGVKHDYH VHWVFUHZVRUFDSVFUHZV 5HIHUWRTable 13. In le t F u n n e l 3. Recheck belt tension and adjust if necessary. Belts WHQVLRQHGVXI¿FLHQWO\WRVOLSRQHWRWZRVHFRQGVDW VWDUWXSZLOOSHUIRUPVDWLVIDFWRULO\H[WHQGLQJOLIHDQG reducing In le t F u n n e l Figure 43: Wheel-to-Inlet Funnel Relationship— Forward Curved Fan Wheels )RUZDUG&XUYHG1 (in.) Unit sizes 003 to 035 Unit sizes 040 to 090 Diameter C2 (mm) Diameter C2 (mm) 9×4 0.25 (6.35) 20 (Class 1 & 2) 0.24 (6.10) 9×7 0.13 (3.30) 22.38 (Class 1 & 2) 0.41 (10.41) 9×9 0.25 (6.35) 25 (Class 1 & 2) 0.47 (11.94) 10 0.22 (5.59) 27.62 (Class 1 & 2) 0.47 (11.94) 12 0.35 (8.89) 30 (Class 1 & 2) 0.47 (11.94) 15 0.44 (11.18) 33 (Class 1 & 2) 0.50 (12.70) 18 0.25 (6.35) 36 (Class 1 & 2) 0.75 (19.05) 20 (Class 1 & 2) 0.73 (8.54) — — 22½ (Class 1 & 2) 0.59 (14.99) — — 24½ (Class 1 & 2) 0.56 (14.22) — — Note: 1To obtain rated air performance, dimensional relationship must be vibration. If retensioning is necessary, be certain to retain held. 2$GMXVWGLPHQVLRQ&E\ORRVHQLQJZKHHOKXEVHWVFUHZVVKLIWLQJVKHDYHDOLJQPHQWZKHHOV D[LDODVQHHGHG DQGUHWLJKWHQLQJVHWVFUHZV ZZZ'DLNLQ$SSOLHGFRP  IM 672-10 • VISION AIR HANDLING UNIT OPERATION Figure 44: Wheel-to-Inlet Funnel Relationship— 13 to 36 Belt-Drive Plenum Fans Figure 45: Wheel-to-Inlet Funnel Relationship— 40 to 60 Belt-Drive Plenum Fans Cross Section Reference Cross Section Reference EQUALLY SPACED AROUND DIAMETER B A FUNNEL END TO FAN WHEEL OPENING FROM FUNNEL END TO FANWHEEL OPENING END A EQUALLY SPACED AROUND DIAMETER B C Table 8: Wheel-to-Inlet Funnel Relationship— 13 to 36 Belt-Drive Plenum Fan C Wheel-Funnel Parameters Size A B C 13 0.25 0.91 3.50 15 0.25 0.91 3.50 16 0.25 0.91 3.50 18 0.38 0.86 3.88 20 0.42 1.11 3.88 Size A B C 22 0.45 1.11 3.88 40 0.82 2.00 4.88 24 0.51 1.11 3.88 44 0.91 2.25 5.50 27 0.55 1.36 4.50 49 1.00 2.50 5.50 30 0.62 1.36 4.50 54 1.10 2.50 5.50 33 0.55 1.50 5.00 60 1.23 3.00 5.50 36 0.63 1.50 5.00 Table 9: Wheel-to-Inlet Funnel Relationship— 40 to 60 Belt-Drive Plenum Fan Wheel-Funnel Parameters 6HWVFUHZVRQ034IDQZKHHOVPXVWEHLQVWDOOHGXVLQJD FDOLEUDWHGWRUTXHZUHQFKWRWKHYDOXHOLVWHGEHORZ“7KH fasteners must be periodically checked to satisfy agency requirements for components on rotating machinery. IM 672-10 • VISION AIR HANDLING UNIT 30 ZZZ'DLNLQ$SSOLHGFRP OPERATION Figure 46: Fan Wheel Rotation Figure 47: Wheel-to-Inlet Funnel Relationship— Inline Fans Overlap Table 11: Wheel-to-Inlet Funnel Relationship— Direct-Drive Fans Only Class II fans Overlap Table 10: Wheel-to-Inlet Funnel Relationship—Inline Fans Overlap 150 .375 165 .438 182 .562 200 .625 222 .688 245 .750 270 .812 300 .875 330 1.000 365 1.125 402 1.250 445 1.375 ZZZ'DLNLQ$SSOLHGFRP Overlap (in.) 11 0.25 12 0.25 15 0.25 16 0.38 18 0.38 20 0.41 22 0.45 24 0.50 27 0.55 30 0.61 33 0.67 36 0.75 40 0.82 44 0.91 Table 12: Wheel-to-Inlet Funnel Relationship— Direct-Drive Class III fans Wheel—Funnel Overlap Size Fan Size  Fan Size Overlap (in.) 13 0.12 15 0.19 16 0.25 18 0.31 20 0.38 22 0.44 24 0.50 27 0.56 30 0.62 33 0.75 36 0.81 40 0.88 44 0.94 49 1.0 54 1.06 60 1.12 IM 672-10 • VISION AIR HANDLING UNIT OPERATION Table 13: 6HWVFUHZ7RUTXH6SHFL¿FDWLRQV² Class II Plenum Fan Size 6HWVFUHZ6L]H 11/12/13 Table 14: Bearing Collar and Wheel Hub Set Screw Torque (All Fans Except Class II Plenum Fans) 6HW6FUHZ'LDPHWHULQ Torque (ft.-lb) Minimum torque ft/lbs (kg/m) Aluminum Steel 1/4 5.5 (0.76) 3/8 19.2 N/A 1/16 10.5 (1.45) 15 3/8 19.2 N/A 3/8 19.0 (2.63) 16 3/8 19.2 N/A 7/16 29.0 (4.01) 18 3/8 19.2 N/A 1/2 42.0 (5.81) 20 3/8 19.2 N/A 5/8 92.0 (12.72) 22 3/8 19.2 N/A 24 3/8 19.2 N/A 27 3/8 19.2 22 30 1/2 41.7 55 33 1/2 41.7 55 36 1/2 41.7 55 40 1/2 41.7 55 44 1/2 41.7 55 49 1/2 41.7 55 54 1/2 41.7 55 60 3/4 115 150 IM 672-10 • VISION AIR HANDLING UNIT 32 ZZZ'DLNLQ$SSOLHGFRP OPERATION Fan Array 7KH'DLNLQ)DQ$UUD\LVDYDLODEOHZLWKRSWLRQDOIDFWRU\ mounted VFDs. See OM manuals OM 1190 and 1191 for details on the Daikin supplied VFD. WARNING Closing the damper on an operational fan could send the fan into surge that could produce fans stall, excessive vibration, unit damage, or personnel injury. &DUHVKRXOGEHWDNHQZKHQSURJUDPLQJDQGV\QFKURQL]LQJ the drives in the Daikin Fan Array such that all fans turn at the same speed. Fans running at unequal speeds can produce YLEUDWLRQDQGFRXOGVWDOODIDQ'H¿QLWLRQRIIDQQXPEHULQJLV given in Figure 48. Figure 48: 'DLNLQ)DQ$UUD\&RQ¿JXUDWLRQ 7KH'DLNLQ)DQ$UUD\LVVWDQGDUGZLWKDPDQXDOEORFNRII SODWH7KHXQLWZLOOVKLSZLWKRQHEORFNRIISODWHWKDWZLOOFRPH installed on fan 1A. This block off plate is to be removed before unit operation and stored outside of the air tunnel. In the event of a lost fan motor, the block off plate is installed on the nonfunctional fan to prevent air re-circulation. This is designed to be a temporary measure unit this fan and/or motor is replaced. After fan and/or motor replacement the block off plate is to be removed and stored outside of the air tunnel. The Daikin Fan Array has an optional gravity actuated block off GDPSHU7KHVHGDPSHUVDUHHTXLSSHGZLWKFRXQWHUZHLJKWV The Daikin Fan Array has an optional actuated block off damper. These dampers are designed to prevent air recirculation in the event of a lost fan. Care should be taken that the damper actuator only be given a close signal if the fan is not operational (motor burnout for example). 7KH'DLNLQ)DQ$UUD\FDQEHHTXLSSHGZLWKDIDQEODQNRIISODWH See Figure 49ZLWKDEORFNRIISODWHPRXQWHGWRIDQ&,IWKH XQLWLVRUGHUHGZLWKWKHPDQXDOEORFNRIISODWHLWZLOOEHLQVWDOOHG to fan 1A. This plate has to be removed before start up. ZZZ'DLNLQ$SSOLHGFRP  6D 5D 4D 3D 2D 1D 6C 5C 4C 3C 2C 1C 6B 5B 4B 3B 2B 1B 6A 5A 4A 3A 2A 1A Viewed from Fan Inlet End Figure 49: Fan Array with Block Off Plate IM 672-10 • VISION AIR HANDLING UNIT OPERATION 2SWLRQDO3LH]RPHWHU5LQJ$LUÀRZ0HDVXUHPHQW'HYLFH Piezometer rings are available as an option on direct drive SOHQXPIDQVWRPHDVXUHDLUÀRZWKRXJKWKHIDQ7KHGHYLFH consists of a piezometer ring mounted in the throat of the funnel and a static pressure tap mounted near the inlet of the funnel. The pressure drop is measured from the tap located near the inlet of the funnel to the piezometer ring in the throat. The inlet tap is connected to the high-pressure side of the WUDQVGXFHUDQGWKHSLH]RPHWHUULQJLVFRQQHFWHGWRWKHORZ pressure side. Table 15: DDPL Factors For Free and Ducted Inlet— Non Standard Density Method Product C1 Free Inlet C1 Ducted Inlet DDPL Size 11-16 753.06 794.06 DDPL Size 18-44 692.03 740.14 Table 16: DDPL Factors For Free and Ducted Inlet— Standard Density Method %HORZDUHWKHHTXDWLRQVDQGIDFWRUVUHTXLUHGWRFDOFXODWHÀRZ using the piezometer ring: DDPL Size Free Inlet F Ducted Inlet F 11 and 12 944.92 996.36 0.344 15 1206.40 1272.08 0.439 16 1518.58 1601.26 0.552 18 1821.92 1948.58 0.721 20 2185.80 2337.76 0.865 22 2713.93 2902.60 1.074 24 3285.02 3513.39 1.300 ZKHUH$ ,QOHWIXQQHOWKURDWDUHDVTXDUHIHHW IURP7DEOH 27 3997.61 4275.53 1.582 ǻ3 7KHGLIIHUHQWLDOLQVWDWLFSUHVVXUHIURPWKHSLH]RPHWHUULQJ DQGWKHLQOHWSUHVVXUHWDSLQFKHVZJ 30 4945.21 5289.01 1.957 33 5968.62 6383.56 2.362 36 7290.21 7797.03 2.885 ȡ $LUGHQVLW\SRXQGVPDVVFXELFIRRW 40 8869.55 9486.16 3.510 & 9DOXHIURP7DEOHEHORZ 44 10827.92 11580.68 4.285 Non-Standard Density Method 7KHIROORZLQJHTXDWLRQLVXVHGWRPHDVXUHWKHÀRZIRUQRQ standard density: $&)0 &î$î¥ǻ3ȡ Standard Density Method 7KHHTXDWLRQFDQEHVLPSOL¿HGE\DVVXPLQJVWDQGDUG GHQVLW\DQGDVVXPLQJIXQQHOGLPHQVLRQVPDWFKWKHGUDZLQJ dimensions. Table 16VKRZVWKHIDFWRU) IRUHDFKIDQVL]H DQGW\SH7KHHTXDWLRQWKHQEHFRPHVWKHIROORZLQJ )RUVWDQGDUGDLUȡ OEIW  Area A Optional Transducer for Piezometer Rings A transducer is available for Piezometer rings. Factory PRXQWLQJORFDWLRQVIRUWKHIDQWUDQVGXFHULVVKRZQLQFigure 50 for direct-drive plenum fans. Figure 51VKRZVWKHLQVWDOODWLRQ IRUIDQDUUD\:LULQJIRUWKHWUDQVGXFHULV¿HOGVXSSOLHGDQG installed. $&)0 )î¥ǻ3 ZKHUH) IDFWRUIURP7DEOH ǻ3 7KHGLIIHUHQWLDOLQVWDWLFSUHVVXUHIURPWKHSLH]RPHWHUULQJ DQGWKHIURQWSUHVVXUHWDSLQFKHVZJ IM 672-10 • VISION AIR HANDLING UNIT 34 ZZZ'DLNLQ$SSOLHGFRP OPERATION Figure 50: Direct-drive Plenum Fan Installation Route tube (DCX56) from the high pressure tap of the transmitter to the outer face of the funnel or the inlet panel. Secure tubing to the fan assembly using cable-tie mount (DCX52) and Cable-tie (DCX54) as needed. Location may vary depending on fan size. Make sure any tubing does not interfere with the fan wheel. Position mounting angle as close to the unit drive side access door as possible without interfering with the door hardware and at eye level. Or equal to half of the cabinet door height. Screw to liner or bulkhead with FS116. NOTE: Never drill or screw through the inlet funnel. Route tube (DCX56) from the low pressure tap of the transmitter to the Piezo Ring located on the throat of the funnel. Figure 51: Fan Array Installation Secure tubing to the fan assembly using cable-tie mount (DCX52) and Cable-tie (DCX54) as needed. Route tube (DCX56) from the high pressure tap of the transmitter to the outer face of the funnel or the inlet panel. Make sure any tubing does not interfere with the fan wheel. Location may vary depending on fan size. Route tube (DCX56) from the low pressure tap of the transmitter to the Piezo Ring located on the throat of the funnel. NOTE: Position the mounting plate on the fan support angle in a location that allows maximum access for field wiring. Never drill or screw through the inlet funnel. Fasten the plate to the fan support angle using two screws (FS116). ZZZ'DLNLQ$SSOLHGFRP  IM 672-10 • VISION AIR HANDLING UNIT OPERATION Operating Limits Do not exceed the operating limits in Table 17 through Table 21$IDQZKHHORSHUDWHGEH\RQGWKHUSPDQGWHPSHUDWXUH OLPLWVVKRZQFDQVXIIHUSHUPDQHQWGLVWRUWLRQRUIUDFWXUH7KH resulting unbalance can cause severe unit vibration. Table 17: Fan Operating Limits—Unit Sizes 003 to 035 Diameter Max. RPM Class I Max. RPM Class Il 9×4 N/A 2244 9×7 2189 2854 )RUZDUG&XUYHG²+RXVHG 9×9 10.62 12.62 15 2223 1934 1614 1328 2896 2518 2091 1725 18 1155 1450 20 1050 1200 22.25 944 1030 24.50 858 910 13.22 3000 4335 14.56 3000 3918 Airfoil—Housed 16.19 19.69 2300 2000 3457 2858 21.56 1700 2427 24.00 1500 2255 33 1209 1579 36.5 1073 1401 Table 18: Fan Operating Limits—Unit Sizes 040–090 Diameter Max. RPM Class I Max. RPM Class Il 20 1010 1281 )RUZDUG&XUYHG²+RXVHG 22.38 25 27.62 930 790 690 1178 1011 910 30.25 650 835 33 600 763 36 560 715 20 2077 2703 Airfoil—Housed 24.5 27 30 1691 1479 1328 2199 1928 1730 22.25 1875 2413 Table 19: Fan Operating Limits—Belt-Drive Plenum Fans Size Max. RPM Class II Max. RPM Class IlI 13 3909 4000 15 3468 4000 16 2820 3887 18 2930 3735 20 2674 3409 Belt-Drive Plenum fans 22 24 27 2403 2183 1860 3065 2780 2423 30 1783 2182 33 1620 1984 36 1465 1759 40 1329 1598 44 1202 1447 49 1091 1314 54 986 1178 60 891 1071 Table 20: Fan Operating Limits—Direct-Drive Plenum Fans Size Max. RPM Class II Max. RPM Class IlI 11 4000 — 12 4000 — 13 — 4000 15 3909 4000 16 3650 3887 Direct-Drive Plenum Fans 18 20 22 24 27 3650 2674 2403 2183 1981 3735 3409 3065 2780 2423 30 1783 2182 33 1620 1984 36 1465 1759 40 1329 1598 44 1202 1447 49 — 1314 54 — 1178 60 — 1071 Table 21: Fan Operating Limits—Inline Fans, Twin Fans Diameter Max. RPM Class I Max. RPM Class II 18.25 2727 3409 Diameter Max. RPM Max. HP 9×9 2575 10 20 22.25 2488 2236 3111 2796 7ZLQ)DQV 10.62 12.62 2400 2000 15 15 24.5 2041 2551 ,QOLQH)DQV7ZLQ)DQV 27 30 1835 1665 2294 2082 15 1700 30 18.12 1400 40 33 1476 1846 36.5 1330 1662 40.25 1208 1510 44.50 1072 1340 49 973 1216 54.25 880 1100 20 1200 40 Fan Vibration Levels Each unit as shipped is trim balanced to operate smoothly. To provide satisfactory operation after shipping and installation, XVHWKHDFFHSWHGLQGXVWU\JXLGHOLQHVIRU¿HOGEDODQFLQJIDQV See Table 22. Vibration Causes 1. Wheel imbalance. a. 'LUWRUGHEULVRQZKHHOEODGHV b. /RRVHVHWVFUHZVLQZKHHOKXERUEHDULQJWRVKDIW c. Wheel distorted from overspeed. 2. Bent shaft. 3. Drive faulty. a. Variable pitch sheaves—axial and radial runout of ÀDQJHVXQHYHQJURRYHVSDFLQJRXWRIEDODQFH Also similar faults in driven sheave. b. Bad V-belts; lumpy, or mismatched; belt tension too tight or too loose. 4. %DGEHDULQJVORRVHEHDULQJKROGGRZQEROWV 5. Motor imbalance. 6. Fan section not supported evenly on foundation. Table 22: Vibration Levels Fan Speed (RPM) Vibration 800 or less 5 mils maximum displacement 801 or greater 0.20 in/sec. maximum velocity Note: Excessive vibration from any cause contributes to premature fan and motor bearing failure. Monitor overall vibration levels every six months of operation. An increase in levels is an indication of potential trouble. IM 672-10 • VISION AIR HANDLING UNIT 36 ZZZ'DLNLQ$SSOLHGFRP MAINTENANCE MAINTENANCE Periodic Maintenance 1. &KHFNDOOPRYLQJSDUWVIRUZHDUHYHU\VL[PRQWKV Fan Shaft Bearings 2. &KHFNEHDULQJFROODUVKHDYHDQGZKHHOKXEVHWVFUHZV VKHDYHFDSVFUHZVDQGEHDULQJKROGGRZQEROWVIRU tightness every six months. 3. Annually check and snug all electrical connections. ,QVSHFWIRUVLJQVRIZDWHUGDPDJHVXFKDVFRUURVLRQ and repair if necessary. Check ground conductor and connection integrity and correct if needed. Ball Bearing Lubrication CAUTION Bearing overheating potential. Can damage the equipment. Do not over lubricate bearings. Use only a high grade mineral JUHDVHZLWKDƒ)VDIHRSHUDWLQJWHPSHUDWXUH6HHEHORZ IRUVSHFL¿FUHFRPPHQGHGOXEULFDQWV Motor Bearings Supply and return fans—Supply and return fan motors should have grease added after every 2000 hours of operation. Using WKHIROORZLQJSURFHGXUHUHOXEULFDWHWKHEHDULQJVZKLOHWKH PRWRULVZDUPEXWQRWUXQQLQJ8VHRQHRIWKHJUHDVHVVKRZQ in Table 23. 1. 5HPRYHDQGFOHDQXSSHUDQGORZHUJUHDVHSOXJV 2. ,QVHUWDJUHDVH¿WWLQJLQWRWKHXSSHUKROHDQGDGGFOHDQ grease (Table 23 ZLWKDORZSUHVVXUHJXQ 3. 5XQWKHPRWRUIRU¿YHPLQXWHVEHIRUHUHSODFLQJWKHSOXJV NOTE: 'LUHFW'ULYH&ODVV,,IDQVWKDWDUHVXSSOLHGZLWK7(&2 motors have double shielded bearings on frame sizes 777KHVHEHDULQJVDUHSUHSDFNHGZLWKD long life grease and are not regreaseable. Larger IUDPHVL]H7(&2PRWRUVDUHUHJUHDVHDEOHDQGIROORZ the same lubrication recommendations as all other motors. Table 23: Recommended Lubricants and Amounts for Fan Motor Bearings Manufacturers’ Grease CAUTION For safety, stop rotating quipment. Add one half of the UHFRPPHQGHGDPRXQWVKRZQLQFigure 24. Start bearing, and UXQIRUDIHZPLQX6WRSEHDULQJDQGDGGWKHVHFRQGKDOIRI the recommended amount. A temperature rise, sometimes 30°F (1°C after lubrication is normal. Bearing should operate at tempe ature less than 200°F (94°C) and should not exceed 225 (107°C) for intermittent operation. For a lubrication schedule, see Table 22. For applications that are not in the range of the table, contact Daikin. CAUTION Table 24, Table 25 and Table 26 state general lubrication recommendations based on our experience and are intended DVVXJJHVWHGRUVWDUWLQJSRLQWVRQO\)RUEHVWUHVXOWVVSHFL¿F applications should be monitored regularly and lubrication intervals and amounts adjusted accordingly. Any good quality lithium or lithium complex base grease, using mineral oil, conforming to NLGI grade 2 consistency, and an oil viscosity of 455-1135 SUS at 100°F (100-200 cSt at 40°C) may be used for re-lubrication. Compatibility of grease is critical. Lubricatable bearings are VXSSOLHGZLWKJUHDVH¿WWLQJVRU]HUNVIRUHDVHRIOXEULFDWLRQZLWK KDQGRUDXWRPDWLFJUHDVHJXQV$OZD\VZLSHWKH¿WWLQJDQG grease nozzle clean. Table 24: Lubrication Intervals Bearing Temperature Speed Cleanliness Lubrication Intervals (Use NLGI #2 Lithium or Lithium Complex Grease) 100 RPM Up to 120°F (50°C) Clean 500 RPM Up to 150°F (65°C) Clean 6 to 12 months 2 to 6 months 1000 RPM Up to 210°F (100°C) Clean ZHHNVWRPRQWKV 1500 RPM Over 210°F (100°C) to 250°F (120°C) Clean Weekly NEMA Size Amount to Add (oz.) Above 1500 RPM Up to 150°F (65°C) Dirty/Wet ZHHNWRPRQWK 56 to 140 0.08 'DLO\WRZHHNV 0.15 Over 150°F (65°C) to 250°F (120°C) Dirty/Wet 140 Max Catalog Rating 180 0.19 Texaco, Polystar or 210 0.30 Polyrex EM (Exxon Mobile) or 250 0.47 5\NRQ3UHPLXPRU 280 0.61 Penzoil Pen 2 Lube 320 0.76 360 0.81 400 1.25 440 2.12 Above 250°F (120°C) &RQWDFW%URZQLQJ NOTE: 6SHFL¿FJUHDVLQJLQVWUXFWLRQVDUHORFDWHGRQD tag attached to the motor. If special lubrication instructions are on the motor, they supersede all other instructions. ZZZ'DLNLQ$SSOLHGFRP  IM 672-10 • VISION AIR HANDLING UNIT MAINTENANCE Table 25: Recommended Lubricants for Fan Shaft Ball Bearings VM/VP Variable Pitch Key Type Sheaves Name Temperature Base Thickener NLGI Grade Texaco, Premium RB 30° to 350°F (34° to 177°C) 3DUD¿QLF Mineral Oil Lithium 2 Mobil, AW2 40° to 437°F (40° to 175°C) Mineral Oil Lithium 2 Mobil, SHC 100 68° to 356°F (50° to 180°C) Synthetic Lithium 2 Chevron, Altiplex Synthetic 60° to 450°F (51° to 232°C) Synthetic Lithium 2 Exxon, Ronex MP 40° to 300°F (40° to 149°C) Mineral Oil Lithium 2 Mounting: 1. 0RXQWDOOVKHDYHVRQWKHPRWRURUGULYLQJVKDIWZLWKWKH VHWVFUHZVAWRZDUGWKHPRWRU 2. Verify that both driving and driven sheaves are in alignment and that shafts are parallel. 3. Fit internal key DEHWZHHQVKHDYHDQGVKDIWDQGORFN VHWVFUHZA securely in place. Adjusting: 1. /RRVHQVHWVFUHZVB and C in moving parts of sheave and pull out external key E. (This key projects a small amount to provide a grip for removing.) 2. To adjust sheave pitch diameter for desired speed, open moving parts by half or full turns from closed position. Do QRWRSHQPRUHWKDQ¿YHIXOOWXUQVIRUA belts or six full turns for B belts. 3. Replace external key EDQGVHFXUHO\WLJKWHQVHWVFUHZVB RYHUNH\DQGVHWVFUHZVCLQWRNH\ZD\LQ¿[HGKDOIRIWKH sheave. 4. Put on belts and adjust tension. Do not force belts over grooves. See Fan Drive Belt on page 42. 5. Make future adjustments by loosening the belt tension and increasing or decreasing the pitch diameter of the sheave by half or full turns as required. Readjust belt tension before starting drive. 6. To provide the same pitch diameter, adjust both halves RIWKHWZRJURRYHVKHDYHVE\WKHVDPHQXPEHURIWXUQV from closed position. 7. 9HULI\WKDWDOONH\VDUHLQSODFHDQGWKDWDOOVHVFUHZV DUHWLJKWEHIRUHVWDUWLQJGULYH&KHFNVHWVFUHZVDQGEHOW tension after 24 hours service. Note: 7HPSHUDWXUHUDQJHVRYHUƒ)DUHVKRZQIRUOXEULFDQWVRQO\+LJKWHPSHUDWXUHDSSOLFDWLRQV are not suitable for standard air handler components. Table 26: Recommended Fan Lubrication Grease Charge Shaft Size in Inches (mm) Weight in Ounces (grams) 1/2 to 3/4 (20) 0.03 (0.85) 7/8 to 1-3/16 (25-30) 0.10 (2.84) 1-1/4 to 1-1/2 (35-40) 0.15 (4.25) 1-11/16 to 1-15/16 (45-50) 0.20 (5.67) 2 to 2-7/16 (55-60) 0.30 (8.51) 2-1/2 to 2-15/16 (65-70) 0.50 (15.59) 3 to 3-7/16 (75-80) 0.85 (24.10) 3-1/2 to 4 (85-105) 1.50 (42.53) Fan Drive Adjustments WARNING %HIRUH VHUYLFLQJ IDQV ORFN RXW DQG WDJ RXW DOO SRZHU WR WKH unit. Fans or belts can cause severe personal injury or death. WARNING 'R QRW RSHQ WKH KLQJHG DFFHVV GRRU DQG VFUHZIDVWHQHUG DFFHVV SDQHOV ZKLOH WKH XQLW LV RSHUDWLQJ 0RYLQJ SDUWV DQG strong suction forces can cause severe personal injury or death. Upon completion of the air balance, replace the variable SLWFKHGPRWRUVKHDYHZLWKDSURSHUO\VL]HG¿[HGVKHDYH$ PDWFKLQJ¿[HGVKHDYHSURYLGHVORQJHUEHOWDQGEHDULQJOLIH and minimizes vibration. Initially, it is best to have a variable pitched motor sheave for the purpose of air balancing. Once WKHEDODQFHLVDFKLHYHG¿[HGVKHDYHVPDLQWDLQEDODQFLQJDQG alignment more effectively. Replace the adjustable sheaves ZLWK¿[HGVKHDYHV Figure 52: VP Type Sheave Adjustment A D E Single Groove D C Key "E" projects to provide a grip for removal. :LWKWKHHOHFWULFDOSRZHUGLVFRQQHFWHGORFNHGDQGWDJJHG RXWPHDVXUHWKHGLDPHWHURIWKH9EHOWRXWHUVXUIDFHZKHUH it passes around the sheave (pitch diameter). Calculate fan speed from the motor nameplate rpm. B Do not operate sheeves with flange projecting beyond the hub end. B A E Two Groove D Measured diameter at motor sheave Fan RPM = motor RPM × Measured diameter at fan sheave C IM 672-10 • VISION AIR HANDLING UNIT 38 C ZZZ'DLNLQ$SSOLHGFRP MAINTENANCE LVP Variable Speed Sheaves Mounting: Adjusting: 1. Slide sheave on motor shaft so that the side of the VKHDYHZLWKVHWVFUHZALVQH[WWRWKHPRWRUZKHQ VHWVFUHZA is in the hub or barrel of the sheave. 1. Slack off belt tension if belts have been installed. 2. /RRVHQVHWVFUHZVD. 3. /RRVHQEXWGRQRWUHPRYHFDSVFUHZVE. 2. :KHQVHWVFUHZALVDWDQDQJOHLQWKHFHQWHUÀDQJHB, PRXQWLWDZD\IURPWKHPRWRUVRWKDWWKHRXWHUORFNLQJ ULQJDQGÀDQJHFDQEHUHPRYHGWRJHWWRWKHVHWVFUHZ 4. Remove key F. NOTE: This key projects a small amount providing a grip for removing. 3. 7RUHPRYHWKHÀDQJHDQGORFNLQJULQJ 5. Adjust pitch diameter by opening or closing the movable ÀDQJHVE\KDOIRUIXOOWXUQV a. /RRVHQVHWVFUHZVD. b. /RRVHQEXWGRQRWUHPRYHFDSVFUHZVE. c. Remove key F. NOTE: This key projects a small amount to provide a grip for removing. d. 5RWDWHWKHÀDQJHFRXQWHUFORFNZLVHXQWLOLW disengages the threads on the sheave barrel. NOTE: 7ZRJURRYHVKHDYHVDUHVXSSOLHGZLWKERWKJURRYHV set at the same pitch diameter. To provide the same pitch diameter for satisfactory operation, move both PRYDEOHÀDQJHVWKHVDPHQXPEHURIWXUQV'RQRW RSHQVKHDYHVPRUHWKDQ¿YHWXUQVIRU$EHOWVRUVL[ turns for B belts. 6. Replace key F. 4. Verify that the driving and driven sheaves are in DOLJQPHQWDQGWKHVKDIWVDUHSDUDOOHO:KHQDOLJQLQJWZR JURRYHVKHDYHVDOORZURRPEHWZHHQWKHVKHDYHDQG PRWRUWRDFFHVVFDSVFUHZVE. 5. Insert key CEHWZHHQWKHVKHDYHDQGWKHVKDIWDQG WLJKWHQVHWVFUHZA securely. 6. ,IÀDQJHDQGORFNLQJULQJKDYHEHHQUHPRYHGZKHQ replacing them make sure that the inner and outer ÀDQJHVDUHRSHQIURPWKHFORVHGSRVLWLRQE\WKHVDPH DPRXQWDVWKHRWKHUÀDQJH'HWHUPLQHWKLVE\DFFXUDWHO\ PHDVXULQJWKHWRSZLGWKRIWKHJURRYHV 7. Insert key F. 8. 7LJKWHQVHWVFUHZVDDQGFDSVFUHZVE. 7. 7LJKWHQVHWVFUHZVDDQGFDSVFUHZVE 8. If belts have been installed, readjust belt tension. If belts have not been installed, install them and adjust belt tension. Do not force belts over grooves. See Fan Drive Belt on page 42. 9. Before starting the drive, ensure that all keys are in SODFHDQGDOOVHWVFUHZVDQGDOOFDSVFUHZVDUHWLJKW &KHFNDQGUHWLJKWHQDOOVFUHZVDQGUHWHQVLRQEHOWVDIWHU approximately 24 hours of operation. 10. Replace variable speed sheaves for 15 hp motors and JUHDWHUZLWKD¿[HGSLWFKVKHDYHDIWHUDLUEDODQFLQJWR maintain fan balance integrity. Fixed sheaves furnished by others. 9. Put on belts and adjust belt tension. Do not force belts over grooves. See Fan Drive Belt. 10. Before starting the drive, ensure that all keys are in SODFHDQGDOOVHWVFUHZVDQGDOOFDSVFUHZVDUHWLJKW &KHFNDQGUHWLJKWHQDOOVFUHZVDQGUHWHQVLRQEHOWVDIWHU approximately 24 hours of service. ZZZ'DLNLQ$SSOLHGFRP  IM 672-10 • VISION AIR HANDLING UNIT MAINTENANCE MVP Variable Speed Sheaves 4. $Q\SLWFKGLDPHWHUFDQEHREWDLQHGZLWKLQWKHVKHDYH range. One complete turn of the outer locking ring changes the pitch diameter 0.233". Mounting: 1. Verify both driving and driven sheaves are in alignment and the shafts are parallel. The centerline of the driving VKHDYHPXVWEHLQOLQHZLWKWKHFHQWHUOLQHRIWKHGULYHQ sheave (Figure 54). 5. 'RQRWRSHQVKHDYHVPRUHWKDQWKHIROORZLQJ a. Do not open B sheaves more than 4-3/4 turns for the A belts or 6 turns for the B belts. 2. 9HULI\WKDWDOOVHWVFUHZVDUHWRUTXHGWRWKHYDOXHVVKRZQ in Table 27EHIRUHVWDUWLQJGULYH&KHFNVHWVFUHZWRUTXH and belt tension after 24 hours of service. b. Do not open C sheaves more than 9-1/2 turns. c. Do not open 5V sheaves more than 6 turns. Adjusting: d. Do not open 8V sheaves more than 8 turns. 1. $GMXVWPRWRUEDVHIRUZDUGWRUHOHDVHEHOWWHQVLRQ Remove the belts for easier adjustment. 6. 7LJKWHQ%27+ORFNLQJVFUHZVA in the outer locking ring EHIRUHRSHUDWLQJWKHGULYH8VHDWRUTXHZUHQFKDQG WLJKWHQWRWKHYDOXHVKRZQLQTable 27. 2. /RRVHQEXWGRQRWUHPRYHERWKRIWKHORFNLQJVHWVFUHZV A in the outer locking ring by using a hex key or torque ZUHQFKZLWKDKH[ELW 7. Replace belts and adjust the motor base to tension the belts properly. See Fan Drive Belt on page 42. 8. 'RQRWORRVHQDQ\VFUHZVRWKHUWKDQWKHWZRORFNLQJ VFUHZVALQWKHRXWHUORFNLQJULQJZKHQDGMXVWLQJWKH sheave pitch. Do not operate the drive until the locking VFUHZVKDYHEHHQVHWWRWKHWRUTXHVSHFL¿FDWLRQV 3. Adjust sheave to desired pitch diameter by turning WKHRXWHUORFNLQJULQJXVLQJDVSDQQHUZUHQFKRUGULIW inserted into the three holes that are located 120° apart on the ring. Figure 53: LVP Type Sheave Adjustment A A A E E E C C F F D A D D B Section A-A IM 672-10 • VISION AIR HANDLING UNIT Section A-A 40 ZZZ'DLNLQ$SSOLHGFRP MAINTENANCE Table 27: Screw Torque Values 6RFNHW+HDG&DS6FUHZV Nominal 6FUHZ6L]H (dia–thds/in) )ODW+HDG6RFNHW6FUHZV Seating Torque Seating Torque +ROORZ+HDG6HW6FUHZV2QO\ Lengths Equal or Greater Than Dia. For Lengths (L) Less Than Dia. Seating Torque Seating Torque Length (L) Seating Torque (in–lbs) (in–lbs) (in–lbs) (in–lbs) (in–lbs) (in) (in–lbs) ±1& 150 12.5 100 87 7.3 3/16 50 ±1& 305 25.4 200 165 13.8 1/4 90 ±1& 545 45.4 350 290 24.2 1/4, 5/16 150, 250 ±1& 1300 108.3 N/A 620 51.7 N/A N/A ±1& N/A N/A N/A 1225 102.1 N/A N/A Figure 54: MVP Sheave Adjustment Adjustable Sheave Split Taper Bushing Locking Setscrews “A” (2) Flathead Socket Screws (Do Not Remove) Motor Outer Locking Ring Capscrews (Do Not Remove) Must be parallel Must be parallel Center lines must coincide Stationary End-Flange Inner Locking Ring Holes (3) for Spanner Wrench or Drift Adjustable Fixed Center-Flange Center-Flange Bearing ZZZ'DLNLQ$SSOLHGFRP  IM 672-10 • VISION AIR HANDLING UNIT MAINTENANCE Fan Drive Belt Figure 55: Drive Belt Adjustment General Rules of Tensioning 1. 7KHLGHDOWHQVLRQLVWKHORZHVWWHQVLRQDWZKLFKWKHEHOW does not slip under peak load conditions. Deflection = 2. &KHFNWHQVLRQIUHTXHQWO\GXULQJWKH¿UVWWRKRXUV of operation. Belt span Belt span 64 3. Over tensioning shortens belt and bearing life. 4. Keep belts free from foreign material that can cause slippage. 5. Inspect V-drive on a periodic basis. Adjust tension if the belt is slipping. Do not apply belt dressing. This can damage the belt and cause early failure. Tension Measurement Procedure 1. Measure the belt span (Figure 55). 2. Place belt tension checker squarely on one belt at the center of the belt span. Apply force to the checker, SHUSHQGLFXODUWRWKHEHOWVSDQXQWLOWKHEHOWGHÀHFWLRQ equals belt span distance divided by 64. Determine the IRUFHDSSOLHGZKLOHLQWKLVSRVLWLRQ 3. Compare this force to the values in Table 28. Table 28: %HOW'HÀHFWLRQ)RUFHSHU%URZQLQJ 6SHFL¿FDWLRQV  1XPEHURI%HOWV'HÀHFWLRQ)RUFHOEV Cross Section A, AX B, BX 5V, 5VX Small Sheave Diameter (in) 1 2 3+ Min Max Min Max Min Max 0.0 to 3.5 3.0 5.0 2.5 4.0 2.0 3.5 3.6 to 4.4 3.5 5.0 3.0 4.5 2.0 4.0 4.5 + 4.0 5.5 3.0 5.0 2.5 4.5 5.5 0.0 to 5.4 5.5 8.0 4.5 7.0 3.5 5.5 to 7.6 5.5 8.5 4.5 7.5 3.5 5.5 7.7 + 6.5 9.0 5.0 8.0 4.0 6.5 0.0 to 8.5 7.0 11.0 5.5 9.0 4.0 7.0 8.6 to 12.0 8.5 13.0 6.5 10.5 5.0 8.0 12.1 + 10.0 15.0 7.5 11.5 5.5 9.0 IM 672-10 • VISION AIR HANDLING UNIT WARNING Moving belt and fan can cause severe personal injury or death. 'XULQJLQVWDOODWLRQDQG¿OWHUPDLQWHQDQFH • Verify that the belt and fan guards on plenum fan units are DOZD\VLQSODFH • Lock and tag out fans to prevent accidental start up. ‡'RQRWHQWHUWKH¿OWHUFRPSDUWPHQWXQWLOWKHIDQLVFRPSOHWHO\ stopped. ‡8VHDSSURYHGHTXLSPHQWIRUUHDFKLQJ¿OWHUVORFDWHGDERYH QRUPDOUHDFK'RQRWVWHSRQ¿OWHUIUDPHVRUXQLWFRPSRQHQWV • Floor surfaces must be dry and free of oil or grease. 42 ZZZ'DLNLQ$SSOLHGFRP MAINTENANCE Filters Table 29: Filter Pressure Drops Front Load Filter Option %DJ¿OWHUV²'UL3DN )URQWORDGHG¿OWHURSWLRQVUHTXLUHWKDWWKH¿OWHUVEHUHPRYHG and replaced from inside the unit. 7RUHPRYH¿OWHUVURWDWHWKHZLUHFOLSV7KLVUHOHDVHVERWKWKH SUH¿OWHUDQGWKH¿QDO¿OWHU:KHQLQVWDOOLQJFOHDQ¿OWHUVFKHFNWR YHULI\WKH¿OWHUVDUHIXOO\VHDWHGLQWKHIUDPHFigure 56). (I¿FLHQF\ 45% 65% 85% 95% Rated velocity (FPM) 625 500 500 500 Initial pressure drop ± ± ± ± 1.0 1.0 1.0 1.0 Initial pressure drop &DUWULGJH¿OWHUV²9DULFHO,,0+" deep Figure 56: Frame and Filters with Holding Clips (I¿FLHQF\ 65% 85% 95% Rated velocity (FPM) 500 500 500 Initial pressure drop 0.43 0.61 0.70 Final pressure drop 1.5 1.5 1.5 &DUWULGJH¿OWHUV²9DULFHO6+" deep (I¿FLHQF\ 70% Rated velocity (FPM) 500 Initial pressure drop 0.39 Final pressure drop 1.2 Type Perfect pleat AMAir 1300 4" (I¿FLHQF\ 30% 30% Rated Velocity (FPM) 500 625 Initial Pressure Drop 0.36 0.36 Final Pressure Drop 1.0 1.0 3OHDWHGSDQHO¿OWHUV F in a l F ilte r P r e filte r R o ta te W ir e C lip s F ilte r F ra m e Filter Gauges ¿OWHUV )LOWHUJDXJHVLQGLFDWHSUHVVXUHGURSIRULQVWDOOHG¿OWHUV,I SUH¿OWHUVDUHSUHVHQWWKHJDXJHZLOOLQGLFDWHWKHSUHVVXUHGURS IRUERWKSUHDQG¿QDO¿OWHUV (I¿FLHQF\ N/A Rated velocity (FPM) 500 Initial pressure drop 0.25 Table 29VKRZVWKHW\SLFDO¿OWHUSUHVVXUHGURSIRUFOHDQ¿OWHUV DWUDWHGDLUÀRZ7KHWDEOHVDOVRVKRZD¿QDOSUHVVXUHGURSIRU IURQWORDGHG¿OWHUV Final pressure drop 1.0 Size 2" 4" (I¿FLHQF\ 70% 70% Initial pressure drop 0.42 0.37 Final pressure drop 1.0 1.0 :KHUHDVLQJOH¿OWHUJDXJHLVXVHGWKHSUH¿OWHUVFDQEH UHPRYHGWRFKHFNWKHSUHVVXUHGURSRIWKH¿QDO¿OWHUV Figure 57: Filter Gauge ZZZ'DLNLQ$SSOLHGFRP  3OHDWHG3OXV¿OWHUV IM 672-10 • VISION AIR HANDLING UNIT MAINTENANCE Coils CAUTION Removing and Replacing Components 6KDUS¿QHGJHVDUHDSRWHQWLDOLQMXU\KD]DUG$YRLGFRQWDFW ZLWKWKHP 1. To obtain maximum performance, the coil must be clean. Check once a year under normal operating conditions and, if dirty, brush or vacuum clean. Use a chemical FRLOFOHDQHURQPXOWLSOHURZFRLOV5HDGDQGIROORZWKH chemical cleaner’s instructions as some cleaners may FRQWDLQKDUVKFKHPLFDOV7DNHFDUHQRWWRGDPDJH¿QV ZKLOHFOHDQLQJCAUTION—Fin edges are sharp. 2. Drain pans in any air conditioning unit may have some PRLVWXUH$OJDHHWFFDQJURZGXHWRDLUERUQHVSRUHV and bacteria. Periodic cleaning is necessary to prevent this buildup from plugging the drain and causing the GUDLQSDQWRRYHUÀRZ$OVRNHHSWKHGUDLQSDQVFOHDQ to prevent the spread of disease. Cleaning should be SHUIRUPHGE\TXDOL¿HGSHUVRQQHO WARNING Before removing any component, lock out and tag out all SRZHUWRWKHXQLW)DQVDQGEHOWVFDQFDXVHVHYHUHSHUVRQDO injury or death. Removing a Side or Top Panel 1. 5HPRYHWKHÀDWKHDGIDVWHQHUVORFDWHGDORQJWKHVLGHV of the panel. 2. Once all fasteners are removed, lift off the panel. Removing a Frame Channel Frame channels that run the length of the unit along the top FDQEHUHPRYHGWRDOORZDFFHVVWRERWKWKHVLGHDQGWRSRIWKH unit. 1. First remove any adjoining side and top panel(s). 3. Dirt and lint can clog the condensate drain, especially ZLWKGLUW\¿OWHUV,QVSHFWWZLFHD\HDUWRKHOSDYRLG RYHUÀRZ 2. 2QFHWKHVLGHSDQHOLVRIIUHPRYHWKHÀDWKHDGIDVWHQHUV in the corner of the frame channels. 3. Pull the frame channel out the side. Winterizing Water Coils 4. ,IDQ\WRSSDQHOIDVWHQVLQWRWKHIUDPHFKDQQHOZKHQ WKHIUDPHFKDQQHOLV´RUZLGHULQGLUHFWLRQRIDLUÀRZ  remove the fasteners in the top panel before pulling out the channel. WARNING Mold can cause personal injury. Clean drain pan regularly so mold does not develop. &RLOVFDQIUHH]HGXHWRDLUVWUDWL¿FDWLRQRUIDLOXUHRIRXWGRRUDLU dampers and/or preheat controls. Drain all coils as thoroughly DVSRVVLEOHDQGWKHQWUHDWLQWKHIROORZLQJPDQQHU • )LOOHDFKFRLOLQGHSHQGHQWO\ZLWKDQDQWLIUHH]HVROXWLRQ using a small circulating pump and again thoroughly drain. • Check freezing point of antifreeze before proceeding WRQH[WFRLO'XHWRDVPDOODPRXQWRIZDWHUDOZD\V remaining in each coil, there is a diluting effect. The small amount of antifreeze solution remaining in the coil must DOZD\VEHVXI¿FLHQWHQRXJKWRSUHYHQWIUHH]HXS NOTE: Carefully read instructions for mixing antifreeze solution used. Some products have a higher freezing point in WKHLUQDWXUDOVWDWHZKHQPL[HGZLWKZDWHU'DLNLQLVQRW responsible for the freezing of coils. IM 672-10 • VISION AIR HANDLING UNIT 44 ZZZ'DLNLQ$SSOLHGFRP MAINTENANCE Removing the Fan Section Removing and Replacing the Coil The fan shaft, motor, and any drive components can be removed and replaced through the access door opening. If required, the side panel can be removed for additional access. The coil can be removed by the side, top, or a combination of ERWK7KHVL]HDQGFRQ¿JXUDWLRQRIWKHFRLODIIHFWVKRZWKHFRLO can be removed. Single banks of coil are fastened only on the connection side of the unit. Stacked and staggered coils are IDVWHQHGRQERWKHQGVRIWKHFRLO6HHWKHLQVWUXFWLRQVEHORZ for details to remove each coil type. If fan replacement is required, the entire fan assembly can be pulled out the side of the cabinet for housed fan assemblies. The fan assembly includes the fan housing, the bearing support, and the fan base. 1. Remove the side panels and any intermediate supports IROORZLQVWUXFWLRQVIRUVLGHSDQHOUHPRYDO  2. Once the panels and any intermediate supports are removed, disconnect the neoprene bulk head seal that is attached to the fan discharge. 3. Remove the four discharge angles that hold the neoprene canvas in place around the discharge opening. 4. Disconnect the fan sled from each of the corner mounts and pull the entire assembly out the side of the unit. 5. After the fan sled is out, loosen the fan bearings and pull out the shaft. Before removing the coil, disconnect all piping. The instructions EHORZDVVXPHWKHFRLOLVPRXQWHGLQDVHFWLRQDOL]HGFRLO VHFWLRQZKHUHWKHIUDPHFKDQQHOFDQEHUHPRYHGZLWKRXW DIIHFWLQJRWKHUFRPSRQHQWV,IWKHFRLOVHFWLRQLVXQLWL]HGZLWK other components, removing the top frame channel requires removing additional panels. Removing Single Coils NOTE: Single coils are bolted to the unit on the connection HQG7KHFRQQHFWLRQHQGLVKHOGLQSODFHZLWKDFODPS 1. Disconnect all piping and remove the brass plugs for the vents and drains located in the connections. 2. 5HPRYHDOOVFUHZVDQGUHPRYHWKHDFFHVVSDQHO 3. 5HPRYHWKHVFUHZVKROGLQJWKHFRLOLQSODFH 6. Disconnect the fan housing from the fan sled, and bearing support by removing the attaching bolts. 4. Lift and pull the coil out the side. 7. 5HSODFHWKHQHZIDQUHFRQQHFWWKHVKDIWDQGEHDULQJV and put the fan assembly in the cabinet. Installing Single Coils 8. Replace panels and fasteners. For plenum fan assemblies, the entire fan cabinet may need to be removed to replace the entire fan assembly depending on the length of the fan section. In some cases, the fan section LVQRWORQJHQRXJKIRUWKHDVVHPEO\WR¿WRXWWKHVLGHRIWKH FDELQHW)RUWKRVHFDVHVZKHUHLWZLOO¿WIROORZWKHDERYHVWHSV except the neoprene seal is a D-gasket on the inlet side that QHHGVWREHUHPRYHGIRUSOHQXPIDQV2WKHUZLVHWKHHQWLUH fan cabinet must be removed from the other sections and then the fan assembly can be removed out the discharge side of the cabinet. 1. Slide the coil through the opening in the coil section onto the bottom coil rests. 2. To prevent any air bypass around the coil, place coils up against the coil bulkheads (refer to Figure 58). 3. Once the coil is in place, fasten the coil to the section. 4. &DXONWKHVHDPVEHWZHHQWKHFRLOFDVLQJVDQG bulkheads (refer to Figure 58). 5. If this is an additional coil being installed and not a replacement, locate the coil supply and return connections dimensionally. Carefully drill holes in the end panels of the unit. 6. Remove the brass plugs for the vents and drains on the connections. 7. Slip the panel over the connections. 8. Replace the brass plugs and panel fasteners. ZZZ'DLNLQ$SSOLHGFRP  IM 672-10 • VISION AIR HANDLING UNIT MAINTENANCE Figure 58: Single Coil Removal Opposite connection end Installing Stacked Coils 1. Slide the bottom coil through the opening in the coil section onto the bottom coil rests. Connection end 2. Place the coil up against the coil bulkheads to prevent any air bypass around the coil. Coil 3. Once the coil is in place, bolt the coil to the section. 4. Caulk the mounting surface of the steel plate and install the plate on the coils. 5. Caulk the mounting surface of the drain trough and install the drain trough on the coils. Coil 6. &DXONWKHVHDPVEHWZHHQWKHFRLOFDVLQJVDQGEORFNRIIV 7. Connect all piping and install the brass plugs for the vents and drains located in the connections. 8. Install the access panel. Removing and Installing Staggered Coils 6WDJJHUHGFRLOVKDYHWZREDQNVRIFRLOVSRVLWLRQHGDIHZ LQFKHVDSDUWLQWKHGLUHFWLRQRIDLUÀRZ%RWKFRLOVDUHVHFXUHG to the unit on the connection and opposite connection end of the unit. 1. Disconnect all piping and remove the brass plugs for the vents and drains located in the connections. 2. To access bolts holding the coils in place, remove the panels on both the connection and opposite connection end of the coil section. 3. (DFKFRLOLVKHOGLQSODFHZLWKEROWVORFDWHGLQWKHFRUQHUV of the coil side plates. Remove the bolts and then lift and pull the coil out the side. 4. The bottom coil is fastened to the air block off plate. 5HPRYHWKHVFUHZVDWWDFKLQJWKLVSODWHWRWKHFRLO 5. Once the fasteners holding the coil in place are removed, pull out the coil from either side of the unit. 6. Install the coils in reverse order of removal. Removing Stacked Coils NOTE: 7RSDQGERWWRPVWDFNHGFRLOVDUHKHOGWRJHWKHUZLWK VWHHOSODWHDQGVFUHZVRQRQHVLGHDQGGUDLQWURXJK DQGVFUHZVRQWKHRWKHUVLGH5HPRYHWKHSODWHDQG trough before removing the coils. The coils cannot be removed attached together. 1. Disconnect all piping and remove the brass plugs for the vents and drains located in the connections. 2. 5HPRYHDOOVFUHZVDQGUHPRYHWKHDFFHVVSDQHO 3. Remove the bolts holding the coil in place and then lift and pull out the coil from the side. 4. Remove the steel plate and the drain trough that hold the coils together. 5. Remove the bolts on both ends of the top coil holding it in place and then lift and slide the coil out. 6. Remove the bolts on both ends of the bottom coil holding it in place and then lift and slide the coil out. IM 672-10 • VISION AIR HANDLING UNIT 46 ZZZ'DLNLQ$SSOLHGFRP PARTS PARTS Replacement Parts :KHQZULWLQJWR'DLNLQIRUVHUYLFHRUUHSODFHPHQWSDUWVUHIHUWRWKHPRGHOQXPEHUDQGVHULDOQXPEHURIWKHXQLWVWDPSHGRQWKH serial plate attached to the unit. If replacement parts are required, mention the date of installation of the unit and date of failure, DORQJZLWKDQH[SODQDWLRQRIWKHPDOIXQFWLRQVDQGDGHVFULSWLRQRIWKHUHSODFHPHQWSDUWVUHTXLUHG ZZZ'DLNLQ$SSOLHGFRP  IM 672-10 • VISION AIR HANDLING UNIT SERVICE AND WARRANTY PROCEDURE SERVICE AND WARRANTY PROCEDURE Warranty &RQVXOW\RXUORFDO'DLNLQ5HSUHVHQWDWLYHIRUZDUUDQW\GHWDLOV 5HIHUWR)RUP<7R¿QG your local Daikin Representative, go to ZZZ'DLNLQ$SSOLHGFRP Warranty Return Material Procedure 'HIHFWLYHPDWHULDOPD\QRWEHUHWXUQHGZLWKRXWSHUPLVVLRQRI authorized factory service personnel of Daikin in Minneapolis, Minnesota, (763) 553-5330. A “Return Goods” tag must EHLQFOXGHGZLWKWKHUHWXUQHGPDWHULDO(QWHUWKHUHTXLUHG information to expedite handling and prompt issuance of credits. All parts must be returned to the appropriate Daikin facility, designated on the “Return Goods” tag. Transportation charges must be prepaid. The return of the part does not constitute an order for replacement. Therefore, a purchase order must be entered through the nearest Daikin representative. The order should include part number, model number, and serial number of the unit involved. &UHGLWZLOOEHLVVXHGRQFXVWRPHU¶VSXUFKDVHRUGHUIROORZLQJ an inspection of the return part and upon determination that WKHIDLOXUHLVGXHWRIDXOW\PDWHULDORUZRUNPDQVKLSGXULQJWKH ZDUUDQW\SHULRG IM 672-10 • VISION AIR HANDLING UNIT 48 ZZZ'DLNLQ$SSOLHGFRP CHECK, TEST, AND START PROCEDURE FORM CHECK, TEST, AND START PROCEDURE FORM Air Handling Equipment Warranty Registration Form To comply with the terms of Daikin Applied Warranty, complete and return this form within 10 days to Daikin Applied, Warranty Department Check, test, and start procedure for air handling units with or without heat recovery. Job Name: ____________________________________________________________ Daikin Applied S.O. No.: __________________ ______________________________________________________________________ Daikin Applied G.O. No.: __________________ Installation address: _____________________________________________________________________________________________ City: _________________________________________________________________ State: _________________________________ Purchasing contractor: ___________________________________________________________________________________________ City: _________________________________________________________________ State: _________________________________ Name of person doing start-up (print): ______________________________________________________________________________ Company name: ___________________________________________________________________________________________ Address: _________________________________________________________________________________________________ City/State/Zip: _____________________________________________________________________________________________ Unit model number: ____________________________________________________ Unit serial number: ______________________ SF VFD model number: __________________________________________________ Serial number: __________________________ RF VFD model number:__________________________________________________ Serial number: __________________________ Circle Yes or No. If not applicable to the type of unit, circle N/A. I. INITIAL CHECK A. Is any shipping damage visible? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes B. Are fan drives properly aligned and belts properly adjusted? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes C. Tightened all setscrews on pulleys, bearings and fans? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes D. Have the hold-down bolts been backed off on spring mounted fan isolators? . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes E. With the power off, do fans turn freely by hand? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes F. Electrical service corresponds to unit nameplate? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes No No No No No No N/A N/A N/A N/A N/A N/A No No No No No N/A N/A N/A N/A N/A No N/A No N/A Volts _____________ Hertz _____________ Phase _____________ G. H. I. J. K. Is the main disconnect adequately fused and are fuses installed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes Are all electrical power connections tight? (Check compressor, electrical box.) . . . . . . . . . . . . . . . . . . . . . . . . .Yes Is the condensate drain trapped? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes Fill the drain pan. Does water drain freely? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes Is the unit mounted level? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes II. FAN DATA A. Check rotation of supply fan? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes B. Voltage at supply fan motor: 1–2_____________ V 2–3 _____________ V 1–3 _____________ V C. Supply fan motor amp draw per phase: L1 _____________ L2 _____________ L3 _____________ D. Overload amp setting: _______________________________________________________________________ E. What is the supply fan rpm? _____________ F. Check rotation of return fan? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes G. Voltage at return fan motor: 1–2_____________ V 2–3 _____________ V 1–3 _____________ V H. Return fan motor amp draw per phase: L1 _____________ L2 _____________ L3 _____________ I. Overload amp setting: _______________________________________________________________________ J. What is the return fan rpm? _____________ K. Record supply static pressure at unit: _____________ inches of H20 L. Record return static pressure at unit (with outside air dampers closed) _____________ inches of H20 Form Number: 415416Y (02/13) ZZZ'DLNLQ$SSOLHGFRP 1  IM 672-10 • VISION AIR HANDLING UNIT CHECK, TEST, AND START PROCEDURE FORM Air Handling Equipment Warranty Registration Form (continued) III. DAMPERS A. Are blades and seals present? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes B. Do damper open smoothly and shut tight?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes No No N/A N/A IV. ELECTRIC HEAT A. Electrical heat service corresponds to unit nameplate? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes No N/A No No No N/A N/A N/A G. FLA: L1 ___________ L2____________ L3 ___________ H. Operate electric heat with fans off. Electric heat must cycle on high limit control . . . . . . . . . . . . . . . . . . . . . . . .Yes No N/A V. CHILLED WATER A. Pressure test OK? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes B. Drain pan draining OK? Yes No No N/A N/A VI. HOT WATER COIL A. Pressure test OK? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes No N/A No No N/A N/A No N/A Volts _____________ Hertz _____________ Phase _____________ B. C. D. E. F. Are there any signs of physical damage to the electric heat coils? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes Have all electrical terminals been tightened? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes Does sequence controller stage contactors properly? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes Electric heater voltage across each phase: ___________ L1 ___________ L2 ___________ L3 Amp draw across each phase at each heating stage: Stage 1 Stage 2 Stage 3 Stage 4 Stage 5 Stage 6 Phase L1: ___________ ____________ ____________ ___________ ___________ ____________ Phase L2: ___________ ____________ ____________ ___________ ___________ ____________ Phase L3 ___________ ____________ ____________ ___________ ___________ ____________ VI. HEAT RECOVERY A. Heat wheel rotates freely? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes B. Heat wheel VFD operates properly? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes C. Heat wheel VFD: Model # _________________________ Serial # _________________________ D. Check for air bypass around heat wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes Comments: Performed by: ______________________________________________ Title: ________________________________ Signature: _________________________________________________ Date of start-up: _______________________ Return completed form by mail to: Daikin Applied Warranty Department 13600 Industrial Park Boulevard Minneapolis, MN 55441 or by email to: [email protected] Please list any additional comments that could affect the operation of this unit; e.g., shipping damage, failed components, adverse installation applications, etc., on a separate sheet and attach to this form or within the email message. Form Number: 415416Y (02/13) IM 672-10 • VISION AIR HANDLING UNIT 2 50 ZZZ'DLNLQ$SSOLHGFRP QUALITY ASSURANCE SURVEY REPORT QUALITY ASSURANCE SURVEY REPORT Quality Assurance Survey Report To whom it may concern: Please review the items below upon receiving and installing our product. Mark N/A on any item that does not apply to the product. Job Name: _____________________________________________________________________ Daikin Applied G.O. No. ______________ Installation address:____________________________________________________________________________________________________ City: ___________________________________________________________________________ State: _______________________________ Purchasing contractor:__________________________________________________________________________________________________ City: ___________________________________________________________________________ State: _______________________________ Name of person doing start-up (print): ___________________________________________________________________________________ Company name: ______________________________________________________________________________________ Address: ____________________________________________________________________________________________ City/State/Zip: _______________________________________________________________________________________ 1. Is there any shipping damage visible? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A Location on unit ____________________________________________________________________________________ 2. +RZZRXOG\RXUDWHWKHRYHUDOODSSHDUDQFHRIWKHSURGXFWLHSDLQW¿QGDPDJHHWF" Excellent Good Fair Poor 3. 'LGDOOVHFWLRQVRIWKHXQLW¿WWRJHWKHUSURSHUO\"  . . . . . . . Yes No N/A 4. Did the cabinet have any air leakage? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A No N/A No N/A No N/A No N/A Location on unit ___________________________________________________________________________________ 5. Were there any refrigerant leaks? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes From where did it occur? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shipping Workmanship Design 6. Does the refrigerant piping have excessive vibration? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes Location on unit ___________________________________________________________________________________ 7. Did all of the electrical controls function at start-up? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes Comments _______________________________________________________________________________________ 8. Did the labeling and schematics provide adequate information? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes 9. How would you rate the serviceability of the product? Excellent Good Fair Poor Excellent Good Fair Poor Excellent Good Fair Poor 10. How would you rate the overall quality of the product? 11. How does the quality of Daikin Applied products rank in relation to competitive products? Comments _______________________________________________________________________________________ Please list any additional comments which could affect the operation of this unit; i.e., shipping damage, failed components, adverse installation applications, etc. If additional comment space is needed, write the comment(s) on a separate sheet, attach the sheet to this completed Quality Assurance Survey Report, and return it to the Warranty Department with the completed preceding “Equipment Warranty Registration Form”. ZZZ'DLNLQ$SSOLHGFRP  IM 672-10 • VISION AIR HANDLING UNIT Daikin Applied Training and Development 1RZWKDW\RXKDYHPDGHDQLQYHVWPHQWLQPRGHUQHI¿FLHQW'DLNLQHTXLSPHQWLWVFDUHVKRXOGEHDKLJK SULRULW\)RUWUDLQLQJLQIRUPDWLRQRQDOO'DLNLQ+9$&SURGXFWVSOHDVHYLVLWXVDWZZZ'DLNLQ$SSOLHGFRP DQGFOLFNRQ7UDLQLQJRUFDOODQGDVNIRUWKH7UDLQLQJ'HSDUWPHQW Warranty $OO'DLNLQHTXLSPHQWLVVROGSXUVXDQWWRLWVVWDQGDUGWHUPVDQGFRQGLWLRQVRIVDOHLQFOXGLQJ/LPLWHG 3URGXFW :DUUDQW\ &RQVXOW \RXU ORFDO 'DLNLQ$SSOLHG UHSUHVHQWDWLYH IRU ZDUUDQW\ GHWDLOV7R ¿QG \RXU ORFDO'DLNLQ$SSOLHGUHSUHVHQWDWLYHJRWRZZZ'DLNLQ$SSOLHGFRP Aftermarket Services 7R ¿QG \RXU ORFDO SDUWV RI¿FH YLVLW ZZZ'DLNLQ$SSOLHGFRP RU FDOO 3$576   7R¿QG\RXUORFDOVHUYLFHRI¿FHYLVLWZZZ'DLNLQ$SSOLHGFRPRUFDOO 7KLVGRFXPHQWFRQWDLQVWKHPRVWFXUUHQWSURGXFWLQIRUPDWLRQDVRIWKLVSULQWLQJ)RUWKHPRVWXSWRGDWH SURGXFWLQIRUPDWLRQSOHDVHJRWRZZZ'DLNLQ$SSOLHGFRP 3URGXFWVPDQXIDFWXUHGLQDQ,62&HUWL¿HG)DFLOLW\ IM 672-10 (03/14) ‹'DLNLQ$SSOLHG_ ±_ZZZ'DLNLQ$SSOLHGFRP HTS Oshawa 2001 Thickson Rd, South Unit #11 Whitby, ON L1N 6J3 T 905.579.6700 F 905.597.5290 ontario.htseng.com SUBMITTAL DATA APPROVAL REQUIRED AIR COOLED CONDENSING UNIT CU-1 – Associated with AHU-1 TECHNICAL INFORMATION AND DRAWINGS NOTES: 1.) Unit requires a 208/1/60 electrical feed. 2.) All refrigerant specialties, piping and refrigerant is by the installing contractor. 3.) Unit is complete with a modulating digital scroll compressor on the lead cct. a. Controls contractor to provide a 1.44vdc (10%) to 5.0Vdc (100%) capacity modulation signal. HTS. Delivering Real Success.® 203 Gum Springs Road - Longview, TX 75602 - Ph. (903) 236-4403 Fax (903) 236-4463 AAONEcat32 Ver. 4.223 (SN: 5375040-F2YBGRPM) C C - C - 0 1 7 Tag: CU# 1 - AHU-1 Air Condensing Unit - 8 - Job Information Job Name: Job Number: Site Altitude: Refrigerant: D - 2 : D 0 0 0 0 0 0 Unit Information Peterborough Art Gallery 2146423 0 ft R-410A Approx. Op./Ship Weights: Suction Temperature: Ambient Temperature: 1054 / 1054 lbs. (±5%) 45.00 ºF 90 ºF DB / 75 ºF WB Cooling Section Cooling @ 45.00º Suction : 205.8 MBH Cooling @ 35º Suction: Cooling @ 40º Suction: Cooling @ 45º Suction: Cooling @ 50º Suction: 172.5 MBH 188.7 MBH 205.8 MBH 224.1 MBH EER - AHRI Listing Information All AAON units are tested in accordance with AHRI Standards. EER @ AHRI Conditions: Application EER @ Op. Conditions: N/A 13.5 EER Compressor Only @ AHRI Conditions: N/A Electrical Data Rating: Unit FLA: 208/3/60Hz 69 Compressor 1: Compressor 2: Condenser Fans: Qty 1 1 2 Minimum Circuit Amp: Maximum Overcurrent: HP 1.00 VAC 208 208 208 Phase 3 3 1 76 100 RPM FLA 1250 7.0 RLA 27.6 27.6 Connection Sizes System 1 2 Suction Line 1.125 1.125 Date Created/Modified: 11/26/2014 1:29:50 PM Using Ver 4.223 (OSN# 5375040) Liquid Line 0.625 0.625 Date Printed: 2/12/2015 5:25:54 PM 203 Gum Springs Road - Longview, TX 75602 - Ph. (903) 236-4403 Fax (903) 236-4463 AAONEcat32 Ver. 4.223 (SN: 5375040-F2YBGRPM) C C - C - 0 1 7 Tag: CU# 1 - AHU-1 Air Condensing Unit Job Name: Job Number: C C C 017 8 D 2 D 0 0 0 0 0 0 - 8 Peterborough Art Gallery 2146423 - D - Unit Submittal For: Unit Submittal Date: Base Option Description Series Condensing Unit Generation 3rd Generation Revision Third Revision Unit Size Seventeen Tons Voltage 208V/3Ø/60Hz Compressors Variable Capacity Scroll Compressor – Lead Circuit Circuits Two Circuits Feature Option Description 1 Ambient Control Modulating Fan Pressure Control (35°F Ambient) 2 Refrigeration Option Standard - Split System Air Conditioner 3 Control Standard - Terminal Block with Control Transformer 4 Coil Standard - Copper tube coil with aluminum fins 5 Cabinet Standard 6 Warranty None 7 Type Standard Date Created/Modified: 11/26/2014 1:29:50 PM Using Ver 4.223 (OSN# 5375040) 2 : D 0 0 0 0 0 0 November 26, 2014 Date Printed: 2/12/2015 5:25:54 PM Control Terminals 2425 South Yukon Ave - Tulsa, Oklahoma 74107-2728 - Ph. (918) 583-2266 Fax (918) 583-6094 AAONEcat32 Ver. 4.223 (SN: 5375040-F2YBGRPM) C C - C - 0 1 7 - 8 - D - 2 : D 0 0 Condensing Unit Tag: 0 0 0 0 Job Information Job Name: Peterborough Art Gallery Job Number: 2146423 Terminals Available/Required for Controlling the Unit Terminal Point [R] [C] [Y1] [Y2] [CC1-] & [CS1+] Description 24VAC Control Voltage Common Cooling Stage 1 Enable Cooling Stage 2 Enable Variable Capacity Compressor (0-5 VDC) Signal Date Created/Modified: 11/26/2014 1:29:50 PM Using Ver 4.223 (OSN# 5375040) Date Printed: 2/12/2015 5:25:54 PM Date Created/Modified: 11/26/2014 1:29:50 PM Using Ver 4.223 (OSN# 5375040) Date Printed: 2/12/2015 5:25:54 PM HTS Oshawa 2001 Thickson Rd, South Unit #11 Whitby, ON L1N 6J3 T 905.579.6700 F 905.597.5290 ontario.htseng.com SUBMITTAL DATA APPROVAL REQUIRED AIR COOLED CONDENSING UNIT CU-2 – Associated with AHU-2 TECHNICAL INFORMATION AND DRAWINGS NOTES: 1.) Unit requires a 208/1/60 electrical feed. 2.) All refrigerant specialties, piping and refrigerant is by the installing contractor. 3.) Unit is complete with a modulating digital scroll compressor on the lead cct. a. Controls contractor to provide a 1.44vdc (10%) to 5.0Vdc (100%) capacity modulation signal. HTS. Delivering Real Success.® 203 Gum Springs Road - Longview, TX 75602 - Ph. (903) 236-4403 Fax (903) 236-4463 AAONEcat32 Ver. 4.223 (SN: 5375040-F2YBGRPM) C C - C - 0 1 0 Tag: CU#2 - AHU-2 Air Cooled Condenser - 8 - Job Information Job Name: Job Number: Site Altitude: Refrigerant: D - 2 : D 0 0 0 0 0 0 Unit Information Peterborough Art Gallery 2146423 0 ft R-410A Approx. Op./Ship Weights: Suction Temperature: Ambient Temperature: 854 / 854 lbs. (±5%) 45.00 ºF 90 ºF DB / 75 ºF WB Cooling Section Cooling @ 45.00º Suction : 121.0 MBH Cooling @ 35º Suction: Cooling @ 40º Suction: Cooling @ 45º Suction: Cooling @ 50º Suction: 100.5 MBH 110.4 MBH 121.0 MBH 132.2 MBH EER - AHRI Listing Information All AAON units are tested in accordance with AHRI Standards. EER @ AHRI Conditions: Application EER @ Op. Conditions: N/A 14.0 EER Compressor Only @ AHRI Conditions: N/A Electrical Data Rating: Unit FLA: 208/3/60Hz 42 Compressor 1: Compressor 2: Condenser Fans: Qty 1 1 1 Minimum Circuit Amp: Maximum Overcurrent: HP 1.00 VAC 208 208 208 Phase 3 3 1 46 60 RPM FLA 1250 7.0 RLA 16.9 17.6 Connection Sizes System 1 2 Suction Line 0.875 0.875 Date Created/Modified: 11/26/2014 1:29:50 PM Using Ver 4.223 (OSN# 5375040) Liquid Line 0.625 0.625 Date Printed: 2/12/2015 5:25:51 PM 203 Gum Springs Road - Longview, TX 75602 - Ph. (903) 236-4403 Fax (903) 236-4463 AAONEcat32 Ver. 4.223 (SN: 5375040-F2YBGRPM) C C - C - 0 1 0 Tag: CU#2 - AHU-2 Air Cooled Condenser Job Name: Job Number: C C C 010 8 D 2 D 0 0 0 0 0 0 - 8 Peterborough Art Gallery 2146423 - D - Unit Submittal For: Unit Submittal Date: Base Option Description Series Condensing Unit Generation 3rd Generation Revision Third Revision Unit Size Ten Tons Voltage 208V/3Ø/60Hz Compressors Variable Capacity Scroll Compressor – Lead Circuit Circuits Two Circuits Feature Option Description 1 Ambient Control Modulating Fan Pressure Control (35°F Ambient) 2 Refrigeration Option Standard - Split System Air Conditioner 3 Control Standard - Terminal Block with Control Transformer 4 Coil Standard - Copper tube coil with aluminum fins 5 Cabinet Standard 6 Warranty None 7 Type Standard Date Created/Modified: 11/26/2014 1:29:50 PM Using Ver 4.223 (OSN# 5375040) 2 : D 0 0 0 0 0 0 November 26, 2014 Date Printed: 2/12/2015 5:25:51 PM Control Terminals 2425 South Yukon Ave - Tulsa, Oklahoma 74107-2728 - Ph. (918) 583-2266 Fax (918) 583-6094 AAONEcat32 Ver. 4.223 (SN: 5375040-F2YBGRPM) C C - C - 0 1 0 - 8 - D - 2 : D 0 0 Condensing Unit Tag: 0 0 0 0 Job Information Job Name: Peterborough Art Gallery Job Number: 2146423 Terminals Available/Required for Controlling the Unit Terminal Point [R] [C] [Y1] [Y2] [CC1-] & [CS1+] Description 24VAC Control Voltage Common Cooling Stage 1 Enable Cooling Stage 2 Enable Variable Capacity Compressor (0-5 VDC) Signal Date Created/Modified: 11/26/2014 1:29:50 PM Using Ver 4.223 (OSN# 5375040) Date Printed: 2/12/2015 5:25:51 PM Date Created/Modified: 11/26/2014 1:29:50 PM Using Ver 4.223 (OSN# 5375040) Date Printed: 2/12/2015 5:25:51 PM HTS Oshawa 2001 Thickson Rd, South Unit #11 Whitby, ON L1N 6J3 T 905.579.6700 F 905.597.5290 ontario.htseng.com SUBMITTAL DATA APPROVAL REQUIRED AIR COOLED CONDENSING UNIT INSTALLATION AND OPERATIONS MANUALS NOTES: HTS. Delivering Real Success.® CC SERIES Condensers & Condensing Units Installation, Operation & Maintenance WARNING WARNING QUALIFIED INSTALLER FOR YOUR SAFETY Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Startup and service must be performed by a Factory Trained Service Technician. A copy of this IOM should be kept with the unit. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WARNING If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. Table of Contents Safety .............................................................................................................................................. 5 General Description ...................................................................................................................... 10 Receiving Unit .............................................................................................................................. 10 Storage .......................................................................................................................................... 10 Direct Expansion (DX) Condensing Units ................................................................................... 11 Wiring Diagrams ........................................................................................................................... 11 Installation..................................................................................................................................... 12 Locating Unit ................................................................................................................................ 12 Forklifting the Unit ....................................................................................................................... 13 Lifting the Unit ............................................................................................................................. 13 Electrical ....................................................................................................................................... 13 Thermostat .................................................................................................................................... 15 Refrigerant Piping ......................................................................................................................... 15 Determining Refrigerant Line Size ....................................................................................... 16 Liquid Line............................................................................................................................ 16 Suction Line .......................................................................................................................... 17 Hot Gas Bypass Line ............................................................................................................ 18 Hot Gas Reheat ..................................................................................................................... 19 Predetermined Line Sizes ..................................................................................................... 19 Startup ........................................................................................................................................... 23 Compressors .................................................................................................................................. 23 Charging Refrigerant & Adjusting Refrigerant Charge ................................................................ 23 Before Charging .................................................................................................................... 23 Checking Liquid Sub-Cooling .............................................................................................. 24 Adjusting Sub-Cooling and Superheat Temperatures........................................................... 24 Operation....................................................................................................................................... 27 Thermostat Operation ................................................................................................................... 27 Compressor Operation .................................................................................................................. 27 Variable Capacity Compressor Controller .................................................................................... 27 Low Voltage Terminals ................................................................................................................ 28 High Voltage Terminals ................................................................................................................ 28 Low Ambient Options................................................................................................................... 30 Maintenance .................................................................................................................................. 30 Coils .............................................................................................................................................. 30 E-Coated Coil Cleaning ................................................................................................................ 30 DX Cooling ................................................................................................................................... 32 Condenser Fan Motor Lubrication ................................................................................................ 32 Replacement Parts ......................................................................................................................... 32 AAON - Longview ....................................................................................................................... 32 Warranty, Service, and Parts Department ..................................................................................... 32 Refrigerant Piping Diagrams ........................................................................................................ 33 CC Series Startup Form ................................................................................................................ 45 Literature Change History............................................................................................................. 49 3 Index of Tables and Figures Tables: Table 1 - CC Series Clearances .................................................................................................... 12 Table 2- Recommended Elevation Minimums ............................................................................. 13 Table 3 - Predetermined Line Sizes for R-410A CC Condensing Units ...................................... 22 Table 4 - Sub-cooling and Superheat ............................................................................................ 24 Table 5 - R-410A Refrigerant Temperature-Pressure Chart ......................................................... 26 Table 6 - Demand Signal vs. Compressor Capacity Modulation.................................................. 28 Table 7 - Thermistor Temperature vs. Resistance Values ............................................................ 29 Figures: Figure 1 - Vertical Air Discharge ................................................................................................. 12 Figure 2 - Horizontal Air Discharge ............................................................................................. 12 Figure 3 - Riser height versus total equivalent line length ........................................................... 21 Figure 4 - Variable Capacity Compressor Controller ................................................................... 28 Figure 5 - Compressor Controller Flash Code Details.................................................................. 29 Figure 6 - A/C only piping, AHU above CU ................................................................................ 33 Figure 7 - A/C only piping, AHU below CU ................................................................................ 34 Figure 8 - Modulating hot gas reheat piping, AHU above CU ..................................................... 35 Figure 9 - Modulating hot gas reheat piping, AHU below CU ..................................................... 36 Figure 10 - Hot gas bypass piping, AHU above CU .................................................................... 37 Figure 11 - Hot gas bypass piping, AHU below CU .................................................................... 38 Figure 12 - Modulating hot gas reheat with hot gas bypass piping, AHU above CU .................. 39 Figure 13 - Modulating hot gas reheat with hot gas bypass piping, AHU below CU .................. 40 Figure 14 - Heat pump piping, AHU above CU ........................................................................... 41 Figure 15 - Heat pump piping, AHU below CU ........................................................................... 42 Figure 16 - Heat pump with modulating hot gas reheat piping, AHU above CU......................... 43 Figure 17 - Heat pump with modulating hot gas reheat, AHU below CU.................................... 44 R59081 · Rev. A · 140305 (ACP J00186) 4 Safety Attention should be paid to the following statements: NOTE - Notes are intended to clarify the unit installation, operation and maintenance. CAUTION - Caution statements are given to prevent actions that may result in equipment damage, property damage, or personal injury. WARNING - Warning statements are given to prevent actions that could result in equipment damage, property damage, personal injury or death. DANGER - Danger statements are given to prevent actions that will result in equipment damage, property damage, severe personal injury or death. WARNING ELECTRIC SHOCK, EXPLOSION HAZARD FIRE WARNING OR Failure to follow safety warnings exactly could result in dangerous operation, serious injury, death or property damage. Improper servicing could result in dangerous operation, serious injury, death or property damage. ¾ Before servicing, disconnect all electrical power to the unit. More than one disconnect may be provided. ¾ When servicing controls, label all wires prior to disconnecting. Reconnect wires correctly. ¾ Verify proper operation after servicing. Secure all doors with key-lock or nut and bolt. Electric shock hazard. Before servicing, disconnect all electrical power to the unit, including remote disconnects, to avoid shock hazard or injury from rotating parts. Follow proper Lockout-Tagout procedures. WARNING FIRE, EXPLOSION OR CARBON MONOXIDE POISONING HAZARD Failure to replace proper controls could result in fire, explosion or carbon monoxide poisoning. Failure to follow safety warnings exactly could result in serious injury, death or property damage. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this appliance. 5 WARNING During installation, testing, servicing and troubleshooting of the equipment it may be necessary to work with live electrical components. Only a qualified licensed electrician or individual properly trained in handling live electrical components shall perform these tasks. Standard NFPA-70E, an OSHA regulation requiring an Arc Flash Boundary to be field established and marked for identification of where appropriate Personal Protective Equipment (PPE) be worn, should be followed. WARNING GROUNDING REQUIRED All field installed wiring must be completed by qualified personnel. Field installed wiring must comply with NEC/CEC, local and state electrical code requirements. Failure to follow code requirements could result in serious injury or death. Provide proper unit ground in accordance with these code requirements. WARNING ROTATING COMPONENTS Unit contains fans with moving parts that can cause serious injury. Do not open door containing fans until the power to the unit has been disconnected and fan has stopped rotating. 6 WARNING UNIT HANDLING To prevent injury or death lifting equipment capacity shall exceed unit weight by an adequate safety factor. Always test-lift unit not more than 24 inches high to verify proper center of gravity lift point to avoid unit damage, injury or death. CAUTION Rotation must be checked on all MOTORS AND COMPRESSORS of 3 phase units at startup by a qualified service technician. Scroll compressors are directional and can be damaged if rotated in the wrong direction. Compressor rotation must be checked using suction and discharge gauges. Fan motor rotation should be checked for proper operation. Alterations should only be made at the unit power connection CAUTION Door compartments containing hazardous voltage or rotating parts are equipped with door latches to allow locks. Door latches are shipped with nut and bolts requiring tooled access. If you do not replace the shipping hardware with a pad lock always re-install the nut & bolt after closing the door. WARNING Do not work in a closed area where refrigerant or nitrogen gases may be leaking. A sufficient quantity of vapors may be present and cause injury or death. CAUTION Do not clean DX refrigerant coils with hot water or steam. The use of hot water or steam on refrigerant coils will cause high pressure inside the coil tubing and damage to the coil. CAUTION To prevent damage to the unit, do not use acidic chemical coil cleaners. Do not use alkaline chemical coil cleaners with a pH value greater than 8.5, after mixing, without first using an aluminum corrosion inhibitor in the cleaning solution. WARNING Some chemical coil cleaning compounds are caustic or toxic. Use these substances only in accordance with the manufacturer’s usage instructions. Failure to follow instructions may result in equipment damage, injury or death. WARNING WARNING COMPRESSOR CYCLING 5 MINUTE MINIMUM OFF TIME To prevent motor overheating compressors must cycle off for a minimum of 5 minutes. 5 MINUTE MINIMUM ON TIME To maintain the proper oil level compressors must cycle on for a minimum of 5 minutes. The cycle rate must not exceed 6 starts per hour. 1. Startup and service must be performed by a Factory Trained Service Technician. 2. The unit is for outdoor use only. See General Information section for more unit information. 3. Every unit has a unique equipment nameplate with electrical, operational and unit clearance specifications. Always refer to the unit nameplate for specific ratings unique to the model you have purchased. 4. READ THE ENTIRE INSTALLATION, OPERATION AND MAINTENANCE MANUAL. OTHER IMPORTANT SAFETY PRECAUTIONS ARE PROVIDED THROUGHOUT THIS MANUAL. 5. Keep this manual and all literature safeguarded near or on the unit. Do not use oxygen, acetylene or air in place of refrigerant and dry nitrogen for leak testing. A violent explosion may result causing injury or death. 7 CC Series Feature String Nomenclature 7 6 5 4 2 3 CIRCUITS COMP TYPE VOLTAGE UNIT SIZE MJREV GEN 1 : Unit Feature Options Model Option CC - C - 010 - 3 - D - 2 : B D 0 0 0 A 0 BASE MODEL OPTIONS Series and Generation CC Revision C = Design Sequence Unit Size 002 = 2 Ton Capacity - Horizontal Discharge 003 = 3 Ton Capacity - Horizontal Discharge 004 = 4 Ton Capacity - Horizontal Discharge 005 = 5 Ton Capacity - Horizontal Discharge 006 = 6 Ton Capacity 007 = 7 Ton Capacity 008 = 8 Ton Capacity 010 = 10 Ton Capacity 014 = 14 Ton Capacity 017 = 17 Ton Capacity 022 = 22 Ton Capacity 025 = 25 Ton Capacity 030 = 30 Ton Capacity 031 = 31 Ton Capacity 034 = 34 Ton Capacity 040 = 40 Ton Capacity 045 = 45 Ton Capacity 050 = 50 Ton Capacity 055 = 55 Ton Capacity 063 = 63 Ton Capacity Voltage 1 = 230V/1Φ/60Hz 2 = 230V/3Φ/60Hz 3 = 460V/3Φ/60Hz 4 = 575V/3Φ/60Hz 8 = 208V/3Φ/60Hz 9 = 208V/1Φ/60Hz Compressor Type 0 = No Compressor - Condenser Only A = R-410A Single Step Scroll Compressor B = R-410A Two Step Scroll Compressor C = R-410A Tandem Scroll Compressors D = R-410A Variable Capacity Scroll Compressor 9 = R-410A Variable Capacity Scroll Compressor Each Circuit 8 Number of Circuits 1 = One Circuit 2 = Two Circuits 4 = Four Circuits UNIT FEATURE OPTIONS Feature 1: Ambient Control 0 = Standard - 55°F Ambient B = Adjustable Fan Cycling - 35°F Ambient D = Modulating Fan Pressure Control - 35°F Ambient F = Flooded Condenser Low Ambient Controls + Option B G = Flooded Condenser Low Ambient Controls + Option D Feature 2: Refrigeration Options 0 = Standard - Split System Air Conditioner A = External Hot Gas Bypass B = Split System Heat Pump D = Modulating Hot Gas Reheat F = Options A + D G = Options B + D Feature 3: Controls 0 = Standard - Terminal Block with Control Transformer A = Suction Pressure Transducer B = Phase and Brown Out Protection C = Factory Wired 115V Outlet D = Options A + B E = Options A + C F = Options B + C G = Options A + B + C J = Variable Capacity Compressor Integrated Controls CC Series Feature String Nomenclature 7 6 5 4 2 3 CIRCUITS COMP TYPE VOLTAGE UNIT SIZE MJREV GEN 1 : Unit Feature Options Model Option CC - C - 010 - 3 - D - 2 : B D 0 0 0 A 0 Feature 4: Coil Protection 0 = Standard, A = Polymer E-Coated Coil Feature 5: Cabinet Options 0 = Standard B = Compressor Sound Blanket D = Exterior Corrosion Protection E = Options B + D R = California OSHPD Certified S = Shake Table Cert. (ASHE 7-05/ICC-ES AC 156) T = Seismic Construction (Non-Certified) U = Options D + R W = Options D + S Z = Options D + T Feature 6: Warranty 0 = Standard A = Second to Fifth Year Extended Compressor Warranty Feature 7: Type 0 = Standard X = Special Price Authorization 9 General Description AAON CC Series air-cooled condensers and condensing units have been designed for outdoor installation only. Startup and service must be performed by a Factory Trained Service Technician. WARNING Coils and sheet metal surfaces present sharp edges and care must be taken when working with equipment. WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Startup and service must be performed by a Factory Trained Service Technician . Codes and Ordinances System should be sized in accordance with the American Society of Heating, Refrigeration and Air Conditioning Engineers Handbook. Installation of CC Series units must conform to the ICC standards of the International Mechanical Code, the International Building Code, and local building, plumbing and waste water codes. All appliances must be electrically grounded in accordance with local codes, or in the absence of local codes, the current National Electric Code, ANSI/NFPA 70 or the current Canadian Electrical Code CSA C22.1. CAUTION The Clean Air Act of 1990 bans the intentional venting of refrigerant as of July 1, 1992. Approved methods of recovery, recycling, or reclaiming must be followed. 10 WARNING Failure to observe the following instructions will result in premature failure of your system and possible voiding of the warranty. Receiving Unit When received, the unit should be checked for damage that might have occurred in transit. If damage is found it should be noted on the carrier’s Freight Bill. A request for inspection by carrier’s agent should be made in writing at once. Nameplate should be checked to ensure the correct model sizes and voltages have been received to match the job requirements. The warranty card must be completed in full and returned to AAON not more than 3 months after unit is delivered. Storage If installation will not occur immediately following delivery, store equipment in a dry protected area away from construction traffic and in the proper orientation as marked on the packaging with all internal packaging in place. Secure all loose-shipped items. Direct Expansion (DX) Condensing Units Condensing units are factory assembled and wired, including a holding charge of refrigerant. Refrigeration systems include factory provided liquid line filter driers and fully hermetic scroll compressors with a positive pressure forced lubrication system. CAUTION CRANKCASE HEATER OPERATION Units are equipped with compressor crankcase heaters, which should be energized at least 24 hours prior to cooling operation, to clear any liquid refrigerant from the compressors. Never cut off the main power supply to the unit, except for servicing, emergency, or complete shutdown of the unit. When power is cut off from the unit, compressors using crankcase heaters cannot prevent refrigerant migration. This means the compressor may cool down and liquid refrigerant may accumulate in the compressor. Since the compressor is designed to pump refrigerant gas, damage may occur when power is restored. Always control the system from the thermostat, or control panel, never at the main power supply, except for servicing, emergency, or complete shutdown of the unit. Note: Low Ambient Operation Units without a low ambient option, such as adjustable fan cycling or the 0°F low ambient option, will not operate in the cooling mode of operation properly when the outdoor temperature is below 55°F. Low ambient and/or air handling unit economizer options are recommended if cooling operation below 55°F is expected. Note: Multiple Systems with Multiple Thermostats When several heating and cooling split systems are used to condition a space all thermostat switches must be set in either heating mode, cooling mode or off. Do not leave part of the systems switched to the opposite mode. Cooling only systems should be switched off at the thermostat during the heating season. Wiring Diagrams Unit specific wiring diagrams are laminated in plastic and affixed inside the controls compartment door. If power to the unit must be off for more than an hour, turn the thermostat system switch to “Off”, or turn the unit off at the control panel, and then cut off the main power supply. Leave the unit off until the main power supply has been turned on again for at least 24 hours. This will give the crankcase heater time to clear any liquid accumulation out of the compressor before it is required to run. 11 Installation AAON equipment has been designed for quick and easy installation. Locating Unit CC Series units are designed for outdoor application and placement at ground level or on a rooftop. Units must be placed on a level and solid foundation that can support the unit’s weight. Figure 1 - Vertical Air Discharge CC Series Orientation When rooftop mounted, a steel frame must be provided that will support the unit above the roof itself for load distribution. When installed at ground level, a one-piece concrete slab - preferably at least 4 inches thick - should be used with footings that extend below the frost line (a substantial base that will not settle). Slab should be surrounded by a graveled area for proper drainage and should not adjoin the building as sound and vibration may be transmitted to the structure. Care must also be taken to protect the coils and fins from damage due to vandalism or other hazards. Table 1 - CC Series Clearances Unit Size Location 2-5 tons 6-63 tons Front Unobstructed 48” Back 12” 48” Left Side 10” 36” Right Side 36” 36” Top 0” Unobstructed Right Side Left Side Front Figure 2 - Horizontal Air Discharge CC Series Orientation Air flow to and from the unit must not be restricted. Coils and fans must be free of any obstructions and debris in order to start and operate properly with a correct amount of airflow. Obstruction to airflow will result in decreased performance and efficiency. 6-63 ton units are vertical air discharge and should not be installed in an enclosure or pit that is deeper than the height of the unit. If recessed installation is necessary, the clearance to maintain proper air flow is at least 6 feet. There must be no obstruction above the equipment. Do not place the unit under an overhang. 12 2-5 ton units are horizontal discharge and must have no obstruction on the discharge side of the unit. Unit should not be installed in an enclosure or pit. Placement relative to the building or other structures must be carefully selected. Consider the effects of outdoor fan noise on any adjacent occupied space. It is recommended that the unit be placed so that air does not discharge toward windows on intakes less than 25 feet away. Service compartments must be accessible for periodic servicing of compressors, controls, safety devices, refrigerant service/shutoff valves, coils, and condenser fans. Heat pumps require special location consideration in areas where snow accumulation can become an obstruction and areas with prolonged continuous subfreezing temperatures. The unit must be placed to permit free drainage of the defrost water and ice. A minimum 3 inches clearance under the outdoor coil is required in the milder climates. In more severe weather locations, it is recommended that the unit include additional elevation to allow unobstructed drainage and airflow. Table 2- Recommended Elevation Minimums Design Suggest Minimum Temperature Elevation 3” +15q F and above 8” -5q F to +17q F 12” Below -5q F Forklifting the Unit Units can be lifted from the base using a forklift. This allows movement and placement without causing physical damage. Larger units may require a fork length of 72 inches or the fork must have 72 inch fork extensions. Smaller units can be lifted from multiple sides, while larger units must be lifted from the front side. Forks must be perpendicular to the unit and they must be in far enough that the back of the fork is no more than 6 inches away from the edge of the unit. CAUTION Incorrect lifting can cause damage to the unit. Lifting the Unit If cables or chains are used to hoist the unit they must be the same length and care should be taken to prevent damage to the cabinet. Arrange spreader bars, blocking, or other lifting devices to prevent any damage to the cabinet, coils, and condenser fans. Before lifting unit, be sure that all shipping material has been removed from unit. Secure hooks and cables at all lifting points/lugs provided on the unit. Electrical Verify the unit nameplate agrees with power supply. Connect power and control field wiring as shown on the unit specific wiring diagram provided laminated and attached to the door in the controls compartment. WARNING Electric shock hazard. Before attempting to perform any installation, service, or maintenance, shut off all electrical power to the unit at the disconnect switches. Unit may have multiple power supplies. Failure to disconnect power could result in dangerous operation, serious injury, death or property damage. 13 Route power and control wiring through the utility entries on the sides of the unit. It is recommended not to run power and control signal wires in the same conduit. If the control wires are run inside the same conduit as the power wiring use 600 volt wire, or as required by applicable codes. Size supply conductors based on the unit MCA rating. Supply conductors must be rated a minimum of 75°C. Protect the branch circuit in accordance with code requirements. The unit must be electrically grounded in accordance with local codes, or in the absence of local codes, the current National Electric Code, ANSI/NFPA 70 or the current Canadian Electrical Code CSA C22.1. Note: Units are factory wired for 208V, 230V, 460V or 575V. In some units, the 208V and 230V options may also be provided in single or three phase configurations. The transformer configuration must be checked by a qualified technician prior to startup. Wire power leads to the unit terminal block or compressor contactor. All wiring beyond this point has been done by the manufacturer and cannot be modified without effecting the unit's agency/safety certification. All units require field supplied electrical overcurrent and short circuit protection. Device must not be sized larger than the Maximum Overcurrent Protection (MOP) shown on the unit nameplate. Codes may require a disconnect switch be within sight of the unit. It is recommended that the field installed overcurrent protection or disconnect switch not be installed on the unit. 14 Supply voltage must be within the min/max range shown on the unit nameplate. Available short circuit current should not exceed the short circuit current rating (SCCR) shown on the unit nameplate. CAUTION Three phase voltage imbalance will cause motor overheating and premature failure. Three phase voltage imbalance will cause motor overheating and premature failure. The maximum allowable imbalance is 2.0%. Voltage imbalance is defined as 100 times the maximum deviation from the average voltage divided by the average voltage. Example: (221V+230V+227V)/3 = 226V, then 100*(226V-221V)/226V = 2.2%, which exceeds the allowable imbalance. Check voltage imbalance at the unit disconnect switch and at the compressor terminal. Contact your local power company for line voltage corrections. Installing contractor must check for proper motor rotation and check fan motor amperage listed on the motor nameplate is not exceeded. CAUTION Rotation must be checked on all MOTORS AND COMPRESSORS of three phase units. Condenser fan motors should be checked by a qualified service technician at startup and any wiring alteration should only be made at the unit power connection. CAUTION Scroll compressors are directional and will be damaged by operation in the wrong direction. High pressure switches on compressors have been disconnected after factory testing. Rotation should be checked by a qualified service technician at startup using suction and discharge pressure gauges and any wiring alteration should only be made at the unit power connection. CAUTION This section is for information only and is not intended to provide all details required by the designer or installer of the refrigerant piping between the condenser or condensing unit and the air handling unit. AAON, Inc. is not responsible for interconnecting refrigerant piping. Consult ASHRAE Handbook – Refrigeration and ASME Standards. Wire control signals to the unit’s low voltage terminal block located in the controls compartment. General Piping from the condensing unit to the air handler is the responsibility of the installing contractor. If any factory installed wiring must be replaced, use a minimum 105°C type AWM insulated conductors. Use only clean type “ACR” copper tubing that has been joined with high temperature brazing alloy. Thermostat If a thermostat is used for unit control, thermostat should be located on an inside wall 4-5 feet above the floor where it will not be subjected to drafts, sun exposure, or heat from electrical fixtures or appliances. Follow thermostat manufacturer’s instructions for general installation procedure. The pipe or line sizes must be selected to meet the actual installation conditions and not simply based on the connection sizes at the condensing unit or air handler. All CC Series condensing units are provided with in-line shutoff valves on both the liquid and suction lines. These should remain closed until the system is ready for start-up after installation. Thermostat control wiring size must be large enough to prevent excess voltage drop and ensure proper operation. Piping should conform to generally accepted practices and codes. All external devices must be powered via a separate external power supply. Care must be taken not to cross the circuits on multiple circuit systems. Refrigerant Piping (See back of the manual for refrigerant piping diagrams.) Upon completion of piping connection, the interconnecting piping and air handler MUST BE evacuated to 500 microns or less; leak checked and charged with refrigerant. 15 Determining Refrigerant Line Size CAUTION Line sizes must be selected to meet actual installation conditions, not simply based on the connection sizes at the condensing unit or air handling unit. The piping between the condenser and low side must ensure: 1. Minimum pressure drop, and 2. Continuous oil return, and 3. Prevention of liquid refrigerant slugging, or carryover Minimizing the refrigerant line size is favorable from an economic perspective, reducing installation costs, and reducing the potential for leakage. However, as pipe diameters narrow, pressure-reducing frictional forces increase. Excessive suction line pressure drop causes loss of compressor capacity and increased power usage resulting in reduced system efficiency. Excessive pressure drops in the liquid line can cause the liquid refrigerant to flash, resulting in faulty TXV operation and improper system performance. In order to operate efficiently and cost effectively, while avoiding malfunction, refrigeration systems must be designed to minimize both cost and pressure loss. Equivalent Line Length All line lengths discussed in this manual, unless specifically stated otherwise, are Equivalent Line Lengths. The frictional pressure drop through valves, fittings, and accessories is determined by establishing the equivalent length of straight pipe of the same diameter. Always use equivalent line 16 lengths when calculating pressure drop. Special piping provisions must be taken when lines are run underground, up vertical risers, or in excessively long line runs. Liquid Line When sizing the liquid line, it is important to minimize the refrigerant charge to reduce installation costs and improve system reliability. This can be achieved by minimizing the liquid line diameter. However, reducing the pipe diameter will increase the velocity of the liquid refrigerant which increases the frictional pressure drop in the liquid line, and causes other undesirable effects such as noise. Maintaining the pressure in the liquid line is critical to ensuring sufficient saturation temperature, avoiding flashing upstream of the TXV, and maintaining system efficiency. Pressure losses through the liquid line due to frictional contact, installed accessories, and vertical risers are inevitable. Maintaining adequate subcooling at the condenser to overcome these losses is the only method to ensure that liquid refrigerant reaches the TXV. Liquid refrigerant traveling upwards in a riser loses head pressure. If the evaporator is below the condenser, and the liquid line does not include risers, the gravitational force will increase the pressure of the liquid refrigerant. This will allow the refrigerant to withstand greater frictional losses without the occurrence of flashing prior to the TXV. A moisture-indicating sight glass may be field installed in the liquid line to indicate the occurrence of premature flashing or moisture in the line. The sight glass should not be used to determine if the system is properly charged. Use temperature and pressure measurements to determine liquid sub-cooling, not the sight glass. Liquid Line Routing Care should be taken with vertical risers. When the system is shut down, gravity will pull liquid down the vertical column, and back to the condenser when it is below the evaporator. This could potentially result in compressor flooding. A check valve can be installed in the liquid line where the liquid column rises above the condenser to prevent this. The liquid line is typically pitched along with the suction line, or hot gas line, to minimize the complexity of the configuration. Liquid Line Insulation When the liquid line is routed through regions where temperature losses are expected, no insulation is required, as this may provide additional sub-cooling to the refrigerant. When routing the liquid line through high temperature areas, insulation of the line is appropriate to avoid loss of subcooling through heat gain. Liquid Line Guidelines In order to ensure liquid at the TXV, frictional losses must not exceed available sub-cooling. A commonly used guideline to consider is a system design with pressure losses due to friction through the line not to exceed a corresponding 1-2°F change in saturation temperature. If the velocity of refrigerant in the liquid line is too great, it could cause excessive noise or piping erosion. The recommended maximum velocities for liquid lines are 100 fpm from the condenser to a receiver tank to discourage fluid backup, and 300 fpm from receiver tank to the evaporator to minimize valve induced liquid hammer. Liquid Line Accessories Liquid line shut off valves and filter driers are factory provided. Filter driers must be field installed on 2-5 ton units. The total length equivalent of pressure losses through valves, elbows and fittings must be considered when adding additional components in the field. It is a good practice to utilize the fewest elbows that will allow the mating units to be successfully joined. Suction Line The suction line is more critical than the liquid line from a design and construction standpoint. More care must be taken to ensure that adequate velocity is achieved to return oil to the compressor at minimum loading conditions. However, reducing the piping diameter to increase the velocity at minimal load can result in excessive pressure losses, capacity reduction, and noise at full load. Suction Line Routing Pitch the suction line in the direction of flow (about 1 foot per 120 feet of length) to maintain oil flow towards the compressor, and keep it from flooding back into the evaporator. Crankcase heaters are provided to keep any condensed refrigerant that collects in the compressor from causing damage or wear. Make sure to provide support to maintain suction line positioning, and insulate completely between the evaporator and condensing unit. It is important to consider part load operation when sizing suction lines. At minimum capacity, refrigerant velocity may not be adequate to return oil up the vertical riser. Decreasing the diameter of the vertical riser will increase the velocity, but also the frictional loss. CAUTION Circuits with variable capacity scroll compressors require suction riser traps every 10 feet. 17 A double suction riser can be applied to the situation of part load operation with a suction riser. A double suction riser is designed to return oil at minimum load while not incurring excessive frictional losses at full load. A double suction riser consists of a small diameter riser in parallel with a larger diameter riser, and a trap at the base of the large riser. At minimum capacity, refrigerant velocity is not sufficient to carry oil up both risers, and it collects in the trap, effectively closing off the larger diameter riser, and diverting refrigerant up the small riser where velocity of the refrigerant is sufficient to maintain oil flow. At full load, the mass flow clears the trap of oil, and refrigerant is carried through both risers. The smaller diameter pipe should be sized to return oil at minimum load, while the larger diameter pipe should be sized so that flow through both pipes provides acceptable pressure drop at full load. Suction Line Insulation The entire suction line should be insulated with a minimum 1 inch thick Armaflex insulation. This prevents condensation from forming on the line, and reduces any potential loss in capacity associated with heat gain placing additional load on the system. Suction Line Guidelines For proper performance, suction line velocities less than a 4,000 fpm maximum are recommended. The minimum velocity required to return oil is dependent on the pipe diameter, however, a general guideline of 1,000 fpm minimum may be applied. In a fashion similar to the liquid line, a common guideline to consider is a system design with pressure losses due to friction through the line not to exceed a corresponding 1-2°F change in saturation temperature. 18 At points where small pipe size can be used to provide sufficient velocity to return oil in vertical risers at part loads, greater pressure losses are incurred at full loads. This can be compensated for by over sizing the horizontal runs and vertical drop sections. This will however require additional refrigerant charge. Circuits with variable capacity scroll compressors require suction riser traps every 10 feet. Suction Line Accessories If the job requirements specify suction accumulators, they must be separately purchased and field installed. Hot Gas Bypass Line Hot Gas Bypass is available for use with DX systems that may experience low suction pressure during the operating cycle. This may be due to varying load conditions associated with VAV applications or units supplying a large percentage of outside air. The system is designed to divert refrigerant from the compressor discharge to the low pressure side of the system in order to keep the evaporator from freezing and to maintain adequate refrigerant velocity for oil return at minimum load. Hot discharge gas is redirected to the evaporator inlet via an auxiliary side connector (ASC) to false load the evaporator when reduced suction pressure is sensed. Field piping between the condensing unit and the evaporator is required. Hot Gas Bypass Piping Considerations for Evaporator above Condensing Unit Pitch the hot gas bypass (HGB) line downward in the direction of refrigerant flow, toward the evaporator. When installing hot gas bypass risers, an oil drip line must be provided at the lowest point in the system. The oil drip line must be vertical, its diameter should be the same as the diameter of the riser, and it should be 1 foot long. Install a sight glass in the oil drip line for observation. Run an oil return line, using 1/8 inch capillary tube, 10 feet in length, from the oil drip line to the suction line. Connect the oil return line below the sight glass and 1 inch above the bottom of the oil drip line. HGB valves are adjustable. Factory HGB valve settings will be sufficient for most applications, but may require slight adjustments for some applications, including some make up air applications. Insulate the entire length of the HGB line with a minimum 1 inch thick Armaflex insulation. Hot Gas Bypass Piping Considerations for Evaporator Below Condensing Unit The line must slope downward from the HGB valve toward the evaporator. Hot Gas Bypass Line Guidelines Choose a small size line to ensure oil return, and minimize refrigerant charge. Maintain velocities below a maximum of 4,000 fpm. A general minimum velocity guideline to use is approximately 1,000 fpm. Hot Gas Reheat The AAON modulating hot gas reheat system diverts hot discharge gas from the condenser to the air handling unit through the hot gas line. Field piping between the condensing unit and the air handler is required. The line delivers the hot discharge gas to the reheat coil and/or the hot gas bypass valve, so it is sized as a discharge line. Discharge lines should be sized to ensure adequate velocity of refrigerant to ensure oil return, avoid excessive noise associated with velocities that are too high, and to minimize efficiency losses associated with friction. Pitch the hot gas line in the direction of flow for oil return. When installing hot gas reheat risers, an oil drip line must be provided at the lowest point in the system. The oil drip line must be vertical, its diameter should be the same as the diameter of the riser, and it should be 1 foot long. Run a drip line, using 1/8 inch capillary tube, 10 feet in length, from the oil drip line to the suction line. Connect the oil return line below the sight glass and 1 inch above the bottom of the oil drip line. Insulate the entire length of the hot gas line with a minimum 1 inch thick Armaflex insulation. Hot Gas Reheat Guidelines Maintain velocities below a maximum of 3,500 fpm. A general minimum velocity guideline is 2,000 fpm. Predetermined Line Sizes To aid in line sizing and selection, AAON has predetermined line sizes for the liquid, suction, and hot gas lines in comfort cooling applications. In order to generate this information, the following cycle assumptions are made: Saturated suction temperature = 50°F, Saturated condensing temperature = 125°F, Sub-cooling = 10°F, Superheat = 15°F. 19 The liquid lines have been chosen to maintain velocities between 100 and 350 fpm. The suction line diameters are selected to limit velocities to a 4,000 fpm maximum, while a minimum velocity restriction is imposed by the ability to entrain oil up vertical suction risers (ASHRAE Handbook - Refrigeration). Acceptable pressure loss criteria are applied to each of the lines: The total equivalent length of the liquid line available is determined such that 3°F of liquid subcooling remain at the TXV. This includes the pressure losses in horizontal and vertical sections, accessories, elbows, etc. Recall that the available sub-cooling for the cycle is assumed as 10°F. To maintain at least 3°F sub-cooling as a factor of safety to avoid flashing at the TXV, we consider a maximum pressure loss equivalent to a 7°F change in saturation temperature. Pressure losses in the suction line are not to exceed 2°F. When to Use Predetermined Line Sizing The line sizes presented are not the only acceptable pipe diameters, they are however appropriate for general comfort cooling applications, and satisfy common job requirements. Examine the conditions, assumptions, and constraints used in the generation of the predetermined pipe diameters to ensure that this method is applicable to a particular case. Do not assume that these line sizes are appropriate for every case. Consult ASHRAE Handbook – Refrigeration for generally accepted system piping practices. How to Use Predetermined Line Sizing First, read the previous section, When to Use Predetermined Line Sizing, to decide if this method is applicable. Next, consult Table 3 for pipe diameters. 20 Examine Figure 3 to determine the acceptable line dimensions associated with the pipe diameters determined in Table 3. The figure is shown as total available riser height versus total equivalent line length for the liquid line. The curve identifies a region of acceptable piping configuration when the predetermined line sizes are selected for any model in the table. A piping configuration above the curve falls outside the assumptions used to determine the line size and will result in a loss of sub-cooling, and additional pressure losses in the suction and hot gas lines. The total equivalent line length definition includes the height of vertical rise, pressure drop through elbows and accessories, and horizontal line length, so elbows, accessories, and vertical rise must be considered when determining horizontal length available from the total equivalent line length. Figure 3 is presented in terms of the liquid line, but it assumes that the suction line length is similar, as these lines are commonly routed together to minimize the space and cost required for split system installation. CAUTION Before using this table read the When to Use Predetermined Line Sizes section. Do not assume that these line sizes are appropriate for every case. Consult ASHRAE Handbook – Refrigeration for generally accepted system piping practices. The AAON Refrigerant Piping Calculator in Ecat32 can be used for job specific line sizing. Note: CC-006, CC-007, CC-008, and CC010 HGB line sizes are based on four stage cooling operation condensing units, with two step compressors. CC-031, CC-034, CC-040, CC-045, CC-050, CC-055, and CC-063 HGB line sizes are based on four stage cooling operation condensing units, with tandem compressors. With HGB, four stage cooling is recommended on these sizes of units. Two stage cooling operation condensing units in these sizes with HGB may need larger HGB line sizes. Figure 3 - Riser Height Versus Total Equivalent Line Length Note: Figure 3 is for R-410A split system applications with CC-002 through CC-063 units. The region of acceptable riser height is the light area. Select the corresponding predetermined line size from the table above. Refer to AAON ECat32 for application specific refrigerant line sizing recommendations. CAUTION Total Equivalent Line Length in this figure is limited to 100 equivalent feet. 21 Table 3 - Predetermined Line Sizes for R-410A CC Condensing Units Connection Size Suction HGB* Model Circuit CC-002 1 3/8'' 3/4'' CC-003 1 3/8'' CC-004 1 CC-005 Predetermined Line Size Suction HGB* HGR** HGR** Liquid 3/8'' 1/2'' 3/8'' 3/4'' 3/8'' 1/2'' 3/4'' 1/2'' 1/2'' 3/8'' 3/4'' 1/2'' 1/2'' 1/2'' 7/8'' 1/2'' 5/8'' 1/2'' 7/8'' 1/2'' 5/8” 1 1/2'' 7/8'' 1/2'' 5/8'' 1/2'' 7/8'' 1/2'' 5/8'' CC-006 2 3/8'' 7/8'' 3/8'' 1/2'' 3/8'' 7/8'' 3/8'' 1/2'' CC-007 2 1/2'' 7/8'' 1/2'' 1/2'' 1/2'' 7/8'' 1/2'' 1/2'' CC-008 2 1/2'' 7/8'' 1/2'' 5/8'' 1/2'' 7/8'' 1/2'' 5/8'' CC-010 2 1/2'' 7/8'' 1/2'' 5/8'' 1/2'' 7/8'' 1/2'' 5/8'' CC-014 2 5/8'' 1 1/8'' 1/2'' 5/8'' 5/8'' 1 1/8'' 1/2'' 5/8'' CC-017 2 5/8'' 1 1/8'' 5/8'' 3/4'' 5/8'' 1 1/8'' 5/8'' 3/4'' CC-022 2 3/4'' 1 3/8'' 5/8'' 3/4'' 3/4'' 1 3/8'' 5/8'' 3/4'' CC-025 2 3/4'' 1 3/8'' 3/4'' 7/8'' 3/4'' 1 3/8'' 3/4'' 7/8'' CC-030 2 7/8'' 1 3/8'' 3/4'' 7/8'' 7/8'' 1 3/8'' 3/4'' 7/8'' 2 4 2 4 2 4 2 4 2 4 2 4 2 4 7/8" 5/8'' 7/8" 5/8'' 1 1/8'' 5/8'' 1 1/8'' 3/4'' 1 1/8'' 3/4'' 1 1/8'' 3/4'' 1 1/8'' 7/8'' 1 3/8'' 1 1/8'' 1 5/8" 1 1/8'' 1 5/8" 1 3/8'' 1 5/8" 1 3/8'' 1 5/8" 1 3/8'' 1 5/8" 1 3/8'' 1 5/8" 1 3/8'' 3/4'' 5/8'' 3/4'' 5/8'' 7/8'' 5/8'' 7/8" 5/8'' 7/8" 5/8'' 7/8" 3/4'' 7/8" 3/4'' 7/8'' 5/8'' 7/8'' 3/4'' 1 1/8'' 3/4'' 1 1/8'' 3/4'' 1 1/8'' 3/4'' 1 1/8'' 7/8'' 1 1/8'' 7/8'' 7/8" 5/8'' 7/8" 5/8'' 1 1/8'' 5/8'' 1 1/8'' 3/4'' 1 1/8'' 3/4'' 1 1/8'' 3/4'' 1 1/8'' 7/8'' 1 3/8'' 1 1/8'' 1 5/8" 1 1/8'' 1 5/8" 1 3/8'' 1 5/8" 1 3/8'' 1 5/8" 1 3/8'' 1 5/8" 1 3/8'' 1 5/8" 1 3/8'' 3/4'' 5/8'' 3/4'' 5/8'' 7/8'' 5/8'' 7/8" 5/8'' 7/8" 5/8'' 7/8" 3/4'' 7/8" 3/4'' 7/8'' 5/8'' 7/8'' 3/4'' 1 1/8'' 3/4'' 1 1/8'' 3/4'' 1 1/8'' 3/4'' 1 1/8'' 7/8'' 1 1/8'' 7/8'' CC-031 CC-034 CC-040 CC-045 CC-050 CC-055 CC-063 Liquid *Hot Gas Bypass Line **Hot Gas Reheat Line 22 Startup (See back of the manual for startup form.) WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Startup and service must be performed by a Factory Trained Service Technician. WARNING Electric shock hazard. Shut off all electrical power to the unit to avoid shock hazard or injury from rotating parts. Compressors All compressors are equipped with crankcase heaters, which should be energized at least 24 hours prior to cooling operation of the compressor. CAUTION Rotation must be checked on all MOTORS AND COMPRESSORS of three phase units. Condenser fan motors should all be checked by a qualified service technician at startup and any wiring alteration should only be made at the unit power connection. CAUTION Scroll compressors are directional and will be damaged by operation in the wrong direction. High pressure switches on compressors have been disconnected after factory testing. Rotation should be checked by a qualified service technician at startup using suction and discharge pressure gauges and any wiring alteration should only be made at the unit power connection. Charging Refrigerant & Adjusting Refrigerant Charge Charging a system in the field must be based on determination of liquid sub-cooling and evaporator superheat. On a system with a thermostatic expansion valve (TXV) liquid sub-cooling is more representative of the charge than evaporator superheat but both measurements must be taken. CAUTION The Clean Air Act of 1990 bans the intentional venting of refrigerant (CFC’s and HCFC’s) as of July 1, 1992. Approved methods of recovery, recycling or reclaiming must be followed. Fines and/or incarceration may be levied for non-compliance. Before Charging Unit being charged must be at or near full load conditions before adjusting the charge. Units equipped with hot gas bypass must have the hot gas bypass valve closed to get the proper charge. 23 Units equipped with hot gas reheat must be charged with the hot gas valves closed while the unit is in cooling mode. After charging, unit should be operated in reheat (dehumidification) mode to check for correct operation. Checking Evaporator Superheat Measure the temperature of the suction line close to the compressor. After adding or removing charge the system must be allowed to stabilize, typically 10-15 minutes, before making any other adjustments. Convert the pressure obtained to a saturated temperature using the appropriate refrigerant temperature-pressure chart or Table 5 below. The type of unit and options determine the ranges for liquid sub-cooling and evaporator superheat. Refer to Table 4 below when determining the proper sub-cooling. The vertical rise of the liquid line must be known in order to adjust the sub-cooling range for proper charge. Checking Liquid Sub-Cooling Measure the temperature of the liquid line as it leaves the condenser coil. Read the gauge pressure reading of the liquid line close to the point where the temperature was taken. You must use liquid line pressure as it will vary from discharge pressure due to condenser coil pressure drop. Convert the pressure obtained to a saturated temperature using the appropriate refrigerant temperature-pressure chart or Table 5 below. Subtract the measured liquid line temperature from the saturated temperature to determine the liquid sub-cooling. Compare calculated sub-cooling to Table 4 below for the appropriate unit type and options. 24 Read gauge pressure at the suction line close to the compressor. Subtract the saturated temperature from the measured suction line temperature to determine the evaporator superheat. Compare calculated superheat to Table 4 below for the appropriate unit type and options. Table 4 - Sub-Cooling and Superheat Air-Cooled Condenser / Air-Source Heat Pump Sub-Cooling* 12-18°F Sub-Cooling with 15-22°F Hot Gas Reheat* Superheat** 8-15°F * Sub-Cooling must be increased by 2°F per 20 feet of vertical liquid line rise for R-410A ** Superheat will increase with long suction line runs. Adjusting Sub-Cooling and Superheat Temperatures The system is overcharged if the sub-cooling temperature is too high and the evaporator is fully loaded (low loads on the evaporator result in increased sub-cooling) and the evaporator superheat is within the temperature range as shown in Table 4 (high superheat results in increased sub-cooling). Correct an overcharged system by reducing the amount of refrigerant in the system to lower the sub-cooling. CAUTION If the sub-cooling is correct and the superheat is too high, the TXV may need adjustment to correct the superheat. DO NOT OVERCHARGE! Refrigerant overcharging leads to excess refrigerant in the condenser coils resulting in elevated compressor discharge pressure. The system is undercharged if the superheat is too high and the sub-cooling is too low. Correct an undercharged system by adding refrigerant to the system to reduce superheat and raise sub-cooling. CAUTION Before completing startup and leaving the unit a complete operating cycle should be observed to verify that all components are functioning properly. 25 °F 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 26 PSIG 78.3 80.0 81.8 83.6 85.4 87.2 89.1 91.0 92.9 94.9 96.8 98.8 100.9 102.9 105.0 107.1 109.2 111.4 113.6 115.8 118.1 120.3 122.7 125.0 127.4 129.8 132.2 Table 5 - R-410A Refrigerant Temperature-Pressure Chart PSIG PSIG PSIG °F °F °F 134.7 213.7 321.0 47 74 101 137.2 217.1 325.6 48 75 102 139.7 220.6 330.2 49 76 103 142.2 224.1 334.9 50 77 104 144.8 227.7 339.6 51 78 105 147.4 231.3 344.4 52 79 106 150.1 234.9 349.3 53 80 107 152.8 238.6 354.2 54 81 108 155.5 242.3 359.1 55 82 109 158.2 246.0 364.1 56 83 110 161.0 249.8 369.1 57 84 111 163.8 253.7 374.2 58 85 112 166.7 257.5 379.4 59 86 113 169.6 261.4 384.6 60 87 114 172.5 265.4 389.9 61 88 115 175.4 269.4 395.2 62 89 116 178.4 273.5 400.5 63 90 117 181.5 277.6 405.9 64 91 118 184.5 281.7 411.4 65 92 119 187.6 285.9 416.9 66 93 120 190.7 290.1 422.5 67 94 121 193.9 294.4 428.2 68 95 122 197.1 298.7 433.9 69 96 123 200.4 303.0 439.6 70 97 124 203.6 307.5 445.4 71 98 125 207.0 311.9 451.3 72 99 126 210.3 316.4 457.3 73 100 127 °F 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 PSIG 463.2 469.3 475.4 481.6 487.8 494.1 500.5 506.9 513.4 520.0 526.6 533.3 540.1 547.0 553.9 560.9 567.9 575.1 582.3 589.6 596.9 604.4 611.9 Operation Unit operations should be controlled with thermostat, or unit controller, never at the main power supply, except for emergency, servicing, or complete shutdown of the unit. Thermostat Operation Heating Thermostat system switch - "Heat" Thermostat fan switch - "Auto" or "On" Thermostat temperature set to desired point. Cooling Thermostat system switch - "Cool" Thermostat fan switch - "Auto" or "On" Thermostat temperature set to desired point. Air Circulation Thermostat system switch - "Off" Thermostat fan switch - "Auto" or "On" No change of the thermostat temperature. With these settings, the air handler’s supply fan will run continuously but the supply air will not be heated, cooled, or dehumidified. System Off Thermostat system switch - "Off" Thermostat fan switch - "Auto" No change of the thermostat temperature. With these settings, the system is shut down, with the exception of the control system power (24 VAC), and the crankcase heaters (about 60 watts/compressor). Compressor Operation The compressors must be off for a minimum of 5 minutes and on for a minimum of 5 minutes. Short cycling of the compressors can causes undue stress and wear. WARNING COMPRESSOR CYCLING 5 MINUTE MINIMUM OFF TIME To prevent motor overheating compressors must cycle off for a minimum of 5 minutes. 5 MINUTE MINIMUM ON TIME To maintain the proper oil level compressors must cycle on for a minimum of 5 minutes. The cycle rate must not exceed 6 starts per hour. Variable Capacity Compressor Controller Units with variable capacity scroll compressors may include variable capacity compressor controller. The following is an explanation of the terminals and troubleshooting of the alert flash codes on the controller. For more information on the compressor controller, see Emerson Climate Bulletin AE8-1328. Night and Weekend Unoccupied Operation To reduce the operating time of the unit when the space is unoccupied, such as nights and weekends, it is recommended that the temperature setting be raised about 5°F while unoccupied during the cooling season and lowered about 10°F during the heating season. 27 High Voltage Terminals A1 & A2 Alarm Relay Out M1 & M2 Contactor L1 Control Voltage N L2 Control Voltage L U1 & U2 Digital Unloader Solenoid V1 & V2 Vapor Injection Solenoid WARNING Figure 4 - Variable Capacity Compressor Controller Low Voltage Terminals 24COM Module Common 24VAC Module Power C1 & C2 Demand Input P1 Pressure Common P2 Pressure Input P3 Pressure Power 5VDC P4 Pressure Shield P5 & P6 Pressure Output T1 & T2 Discharge Temperature Sensor To avoid damaging the compressor controller, DO NOT connect wires to terminals C3, C4, T3, T4, T5, or T6. The compressor controller modulates the compressor unloader solenoid in an on/off pattern according the capacity demand signal of the system. The following table shows the linear relationship between the demand signal and compressor capacity modulation. The compressor controller also protects the compressor against high discharge temperature. Refer to Table 7 for the relationship between thermistor temperature readings and resistance values. Table 6 - Demand Signal vs. Compressor Capacity Modulation Demand Signal (VDC) 1.00 1.44 3.00 4.20 5.00 28 Loaded % Unloaded % Time Loaded Off 10% 50% 80% 100% Off 90% 50% 20% 0% Off 1.5 sec 7.5 sec 12 sec 15 sec Time Unloaded Off 13.5 sec 7.5 sec 3 sec 0 sec % Compressor Capacity 0% 10% 50% 80% 100% Figure 5 - Compressor Controller Flash Code Details °C -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 Table 7 - Thermistor Temperature vs. Resistance Values °F kΩ °C °F -40 2889.60 75 167 -31 2087.22 80 176 -22 1522.20 85 185 -13 1121.44 90 194 -4 834.72 95 203 5 627.28 100 212 14 475.74 105 221 23 363.99 110 230 32 280.82 115 239 41 218.41 120 248 50 171.17 125 257 59 135.14 130 266 68 107.44 135 275 77 86.00 140 284 86 69.28 145 293 95 56.16 150 302 104 45.81 155 311 113 37.58 160 320 122 30.99 165 329 131 25.68 170 338 140 21.40 175 347 149 17.91 180 356 158 15.07 kΩ 12.73 10.79 9.20 7.87 6.77 5.85 5.09 4.45 3.87 3.35 2.92 2.58 2.28 2.02 1.80 1.59 1.39 1.25 1.12 1.01 0.92 0.83 29 Low Ambient Options Adjustable fan cycling is a low ambient head pressure control option that cycles the condenser fans to maintain refrigerant circuit head pressures at acceptable levels during cooling operation. The head pressure set point (100-470 psi) and pressure differential (35-200 psi) are field adjustable. Modulating fan pressure control is a low ambient head pressure control option that sends to an electronically commutated motor a variable signal in relation to the refrigerant circuit head pressure of the system. The motor either speeds up or slows down air flow accordingly in order to maintain constant head pressure. Both head pressure control options allow mechanical cooling with ambient temperatures down to 35°F. The AAON 0°F low ambient system maintains normal head pressure during periods of low ambient by effectively reducing the heat transfer surface area, reducing capacity and increasing condensing pressure, allowing the system to operate properly. During periods with higher ambient temperatures the entire condenser is required to condense refrigerant. Maintenance (See back of the manual for maintenance log) pressures and checking for normal subcooling and superheat. Only Factory Trained Service Technicians experienced in both condensing units and air conditioning are permitted to service the CC Series units to keep warranties in effect. Coils The condenser coils should be inspected yearly to ensure unrestricted airflow. If the coils contain a large amount of airborne dust or other material, they should be cleaned. Care must be taken to prevent bending of the aluminum fins on the coils. Before attempting to clean the coils; set thermostat to the "OFF" position; turn the electrical power to the unit to the "OFF" position at the disconnect switch. The condenser coil can be thoroughly cleaned by washing from the inside out with water and a coil cleaner. If coil is extremely dirty with clogged fins, a service professional specializing in coil cleaning should be called. E-Coated Coil Cleaning Documented routine cleaning of e-coated coils is required to maintain coating warranty coverage. WARNING WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Startup and service must be performed by a Factory Trained Service Technician. At least once each year, a qualified service technician should check out the unit. This includes reading and recording suction 30 Electric shock hazard. Shut off all electrical power to the unit to avoid shock hazard or injury from rotating parts. Surface loaded fibers or dirt should be removed prior to water rinse to prevent restriction of airflow. If unable to back wash the side of the coil opposite of the coils entering air side, then surface loaded fibers or dirt should be removed with a vacuum cleaner. If a vacuum cleaner is not available, a soft non-metallic bristle brush may be used. In either case, the tool should be applied in the direction of the fins. Coil surfaces can be easily damaged (fin edges bent over) if the tool is applied across the fins. Use of a water stream, such as a garden hose, against a surface loaded coil will drive the fibers and dirt into the coil. This will make cleaning efforts more difficult. Surface loaded fibers must be completely removed prior to using low velocity clean water rinse. A monthly clean water rinse is recommended for coils that are applied in coastal or industrial environments to help to remove chlorides, dirt, and debris. It is very important when rinsing, that water temperature is less than 130°F and pressure is than 900 psig to avoid damaging the fin edges. An elevated water temperature (not to exceed 130°F) will reduce surface tension, increasing the ability to remove chlorides and dirt. CAUTION High velocity water from a pressure washer or compressed air should only be used at a very low pressure to prevent fin and/or coil damages. The force of the water or air jet may bend the fin edges and increase airside pressure drop. Reduced unit performance or nuisance unit shutdowns may occur. Quarterly cleaning is essential to extend the life of an e-coated coil and is required to maintain coating warranty coverage. Coil cleaning shall be part of the unit’s regularly scheduled maintenance procedures. Failure to clean an e-coated coil will void the warranty and may result in reduced efficiency and durability. CAUTION Harsh chemicals, household bleach, or acid cleaners should not be used to clean outdoor or indoor e-coated coils. These cleaners can be very difficult to rinse out of the coil and can accelerate corrosion and attack the e-coating. If there is dirt below the surface of the coil, use the recommended coil cleaners. For routine quarterly cleaning, first clean the coil with the below approved coil cleaner. After cleaning the coils with the approved cleaning agent, use the approved chloride remover to remove soluble salts and revitalize the unit. Recommended Coil Cleaner The following cleaning agent, assuming it is used in accordance with the manufacturer’s directions on the container for proper mixing and cleaning, has been approved for use on e-coated coils to remove mold, mildew, dust, soot, greasy residue, lint, and other particulate: Enviro-Coil Concentrate, Part Number HEC01. Recommended Chloride Remover CHLOR*RID DTS™ should be used to remove soluble salts from the e-coated coil, but the directions must be followed closely. This product is not intended for use as a degreaser. Any grease or oil film should first be removed with the approved cleaning agent. Remove Barrier - Soluble salts adhere themselves to the substrate. For the effective 31 use of this product, the product must be able to come in contact with the salts. These salts may be beneath any soils, grease or dirt; therefore, these barriers must be removed prior to application of this product. As in all surface preparation, the best work yields the best results. Apply CHLOR*RID DTS - Apply directly onto the substrate. Sufficient product must be applied uniformly across the substrate to thoroughly wet out surface, with no areas missed. This may be accomplished by use of a pump-up sprayer or conventional spray gun. The method does not matter, as long as the entire area to be cleaned is wetted. After the substrate has been thoroughly wetted, the salts will be soluble and is now only necessary to rinse them off. Rinse - It is highly recommended that a hose be used, as a pressure washer will damage the fins. The water to be used for the rinse is recommended to be of potable quality, though a lesser quality of water may be used if a small amount of CHLOR*RID DTS is added. Check with CHLOR*RID International, Inc. for recommendations on lesser quality rinse water. DX Cooling Set unit controls to cooling mode of operation with supply fans on. Check compressor operation, rotation, amperage and voltage to the unit nameplate (check the 32 amperage on the load side of the compressor contactor). The scroll compressors are fully hermetic and require no maintenance except for keeping the shell clean. Each refrigerant circuit includes a factory provided liquid line filter drier. The unit does not include a liquid line solenoid valve. This must be field furnished and installed if required by job conditions. Condenser Fan Motor Lubrication All original motors and bearings are furnished with factory lubrication. They require no lubrication. Replacement Parts Parts for AAON equipment may be obtained from AAON, Inc. at www.aaonparts.com. When ordering parts, reference the unit serial number and part number. AAON - Longview Warranty, Service, and Parts Department 203 Gum Springs Rd. Longview, TX 75602 Ph: 903-236-4403 Fax: 903-247-9219 www.aaon.com Note: Before calling, technician should have model and serial number of the unit available for the customer service department to help answer questions regarding the unit. Refrigerant Piping Diagrams Figure 6 - A/C Only Piping, AHU Above CU 33 Figure 7 - A/C Only Piping, AHU Below CU 34 Figure 8 - Modulating Hot Gas Reheat Piping, AHU Above CU 35 Figure 9 - Modulating Hot Gas Reheat Piping, AHU Below CU 36 Figure 10 - Hot Gas Bypass Piping, AHU Above CU 37 Figure 11 - Hot Gas Bypass Piping, AHU Below CU 38 Figure 12 - Modulating Hot Gas Reheat with Hot Gas Bypass Piping, AHU Above CU 39 Figure 13 - Modulating Hot Gas Reheat with Hot Gas Bypass Piping, AHU Below CU 40 Figure 14 - Heat Pump Piping, AHU Above CU 41 Figure 15 - Heat Pump Piping, AHU Below CU 42 Figure 16 - Heat Pump with Modulating Hot Gas Reheat Piping, AHU Above CU 43 Figure 17 - Heat Pump with Modulating Hot Gas Reheat, AHU Below CU 44 CC Series Startup Form Date:______________ Job Name:_____________________________________________________________________ Address:______________________________________________________________________ Model Number:_________________________________________________________________ ______________________________________________________________________________ Serial Number:_____________________________________________ Tag:_______________ Startup Contractor:______________________________________________________________ Address:__________________________________________________ Phone:_____________ _________________________________________________________ Pre Startup Checklist Installing contractor should verify the following items. 1. Is there any visible shipping damage? 2. Is the unit level? 3. Are the unit clearances adequate for service and operation? 4. Do all access doors open freely and are the handles operational? 5. Have all shipping braces been removed? 6. Have all electrical connections been tested for tightness? 7. Does the electrical service correspond to the unit nameplate? 8. On 208/230V units, has transformer tap been checked? 9. Has overcurrent protection been installed to match the unit nameplate requirement? 10. Have all set screws on the fans been tightened? 11. Do all fans and pumps rotate freely? 12. Is all copper tubing isolated so that it does not rub? Ambient Temperature Ambient Dry Bulb Temperature ________°F Yes Yes Yes Yes Yes Yes Yes Yes No No No No No No No No Yes Yes Yes Yes No No No No Ambient Wet Bulb Temperature ________°F Compressors / DX Cooling Compressor Number 1 2 3 4 L1 L2 L3 Head Pressure PSIG Suction Pressure PSIG Crankcase Heater Amps 45 Refrigeration System 1 - Cooling Mode Saturated Pressure Temperature Discharge Suction Liquid Refrigeration System 2 - Cooling Mode Saturated Pressure Temperature Discharge Suction Liquid Refrigeration System 3 - Cooling Mode Saturated Pressure Temperature Discharge Suction Liquid Refrigeration System 4 - Cooling Mode Saturated Pressure Temperature Discharge Suction Liquid 46 Line Temperature Sub-cooling Superheat N/A N/A N/A N/A Line Temperature Sub-cooling Superheat N/A N/A N/A N/A Line Temperature Sub-cooling Superheat N/A N/A N/A N/A Line Temperature Sub-cooling Superheat N/A N/A N/A N/A Refrigeration System 1 - Heating Mode (Heat Pump Only) Saturated Line Pressure Temperature Temperature Discharge Suction Liquid Refrigeration System 2 - Heating Mode (Heat Pump Only) Saturated Line Pressure Temperature Temperature Discharge Suction Liquid Refrigeration System 3 - Heating Mode (Heat Pump Only) Saturated Line Pressure Temperature Temperature Discharge Suction Liquid Refrigeration System 4 - Heating Mode (Heat Pump Only) Saturated Line Pressure Temperature Temperature Discharge Suction Liquid Sub-cooling Superheat N/A N/A N/A N/A Sub-cooling Superheat N/A N/A N/A N/A Sub-cooling Superheat N/A N/A N/A N/A Sub-cooling Superheat N/A N/A N/A N/A Condenser Fans Alignment Number 1 2 3 4 5 6 Check Rotation hp L1 Nameplate Amps________ L2 L3 Condenser Pump Check Rotation Number 1 2 hp Nameplate Amps________ L1 L2 L3 47 Maintenance Log This log must be kept with the unit. It is the responsibility of the owner and/or maintenance/service contractor to document any service, repair or adjustments. AAON Service and Warranty Departments are available to advise and provide phone help for proper operation and replacement parts. The responsibility for proper start-up, maintenance and servicing of the equipment falls to the owner and qualified licensed technician. Entry Date 48 Action Taken Name/Tel. Literature Change History March 2009 Update of IOM revising the model numbers, manual format, and piping diagrams to show factory installed liquid line receiver tank. November 2009 Update of IOM adding variable capacity scroll compressor information September 2010 Update of IOM to include water cooled condenser options and updated model and feature options. Text size in piping diagrams was increased for readability. March 2012 Update of piping diagrams P1, P3, P4, and P6 and addition of piping diagram P7. Added oil drip note below piping diagrams. Updated startup form. May 2012 Updated table of contents. March 2013 Update of the manual adding information about compressor cycling. May 2013 Add variable capacity compressor section, updated piping diagrams to show internal receivers and modulating reheat valves, updated predetermined line sizing, updated features description, and updated design revision from B to C. New part number assigned. March 2014 Updated predetermined line sizing chart and unit feature options. 49 50 AAON 203 Gum Springs Rd. Longview, TX 75602-1721 Phone: 903-236-4403 Fax: 903-236-4463 www.aaon.com CC Series Installation, Operation & Maintenance R59081 · Rev. A · 140305 (ACP J00186) It is the intent of AAON, Inc. to provide accurate and current specification information. However, in the interest of product improvement, AAON, Inc. reserves the right to change pricing, specifications, and/or design of its products without notice, obligation or liability Copyright © AAON, Inc., all rights reserved throughout the world. AAON® & AAONAIRE® are registered trademarks of AAON, Inc., Tulsa, OK. Project Name: 2146423 Peterborough Art Gallery Tag H−1 Qty Multi 1 Humidifier Model (1)VM−10 Load (lbs/hr) 25.71 Air Volume (CFM) 5725.00 Volts/Phase/ Amp (Each) 208 / Three / 29.1 Control Input Signal 2−10 VDC Dispersion Model (1)ULTRA−SORB LH Absorp. Entering Dist. Conditions (inches) Dry Bulb/RH 6 54.2(°F)/ 59% Leaving Conditions Dry Bulb/RH 55.0(°F)/ 69% Duct Area WxH (inches) Heat Gain from Assembly 40 x 16 0.48(°F) Heat Gain from Steam 0.30(°F) DRI−STEEM Schedule Report Page 1 of 1 Version DRI−CALC 3.26.00P HTS Oshawa 2001 Thickson Rd, South Unit #11 Whitby, ON L1N 6J3 T 905.579.6700 F 905.597.5290 ontario.htseng.com SUBMITTAL DATA APPROVAL REQUIRED ELECTRIC TO STEAM HUMIDIFIER HUM-1 – Associated with AHU-1 – GALLERY, VAULT AND STORAGE TECHNICAL INFORMATION AND DRAWINGS NOTES: 1.) Humidifier requires a 208/3/60 electrical feed. 2.) Humidifier is complete with the following accessories shipped loose for installation: a. Ultra-Sorb Dispersion Unit (Duct Mounted) b. Air Proving Switch c. High Limit Humidistat (ON-OFF) d. Drane-Kooler – Floor Mounted HTS. Delivering Real Success.® Project Name: 2146423 Peterborough Art Gallery Quote Date: 02.12.2015 Unit of Measure: Inch−Pound Humidifier Tag: H−1 1 Calculation Method: System Quantity: 500.0 Desired Dry Bulb (°F) Elevation (feet) Entering Dry Bulb (°F) −12.0 Desired RH (%) 86.05 Actual RH (%) Entering RH (%) Mechanical 72.0 40 39 Airflow (CFM) Entering Outside Air (%) Load (lbs/hr) Load Plus Loss (lbs/hr) 5725.00 16 25.71 30.78 (All Values are per unit, unless otherwise noted) Energy Source Electric Water Type Potable Total Humidifier Capacity (lbs/hr) 30.0 Model Multi Qty. Volts/Phase/Amp (Each) VM−10 1 208/Three/29.1 Selected Humidifier Options: · Type of Water:Potable · DRANE−KOOLER · DRANE−KOOLER, Floor Stand Humidifier Outlet Type Hose Size (inches) WxHxL Stages kW 16.09 x 18.59 x 24.19 1 10.0 Diameter Qty. (inches) 1 1/2 1 Selected Control Options: · VAPOR−LOGIC 4 · Building Automation System, BacNet · Type of Control, Modulating · SSR · Type of Signal by Others 2−10 VDC · Airflow Proving Switch, Pressure · Humidistat, On−Off High Limit, Duct Selected Cabinet Options: · Remote Keypad · Keypad Cable Length, 10 (feet) · Keypad, Language, English · Keypad, Unit Of Measure, Inch−Pound Humidifier Notes: Your humidifier max capacity is less than the load + loss Minimum water conductivity of 2 grains/gallon (100 μS/cm) Power block maximum wire connection size of 6 gauge. Dispersion Inlet Type Hose Diameter (inches) 1 1/2 Position B3 Model Qty. ULTRA−SORB LH 1 Duct Conditions Absorption Dist. (inches) Duct Width (inches) Duct Height (inches) Entering Duct Temp (°F) Leaving Duct Temp (°F) Header Location Water Seal Location Face Dimensions (inches) Width Height 40 Header Size (inches) 3 6 40 16 54.2 55.0 Outside Duct Outside Duct 16 Tube Center (inches) 3 Overall Dimensions (inches) Width Height 49 19 Condensate Position Position #1 Position #2 C2 C4 Airflow Air Velocity (ft/min) Airflow Pressure Drop (in.) Entering RH (%) Leaving RH (%) Heat Gain: Assembly (°F) Heat Gain: Steam (°F) Ins. Load + Loss (lbs/hr) Vertical 1288 0.145 59 69 0.47 0.30 30.78 Selected Dispersion Options: · Vapor Hose 1 1/2 (inches), 10 (feet) · Casing, 304 Stainless Steel · Insulated Tube(s) Dispersion Notes: DRI−STEEM Detail Report Page 1 of 2 Version DRI−CALC 3.26.00P 6MUSBTPSC
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 Va p o r m i s t ®hhuummi di di fi ifei er,r, t a t app/ s/ soof tf e t enneedd wwaat e t er r Figure 1-1: Vapormist (tap/softened water) field piping overview Water supply line: • ¼" NPT (DN8) connection size • 25 to 80 psi (175 to 550 kPa) required water pressure. • 100 μS/cm minimum water conductivity. • If water piping to humidifier is nonmetallic, the first 3' (1 m) of water supply piping from humidifier should be metallic. Steam vapor hose (maximum run 10' [3 m]). May also use pipe or tubing. See the DRI-STEEM Design Guide for maximum pipe or tubing lengths. Unions by installer 2" (50 mm) water seal or loop in supply line to isolate steam from nonmetallic supply piping Shock arrester Install plumb recommended to reduce water hammer ¾" pipe thread (DN20) tank drain, skimmer, and P-trap piping, rated for 212 °F (100 °C). If piping run is over 10' (3 m), increase pipe to 1¼" (DN32) after P-trap. 12" (300 mm) 2" (50 mm) 1" (25 mm) air gap Cover Spill funnel. Plumb to floor drain. Frame drain Open drain required. See first note below. ¾" pipe thread (DN20) frame drain and P-trap piping, rated for 212 °F (100 °C) DC-1136 Notes: • Locate air gap only in spaces with adequate temperature and air movement to absorb flash steam; otherwise, condensation may form on nearby surfaces. Refer to governing codes for drain pipe size and maximum discharge water temperature. • Offset humidifier from spill funnel or floor drain to prevent flash steam from rising into cabinet. • Dashed lines indicate provided by installer. • Water supply inlet is more than 1" (25 mm) above skim/overflow port, eliminating the possibility of backflow or siphoning from tank. No additional backflow prevention is required; however, governing codes prevail. • Install a union in water supply and drain lines as shown to allow tank removal. • Damage caused by chloride corrosion is not covered by your DRI-STEEM warranty. mc_042710_1327 01_VAPORMIST_Humidifier_standard_water_models Rev. 0510 DRI-STEEM Installation Guide • Page 1 of 9 Va p o r m i s t h u m i d i f i e r, t a p / s o f t e n e d w a t e r Table 2-1: Vapormist capacities, electrical specifications, and weights Model kW Current draw (amps) Maximum steam capacity Weights ‡ Single-phase lbs/hr kg/h 120V 208V* VM-2 6 2.7 16.7 9.6 VM-4 12 5.4 33.3 19.2 VM-6 18 8.2 — 28.8 VM-8 24 10.9 — 38.5 VM-10 30 13.6 — — VM-12 36 16.3 — VM-14 42 19.1 — VM-16 48 21.8 — VM-21 63 28.6 — VM-25 75 34.0 240V* Three-phase 208V* 240V† — — 277V Shipping 480V† Operating 277V 480V† 600V† 600V† lbs kg lbs kg 8.3 7.2 4.2 3.3 — 16.7 14.4 8.3 6.7 16.7** 14.4** 12.5 — — 80 36 95 43 7.2** 5.8** 80 36 95 43 25.0 21.7 12.5 10.0 25.0** 21.7** 18.8 10.8** 8.7** 88 40 122 55 33.3 28.9 16.7 13.3 33.3** 28.9** 25.0 14.4** 11.5** 88 40 122 55 41.7 36.1** 20.8 16.7 29.1** 25.3** 21.9 12.6** 10.1** 93 42 139 63 — — 43.3 25.0 20.0 33.3 28.9 25.0 14.4 11.5 93 42 139 63 — — — 29.2 23.3 38.9 33.7 29.2 16.8 13.5 93 42 139 63 — — — 33.3 26.7 44.4 38.5 33.3 19.2 15.4 93 42 139 63 — — — 43.8 35.0 — — 43.8 25.3 20.2 95 43 152 69 — — — — — 41.7 — — — 30.1 24.1 95 43 152 69 VM-30 90 40.9 — — — — — — — — — 36.1 28.9 101 46 156 71 VM-34 102 46.3 — — — — — — — — — 40.9 32.7 101 46 156 71 * On 208V/240V/single-phase/three-wire and on 208V/three-phase/four-wire supplies, the neutral line provides a separate 120V circuit for the SDU fan unit. ** For wire sizing, the highest leg draw is shown due to current imbalance. † Add the following to Vapormist weights if using an SDU option (these weights are for additional control components housed within the Vapormist cabinet): – SDU-I: 12 lbs (5.5 kg) (SDU-I operating weight is 58 lbs [26 kg]) – SDU-E: 9 lbs (4 kg) (SDU-E operating weight is 51 lbs [23 kg])) ‡ Add the following if using the SSR option: – For single-phase or three-phase models drawing less than 21.7 amps, add 2 lbs (1 kg) – For three-phase models drawing more than 21.7 amps, add 4 lbs (2 kg) All Vapormist models operate at 50/60 Hz. mc_042610_0900 SDU-I is available for Vapormist humidifier models VM-2 through VM-8, and all VM-10 models except those using 240V, three-phase power with SSR control. SDU-E is available for all Vapormist humidifiers except those models using 240V/480V/600V/three-phase power with the SSR control option and drawing more than 21.7 amps. Table 2-2: Vapormist steam connection sizes Vapormist model Figure 2-1: Vapormist steam outlet connections Steam outlet Hose clamp (for vapor hose) VM-2, VM-4, VM-6, VM-8 1 ½" hose or NPT connection VM-10*, VM-12*, VM-14*, VM-16* 1 ½" or 2" hose or NPT connection VM-21, VM-25, VM-30, VM-34 2" hose or NPT connection * If using with an SDU-E (Space Dispersion Unit External Absorption), the Vapormist steam outlet must be 2" to match the SDU-E steam inlet. 01_VAPORMIST_Humidifier_standard_water_models Rev. 0510 The Vapormist steam outlet is designed to connect to a vapor hose or NPT connection. DC-1168 DRI-STEEM Installation Guide • Page 2 of 9 Va p o r m i s t h u m i d i f i e r, t a p / s o f t e n e d w a t e r Figure 3-1: Vapormist dimensions 24.2" (614 mm) Top view 2" (50 mm) 10.9" (276 mm) 2" (50 mm) 1" (25 mm) 2.25" (57 mm) Power wiring knockout Steam outlet Control or SDU wiring knockout Venting Front view Left side view 18.6" (472 mm) 1.50" (38 mm) 2.25" (57 mm) ¾" pipe thread (DN20) frame drain 5.75" (146 mm) 16.1" (409 mm) ¾" pipe thread (DN20) tank drain Bottom view 0.50" (13 mm) hole in base for water fill line 0.75" (19 mm) 0.63" (16 mm) 2.25" (57 mm) Power wiring knockout 1.50" (38 mm) 5.75" (146 mm) 24.2" (614 mm) mc_042710_1325 01_VAPORMIST_Humidifier_standard_water_models Rev. 0510 Control or SDU wiring knockout DC-1167 DRI-STEEM Installation Guide • Page 3 of 9 Va p o r m i s t h u m i d i f i e r, t a p / s o f t e n e d w a t e r Figure 4-1: Drane-kooler field piping connections Notes: • Dashed lines indicate provided by installer. • Total length of pipe between humidifier and Drane-kooler not exceed 10' (3 m). Drane-kooler mc_050610_1335 DC-1160 Figure 4-2: Lifting drain water Tank drain Figure 4-3: Vapormist clearance recommendations Frame drain Maintain these clearances for service and maintenance. Discharge piping by installer To dispersion assembly Funnel Check valve Top (when SDU is not mounted directly above the Vapormist): 18"(460 mm) Right side electrical controls: 36" (915 mm) Secured to supporting wall Supporting wall Condensate pump Left side: 12" (305 mm) Note: Use a condensate pump rated for your application. Pumps are rated by fluid temperature, head (pressure), and flow (gpm). Contact your local DRI-STEEM representative for pump selection. mc_050610_1345 DC-1138 01_VAPORMIST_Humidifier_standard_water_models Rev. 0510 Front 36" (915 mm) Floor: 24" (610 mm) mc_042710_1326 DC-1201 DRI-STEEM Installation Guide • Page 4 of 9 Humidifier dispersion and humidity sensor placement Use these examples as guidelines Proper humidifier placement is crucial for successful system operation. Usually, there is no single correct placement for a humidifier. Much depends on system design and application. The following paragraphs and dispersion assembly placement examples are presented as guidelines for common situations. First, check available absorption distance Available absorption distance affects system choice. Dispersed steam must be absorbed into the airflow before it comes in contact with any duct elbows, fans, vanes, filters, or any object that can cause condensation and dripping. Placing a steam injection humidifier in an AHU (see Figure 1-1) • Location A is the best choice. Installing downstream of heating and cooling coils provides laminar flow through the dispersion unit; plus, the heated air provides an environment for best absorption. Use a multiple tube dispersion unit to ensure complete absorption of steam vapor before fan entry. • Location B is the second-best choice. In change-over periods, the cooling coil will eliminate some moisture for humidification. • Location C is the third-best choice. Air leaving a fan is usually very turbulent and may cause vapor to not absorb at the expected absorption distance. Allow for more absorption distance if installing downstream of a fan. • Location D is the poorest choice. The cooler air at this location requires an increased absorption distance. Figure 1-1: Placing a Steam Injection humidifier in an air handling unit (AHU) Filters Economizer control device Cooling coil Heating coil 8' to 12' (2.4 m to 3.7 m) Duct high limit humidity control for humidifier locations A, B Airflow proving switch Outside air Fan Exterior building wall Preheat coil D B A Humidifier discharges against airflow 3' to 5' (1 m to 1.5 m) Motorized air dampers C 8' to 12' (2.4 m to 3.7 m) Relief air Airflow proving switch Duct high limit humidity control for humidifier location C Return airflow Supply airflow DC-1081 01_Humidifier_dispersion_and_humidity_sensor_placement Rev. 1110 DRI-STEEM Installation Guide • Page 1 of 2 Humidifier dispersion and humidity sensor placement Placing a Steam Injection humidifier near an elbow (see Figure 2-1) • Location A is the best choice. Better absorption occurs on the downstream side of an elbow than on the upstream side. • Location B is the second-best choice. Installing upstream of an elbow can cause wetting at the turning vanes. In cases where it is structurally impossible to avoid Location B, use a multiple tube humidifier to ensure complete absorption. Also, since more air flows along the outside of a turn, better absorption occurs if the humidifier discharges proportionately more steam in that part of the airstream. • At both locations, discharging steam against or perpendicular to the airstream gives slightly better mixing and absorption than discharging with the airstream. Figure 2-1: Placing a Steam Injection humidifier assembly near an elbow Duct Mist can collect on vanes B Airflow 3' to 5' (1 m to 1.5 m) Less airflow on this side of elbow A 8' to 12' (2.4 m to 3.7 m) Duct high limit humidistat Airflow 01_Humidifier_dispersion_and_humidity_sensor_placement Rev. 1110 DRI-STEEM Installation Guide • Page 2 of 2 Installation Guide ULTRA-SORB Model LH, installed in a duct vertical airflow (for use with evaporative steam) ® Field piping overview Airflow Install panel level Slip coupling without shoulder Depending on humidification load, interconnecting plumbing may be hose, tubing or hard pipe. Insulate tubing and hard pipe to reduce steam loss. Position tubelets perpendicular to airflow Pit ch 1/8 "/ft (1% ) ¾" NPT (DN20) condensate drain Slip coupling with shoulder Install panel level ULTRA-SORB mounting flange 90° long sweep or two 45° elbows 6" (150 mm) minimum Open drain 5" (125 mm) minimum P-trap 1" (25 mm) air gap Open drain Typical evaporative humidifier Note: Dashed lines indicate provided by installer. DC-1182 Maximum steam carrying capacity and length of interconnecting vapor hose, tubing and pipe* Copper or stainless steel tubing and Schedule 40 steel pipe Vapor hose Hose I.D. Maximum capacity Tube or pipe size*** Maximum length** Maximum capacity Maximum developed length† inches DN lbs/hr kg/h ft m inches DN lbs/hr kg/h ft m 1½ 40 150 68 10 3 1½ 40 150 68 20 6.1 2 50 250 113 10 3 2 50 220 100 30 9.2 3 4 †† 75 †† 5 †† 6†† 450 204 80 24.4 100 †† 750 340 100 30.5 125 †† 1400 635 100 30.5 150†† 2300 1043 100 30.5 †† Notes: * Based on total maximum pressure drop in hose, tubing or piping of 5" wc (1244 Pa) ** Maximum recommended length for vapor hose is 10' (3 m). Longer distances may cause kinking or low spots. *** To minimize loss of capacity and efficiency, insulate tubing and piping. † Developed length equals measured length plus 50% of measured length, to account for pipe fittings. †† Requires flange connection DRI-STEEM Installation Guide: ULTRA-SORB® Model LH, evaporative steam, installed in a duct vertical airflow 1 of 3 Mounting an ULTRA-SORB® panel in a duct The ULTRA-SORB panel is contained within a mounting frame. Mounting flanges with a width of 1½" (38 mm) are provided on two sides of the unit. In addition, a 1½"-wide (38 mm) portion of each header enclosure is intended to be a mounting flange (see drawing below). A matching flange or metal frame is required on the ductwork for connection to the ULTRA-SORB flanges. The recommended fastener is a No. 12 x ¾" (M6 x 20 mm) self-drilling and -tapping screw, with spacing not to exceed 12" (305 mm). If an angle iron frame is provided on the duct section, a longer screw may be required. Note: Screw penetration into header enclosure should not exceed ¾" (20 mm) to avoid puncturing header. Headers and tubes are pitched to accommodate mounting in a vertical airflow. Top view Header enclosure 1½" (38 mm) mounting flange 1½" (38 mm) mounting flange Mounting flanges on duct attach to header enclosure here DC-1044 Drip tee installation Install a drip tee as shown below when the humidifier is mounted higher than the ULTRA-SORB, when interconnecting hose or piping needs to go over an obstruction, or when interconnecting piping runs are long. IMPORTANT: Vapor hose must be supported to prevent sagging or low spots. Dashed lines indicate provided by installer. 90° long sweep or two 45° elbows Pitch: 1/8"/ft (1%) Obstruction Typical evaporative humidifier Insulate tubing and hard pipe to reduce steam loss To dispersion device 6" (152 mm) recommended 8" (200 mm) minimum 1" (25 mm) air gap Tubing or pipe drip tee, by installer. DRI-STEEM part numbers for 304 stainless steel inline tees: • 1½" dia. (DN40): No. 162710 • 2" dia. (DN50): No. 162712 ¾" (DN20) Funnel or floor drain. Refer to local codes for drain pipe size and maximum temperature requirements. DRI-STEEM Installation Guide: ULTRA-SORB® Model LH, evaporative steam, installed in a duct vertical airflow DC-1166 2 of 3 Draining and lifting condensate Since the ULTRA-SORB® operates with virtually zero internal pressure, condensate cannot be piped directly into a return main and, therefore, should either be wasted to a floor drain or piped into a small condensate pump for return to the steam source. In either case, the drain connection of the ULTRA-SORB must be at an elevation that will permit gravity drainage. To prevent steam from escaping from the drain line, install a water seal P-trap in the drain line. See drawing below for water seal height. For lifting condensate, use DRI-STEEM condensate pump (Part No. 400280 for 115 V or Part No. 400281 for 230 V) rated for 212 °F (100 °C) and suitable for lifting 250 gph (16 L/m) with a 20-foot head (60 kPa). Elevation view Evaporative steam inlet 6" (150 mm) minimum 6" (150 mm) minimum 5" (125 mm) minimum 5" (125 mm) minimum Airflow Pitch 1/8"/ft (1%) ¾" (DN20) minimum copper line Check valve DC-1103 Pump for lifting condensate Steam loss of interconnecting vapor hose, tubing or pipe Description Hose Tubing Pipe Steam loss Nominal hose, tubing or pipe size Insulation thickness Noninsulated Insulated inches DN lbs/hr/ft kg/h/m lbs/hr/ft kg/h/m inches mm 1.5 40 0.15 0.22 N/A N/A N/A N/A 2.0 50 0.20 0.30 N/A N/A N/A N/A 1.5 40 0.11 0.164 0.02 0.03 2.0 50 2.0 50 0.14 0.21 0.025 0.037 2.0 50 3.0 80 0.20 0.30 0.03 0.045 2.5 63 4.0 100 0.26 0.39 0.03 0.045 3.0 75 5.0 125 0.31 0.46 0.035 0.052 3.0 75 6.0 150 0.36 0.54 0.039 0.058 3.0 75 1.5 40 0.22 0.33 0.02 0.03 2.0 50 2.0 50 0.25 0.38 0.025 0.037 2.0 50 3.0 80 0.39 0.58 0.03 0.045 2.5 63 4.0 100 0.49 0.73 0.03 0.045 3.0 75 5.0 125 0.59 0.88 0.035 0.052 3.0 75 6.0 150 0.70 1.04 0.039 0.058 3.0 75 Notes: This data is based on an ambient air temperature of 80 °F (26.7 °C), fiberglass insulation, copper tubing, and Schedule 40 pipe. lbs/hr/ft = Btu/hr/ft ________ 970 Btu/lb kg/hr/m = Btu/hr/m _________ 1444 Btu/kg DRI-STEEM Installation Guide: ULTRA-SORB® Model LH, evaporative steam, installed in a duct vertical airflow 3 of 3 Humidistat or sensor placement Humidistat and sensor locations are critical (see Figure 1-1) E These locations are not acceptable because they may not represent actual overall conditions in the space. F These locations are not acceptable. Do not place sensors near windows, door passageways, or areas of stagnant airflow. G This is the best location for a duct high limit humidistat or humidity sensor. Humidistat and sensor location have a significant impact on humidifier performance. In most cases, we recommend that you do not interchange duct and room humidity devices. Room humidity devices are calibrated with zero or little airflow; whereas duct humidity devices require air passing across them. Recommended sensor locations: A This is the ideal sensing location because this placement ensures the best uniform mix of dry and moist air with stable temperature control. B This location is acceptable, but the room environment may affect controllability such as when the sensor is too close to air grilles, registers, or heat radiation from room lighting. C This location is acceptable because it provides a good uniform mixture of dry and moist air, but if an extended time lag exists between moisture generation and sensing, make sure the control contractor extends the sampling time. D This location behind a wall or partition is acceptable for sampling the entire room if the sensor is near an air exhaust return outlet. This location is also typical of sensor placement for sampling a critical area. Figure 1-1: Recommended sensor locations High limit humidistat or high limit transmitter (set at 90% RH maximum) for VAV applications 8' to 12' (2.4 m to 3.7 m) minimum Outside air Airflow switch (sail type) or differential pressure switch recommended for VAV applications) Damper control Relief air Return air AHU C G Window Vapor absorption has taken place Wall Point of vapor absorption D E Humidifier dispersion assembly F Turning vanes B A E F F DC-1084 Doorway 02_Humidistat_or_sensor_placement Rev. 1110 Window % RH offset option: Place a temperature compensation transmitter on the lower corner of the inside surface of doublepane window glass on north or northeast facing window DRI-STEEM Installation Guide • Page 1 of 1 Installation Guide Control cabinet mounting and wiring (All installations must comply with national and local electric codes.) Control cabinet location and mounting • Pick a location within sight of the humidifier tank that allows easy access to the control cabinet and internal electrical components. ! IMPORTANT: Locate the control cabinet so that wire lengths to the humidifier are 30' (9 m) for the LW417 and VAPOR-LOGIC®2 and 50' (15 m) or less for the VAPOR-LOGIC1 and VAPOR-LOGIC3. • Secure control cabinet to appropriate structure using the mounting tabs. • Every control cabinet requires an adjacent fused safety disconnect switch, provided by installer. • Maximum ambient temperature is 104 oF (40 oC). • Never run the control system wires bundled with, or in the same conduit as, power wires. • For outdoor NEMA-4 cabinet applications, keep cabinet out of direct sunlight. • ! CAUTION: When making holes and penetrations in the control cabinet, protect all internal components from debris and vacuum out cabinet when finished. Failure to comply with this warning can damage sensitive electronic components and void the DRI-STEEM warranty. • Proper wiring prevents electrical noise Electrical noise can produce undesirable effects on electronic control circuits, thereby affecting controllability. Electrical noise is generated by electrical equipment such as inductive loads, electric motors, solenoid coils, welding machinery, or fluorescent light circuits. The electrical noise or interference generated from these sources (and the effect on controllers) is difficult to define, but the most common symptoms are erratic control or intermittent operational problems. Most electrical noise problems can be prevented by using proper wiring practices and techniques to prevent coupling or inducing of electrical interference into control circuits. The following wiring practices should minimize interaction of noise and controls: – Connect humidifier and control cabinet to a code-approved earth ground. – Separate the line voltage wiring from low voltage control circuit wiring when routing electrical wiring inside the control cabinet. – Use separate electrical conduits for line and low voltage wiring to the humidifier. – Do not use chassis or safety grounds as current-carrying commons. A safety ground should never be used as a conductor or neutral to return circuit current. – When wiring external electrical connections to humidistats, humidity and temperature transmitters, or 2 control signal input connections from a building control system, use 18-gauge minimum (1 mm ) plenum-rated twisted-pair wire with cable shielding (screening) and drain wire for grounding. – Return all shielded (screened) cable connections to the control cabinet for grounding. Do not ground shield at the device end. Installing the keypad (when shipped loose) ! IMPORTANT: Position the keypad in a convenient location for easy access, but do not locate the keypad inside the control cabinet. Mount the keypad using a field supplied network phone wall plate. To mount, slide the keypad onto the tabs on the phone plate. Note that the keypad requires an ambient temperature range of 32 oF to 122 oF (0 oC to 50 oC) to operate properly. Exceeding these limits results in a poor reading or no reading. DRI-STEEM® Installation Guide: Control cabinet mounting and wiring 1 of 3 Water control device wiring 2 • Use 18-gauge (1 mm ) stranded wire run in conduit for probe and low water cutoff wiring. • ! IMPORTANT: Do not use shielded cable for probe and low water cutoff switch wiring. Humidifiers with LW417 and VAPOR-LOGIC®2 Brown, top probe rod (full water condition) To humidifier probe head on tank Orange, middle probe rod (refill water condition) Violet, bottom probe rod (low water condition on standard water models) or low water cutoff switch on DI water models (LW417 not used with DI water) O V Y Probe wiring BR OM-829 Note: LW417 is grounded through the board. Humidifiers with VAPOR-LOGIC®3 Brown or black, top probe rod (full water condition) Orange or white, middle probe rod (refill water condition) Violet or red, bottom probe rod (low water condition on standard water models) or low water cutoff switch on DI water models Low water cutoff switch on DI water models OM-VL3-11 Humidifiers with VAPOR-LOGIC® Brown, top probe rod (full water condition) To humidifier probe head on tank Orange, middle probe rod (refill water condition) Violet, bottom probe rod (low water condition on standard water models) or low water cutoff switch on DI water models 4 3 Probe wiring 2 1 OM-829 DRI-STEEM® Installation Guide: Control cabinet mounting and wiring 2 of 3 Control cabinet penetrations ! CAUTION: When making penetrations into the control cabinet, protect all internal components from debris and vacuum out cabinet when finished. Failure to comply with this warning can damage sensitive electronic components and void the DRI-STEEM warranty. VAPORSTREAM® VLC and VLDI Standard control cabinets for Models VLC and VLDI are shipped loose. An available option is to order the cabinet mounted and wired to the humidifier. Low voltage conduit penetration Incoming power conduit penetration, depending on humidifier load, volts, phase Cabinet door hinge Allow minimum of 36" (914 mm) from front for cabinet access Heater wire connection (Hole size determined by amp draw. Check local governing codes.) VLC-OM-028 CRUV™ and CRUV-DI A prewired electric subpanel is available as an option, with or without a control cabinet. Options: ½" (hole dia. 22.3 mm) fill, drain, probe, or aquastat conduit penetrations Cabinet door hinge High voltage conduit penetration range ½" to 1" (hole dia. range 22.3 mm to 34.9 mm) depending on humidifier load, volts, and phase Note: Conduit penetrations provided by installer Allow minimum of 36" (914 mm) from front for cabinet access Heater wire connection conduit penetration range ½" to 1" (hole dia. range 22.3 mm to 34.9 mm) DC-1088 STS®, STS-DI, LTS®, and LTS-DI Control cabinets for all STS and LTS models are shipped loose. An available option is to order the cabinet mounted and wired to the humidifier. High voltage conduit penetration, ½" hole dia. (22.3 mm)* Cabinet door hinge Options: Fill, drain, probe, or aquastat conduit penetrations, ½" hole dia. (22.3 mm) Low voltage conduit penetration, ½" hole dia. (22.3 mm) High voltage conduit penetration, ½" hole dia. (22.3 mm)* Allow minimum of 36" (914 mm) from front for cabinet access DRI-STEEM® Installation Guide: Control cabinet mounting and wiring Note: Conduit penetrations provided by installer *Choose location closest to power terminals. DC-1469 3 of 3 Drane-kooler™ water tempering device Figure 1-1: Drane-kooler piping Cold water supply piping: 3/8” (DN10) pipe thread Water pressure must be between 25 psi and 80 psi (172 kPa and 552 kPa). Connect directly to the main water supply line. To ensure adequate water pressure to the Drane-kooler, do not connect to a supply water line that is dedicated to other appliances. Cold water inlet service union: 3/8" (DN10) pipe thread Alternate water seal shown (by installer) Evaporative humidifier Hot water inlet service union: 1" (DN25) pipe thread Cold water supply shut-off valve Tempered water outlet service union: 2" (DN50) pipe thread Anchor mounting plate to floor Tempered water drain piping: 2" (DN50) pipe thread Piping must be run full size to drain with no reducers. Recommended minimum pitch: 1/8" per ft (1%) 1" (25 mm) air gap before drain Drain OM-1120 Table 1-1: Drane-kooler connections Table 1-2: Drane-kooler capacities* Maximum flow rate Maximum temperature Hot water inlet connection 1" (DN25) pipe thread U.S. gpm L/m °F °C Tempered water outlet connection 2" (DN50) pipe thread Hot water inflow 6 22.7 212 100 Cold water supply connection 3/8" (DN10) pipe thread Cold water inflow** 6 22.7 70 21 Tempered water outflow 12 45.4 140 60 Note: * This table applies only if one humidifier is connected to one Drane-kooler, with no more than 10' (3m) of vertical dimension between the Drane-kooler and the humidifier. ** Cold water inflow pressure must be between 25 psi and 80 psi (172 kPa and 552 kPa). 01_DRANE-KOOLER_water_tempering_device_option Rev. 1110 DRI-STEEM Installation Guide • Page 1 of 4 Drane-kooler™ water tempering device Step-by-step installation instructions 1. Verify that maximum flow of hot water into the Drane-kooler does not exceed 6 U.S. gallons per minute (gpm) (22.7 L/m). 2. Note that there are three connections to be made to the Drane-kooler: • Cold water supply • Hot water inlet (from a humidifier or other appliance) • Tempered water piping to drain 3. Position the Drane-kooler to allow the most direct path of piping to minimize fittings (see the piping diagram on Page 1). 4. Position unions on all connections as close to the Drane-kooler as possible to make cleaning and maintenance easier. 5. Cold water supply connection instructions: • Cold water supply connection on valve is 3/8" (DN10) pipe thread. • Pipe a 3/8" (DN10) line directly to the Drane-kooler from the main water supply line. To ensure adequate water pressure to the Drane-kooler, do not connect to a supply water line that is dedicated to other appliances. If installing the Drane-kooler with a humidifier, do not branch off the 1/4" (DN8) cold water supply line to the humidifier. • Verify that the supply water pressure to the valve is at least 25 psi (172 kPa) and not more than 80 psi (552 kPa). • Install a cold water supply union as close to the Drane-kooler as possible. • Install a cold water shut-off valve before the union in the cold water supply line. 6. Hot water inlet connection instructions: • Hot water inlet connection is 1" (DN25) pipe thread. • Locate a union as close to the Drane-kooler as possible • Run 1" (DN25) pipe as directly as possible from the hot water appliance (humidifier) to the Drane-kooler. If the piping to the hot water inlet has a horizontal run, maintain a pitch to the Drane-kooler of at least 1/8"/ft (1%). 7. Tempered water (to drain) connection instructions: • Tempered water outlet connection is 2” (DN50) pipe thread. • Install a union as close to the Drane-kooler as possible. • Run a 2” (DN50) pipe as directly as possible from the Drane-kooler to the drain. Maintain a pitch to drain of at least 1/8”/ft (1%). • Make sure there is a 1” (25 mm) air gap between the drain piping and the drain. 01_DRANE-KOOLER_water_tempering_device_option Rev. 1110 DRI-STEEM Installation Guide • Page 2 of 4 Drane-kooler™ water tempering device Figure 3-1: Drane-kooler dimensions Side Elevation Front Elevation H J D C B E F A G Floor OM-1113 Table 3-1: Drane-kooler dimensions Description inches mm Height with floor stand (from floor to top of hot water inlet in 1" [25 mm] increments) 8.25 to 12.25 210 to 312 Height with floor stand and extension (from floor to top of hot water inlet in 1" [25 mm] increments) 13.25 to 20.25 337 to 515 A B Height from bottom of tank to top of hot water inlet 7.5 191 C Height from bottom of tank to top of valve 10.5 268 D Height from top of hot water inlet to top of valve 3.0 76 E Height from bottom of tank to center of mounting hole 6.25 159 F Height from bottom of tank to center of tempered water outlet 3.0 76 G Width of tank and tempered water outlet 7.5 191 H Width of mounting plate holes, center to center 4.0 102 J Length, from valve inlet to mounting plate 12.0 305 01_DRANE-KOOLER_water_tempering_device_option Rev. 1110 DRI-STEEM Installation Guide • Page 3 of 4 Drane-kooler™ water tempering device Three mounting options Use one of the mounting options shown on this page to ensure that the Drane-kooler will be properly supported and not secured entirely by piping. Floor stand and suspension mount hanger assembly are ordered separately. Figure 4-2: Optional suspension mount* Figure 4-1: Standard wall mount OM-1116 Note: * The optional suspension mount hanger assembly includes an L-bracket, two nuts, and two bolts that attach to the Drane-kooler. Beam clamp assembly and 1/4" threaded rod are supplied by others. Figure 4-3: Optional floor mount OM-1114 OM-1115 01_DRANE-KOOLER_water_tempering_device_option Rev. 1110 DRI-STEEM Installation Guide • Page 4 of 4 HTS Oshawa 2001 Thickson Rd, South Unit #11 Whitby, ON L1N 6J3 T 905.579.6700 F 905.597.5290 ontario.htseng.com SUBMITTAL DATA APPROVAL REQUIRED ELECTRIC TO STEAM HUMIDIFIER INSTALLATION AND OPERATIONS MANUALS NOTES: HTS. Delivering Real Success.® READ AND SAVE THESE INSTRUCTIONS VAPORMIST ® Electric-to-Steam Humidifier Installation, Operation, and Maintenance Manual WARNINGS AND CAUTIONS Warnings and cautions WARNING Indicates a hazardous situation that could result in death or serious injury if instructions are not followed. CAUTION Indicates a hazardous situation that could result in damage to or destruction of property if instructions are not followed. mc_051508_1145 WARNING Attention installer Read this manual before installing, and leave this manual with product owner. This product must be installed by qualified HVAC and electrical contractors and in compliance with local, state, federal, and governing codes. Improper installation can cause property damage, severe personal injury, or death as a result of electric shock, burns, or fire. DriSteem Technical Support: 800-328-4447 Read all warnings and instructions Read this manual before performing service or maintenance procedures on any part of the system. Failure to follow all warnings and instructions could produce the hazardous situations described, resulting in property damage, personal injury, or death. Failure to follow the instructions in this manual can cause moisture to accumulate, which can cause bacteria and mold growth or dripping water into building spaces. Dripping water can cause property damage; bacteria and mold growth can cause illness. mc_011909_1215 Hot surfaces and hot water This steam humidification system has extremely hot surfaces. Water in tanks, steam pipes, and dispersion assemblies can be as hot as 212 °F (100 °C). Discharged steam is not visible. Contact with hot surfaces, discharged hot water, or air into which steam has been discharged can cause severe personal injury. To avoid severe burns, follow the cool-down procedure in this manual before performing service or maintenance procedures on any part of the system. mc_011909_1130 ii VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL Warnings and cautions WARNING Disconnect electrical power Disconnect electrical power before installing supply wiring or performing service or maintenance procedures on any part of the humidification system. Failure to disconnect electrical power could result in fire, electrical shock, and other hazardous conditions. These hazardous conditions could cause property damage, personal injury, or death. Contact with energized circuits can cause property damage, severe personal injury, or death as a result of electrical shock or fire. Do not remove humidifier electrical panel cover, heater terminal cover, or subpanel access panels until electrical power is disconnected. Follow the shutdown procedure in this manual before performing service or maintenance procedures on any part of the system. mc_052410_1510 Electric shock hazard If the humidifier starts up responding to a call for humidity during maintenance, severe bodily injury or death from electric shock could occur. To prevent such start-up, follow the procedure below before performing service or maintenance procedures on this humidifier (after the tank has cooled down and drained): 1. Use Vapor-logic® keypad/display to change control mode to Standby. 2. Shut off all electrical power to humidifier using field-installed fused disconnect, and lock all power disconnect switches in OFF position. 3. Close field-installed manual water supply shut-off valve. mc_050808_1540 CAUTION Hot discharge water Discharge water can be as hot as 212 °F (100 °C) and can damage the drain plumbing. To prevent such damage from humidifiers without water tempering, allow the tank to cool before draining. Humidifiers equipped with a water tempering device such as a DriSteem Drane-kooler need fresh make-up water in order to function properly. Make sure the water supply to the water tempering device remains open during draining. Excessive supply water pressure Supply water pressure greater than 80 psi (550 kPa) can cause the humidifier to overflow. mc_030910_1440 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL iii Table of contents ATTENTION INSTALLER Read this manual before installing. Leave manual with product owner. DriSteem® Technical Support 800-328-4447 WHERE TO FIND MORE INFORMATION Our web site: The following documents are available on our web site: www.dristeem.com • Catalogs – Vapormist – Ultra-sorb® • Installation, Operation, and Maintenance manuals (IOM) – Ultra-sorb – Vapor-logic controller (includes humidifier operation and troubleshooting) • DriSteem Humidification System Design Guide (includes steam loss tables and general humidification information) DriCalc®: DriCalc, our software for humidification system sizing and selection, can be ordered at our web site. Also in DriCalc: • Library of installation guides WARNINGS AND CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii OVERVIEW Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS Capacities, electrical specifications, and weights Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . Dispersion options . . . . . . . . . . . . . . . . . . . . . . Selecting a location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 .5 .6 .7 INSTALLATION Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . Piping Tap/softened water . . . . . . . . . . . . . . . . RO/DI water option . . . . . . . . . . . . . . . . Supply water and drain piping . . . . . . . . Drane-kooler . . . . . . . . . . . . . . . . . . . . . Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensor placement . . . . . . . . . . . . . . . . . . . . Dispersion Selecting the dispersion assembly location Interconnecting piping requirements . . . . . Drip tee installation . . . . . . . . . . . . . . . . SDU-I and SDU-E . . . . . . . . . . . . . . . . . . Single dispersion tube . . . . . . . . . . . . . . Rapid-sorb . . . . . . . . . . . . . . . . . . . . . . Ultra-sorb . . . . . . . . . . . . . . . . . . . . . . . • Dispersion and sensor placement in ducts and air handlers • Vertical airflows Call us at 800-328-4447 Obtaining documents from our web site or from DriCalc is the quickest way to view our literature, or we will be happy to mail literature to you. iv . . . . VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL . . . . . . . . . . . . . . . . . . . .8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . 11 . 12 . 13 . 14 . 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 . 19 . 21 . 22 . 28 . 30 . 36 Table of contents Keypad/display and troubleshooting OPERATION Principle of operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Start-up checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 MAINTENANCE Tap/softened water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 RO/DI water option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Download DriSteem literature REPLACEMENT PARTS Humidifier SDU-E . . . SDU-I . . . . Subpanel . . . . . . . . . The Vapor-logic version 5 Installation and Operation Manual, which was shipped with your humidifier, is a comprehensive operation manual. Refer to it for information about using the keypad/display and Web interface, and for troubleshooting information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back . . . . . 46 . 48 . 49 . 50 Most DriSteem product manuals can be downloaded, printed, and ordered from our web site: www.dristeem.com mc_052410_1335 cover VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 1 OVERVIEW Product overview Vapormist humidifiers use heat caused by electrical resistance in submerged heating elements boil fill water into humidification steam. Water level is controlled by means of conductivity probes or a float valve, depending on the water type. Supply water quality is an important component of humidifier reliability and maintenance. Examples: • Corrosive water can decrease the service life of the humidifier. FIGURE 2-1: VAPORMIST HUMIDIFIER • Excessive water hardness can increase the humidifier maintenance requirements. Water level control Steam outlet Supply water guidelines To maximize humidifier service life and minimize humidifier maintenance, DriSteem has established guidelines for supply water See Table 2-1. Vapor-logic controller keypad/display Fill valve Table 2-1: DriSteem supply water guidelines Heating elements Evaporating chamber Total hardness OM-2000-X Shroud TAP/SOFTENED WATER Tap/softened water Vapormist humidifiers (shown above) use conductivity probes to monitor the water level. See Figure 3-2. Water conductivity must be at least 30 μS/cm for proper operation. Vapormist humidifiers for tap or softened fill water will not operate with RO/DI water. For RO/DI water, use Vapormist with the RO/DI water option. RO/DI WATER OPTION Vapormist humidifiers with the RO/DI water option (deionized water or water that has been treated using reverse osmosis) control water level with a float valve and low water cutoff switch. See Figure 3-3. Float valves are compatible with RO/DI water only. Humidifiers with the RO/DI water option are virtually maintenance free and require little or no downtime. WATER TYPE CONVERSION Vapormist humidifiers can be converted in the field for use with tap/softened water or RO/DI water. Contact your DriSteem representative or distributor for parts and instructions. mc_061610_1640-VM 2 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 0 to 500 ppm Chlorides* RO or DI water Softened water Tap water < 5 ppm < 25 ppm * Damage caused by chloride < 50 ppm corrosion is not covered by your DriSteem warranty. pH RO, DI, or softened water Tap water 7 to 8 6.5 to 8.5 Silica < 15 ppm You may wish to take action to mitigate potential negative effects to your humidifier. Supply water outside of these guidelines may void your DriSteem warranty. Please contact your DriSteem Representative or DriSteem Technical Support if you need advice. mc_071912_1545 OVERVIEW Product overview CONTROLLER Notes: The Vapor-logic controller in Vapormist humidifiers provides menus for all humidifier functions, with a Web interface for Ethernet access (see Figure 3-1). See Pages 10 and 11 for detailed installation drawings. The Vapor-logic version 5 Installation and Operation Manual ships with Vapormist humidifiers. Refer to it for information on using the keypad/display and Web interface, and for troubleshooting information. FIGURE 3-2: WATER LEVEL CONTROL FOR TAP/SOFTENED WATER HUMIDIFIER FIGURE 3-1: VAPOR-LOGIC KEYPAD/DISPLAY AND WEB INTERFACE Fill valve closes when water level rises to this probe. KEYPAD/DISPLAY Room RH Mode Softkeys for direct menu access Set point Fill valve opens when water level is below this probe. Tank water level Steam output Low-water cutoff. Power to heaters is cut if water level drops below this probe. Tank status Navigation buttons for item selection System alarms System messages Humidifiers using tap or softened water control water levels electronically using a three-rod probe. The controller responds with the above actions when the water level reaches each rod. mc_030910_1335 WEB INTERFACE VLC-OM-030 FIGURE 3-3: WATER LEVEL CONTROL FOR RO/DI WATER OPTION HUMIDIFIER Supply water connection Float ball Float rod Humidifiers using RO/DI water control water levels using a float valve and low-water cutoff switch. mc_052710_1644 OM-7396 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 3 SPECIFICATIONS Capacities, electrical specifications, and weights Table 4-1: Vapormist capacities, electrical specifications, and weights VM model Current draw (amps) Maximum steam capacity kW lbs/hr kg/h 2 6 Weights ‡ Single-phase Three-phase Shipping Operating 120V 208V* 240V* 277V 480V† 600V† 208V* 240V† 277V 480V† 600V† lbs kg lbs kg 2.7 16.7 80 36 95 43 9.6 8.3 7.2 4.2 3.3 — — 7.2** 5.8** 80 36 95 43 10.0 25.0** 21.7** 18.8 10.8** 8.7** 88 40 122 55 — — 4 12 5.4 33.3 19.2 16.7 14.4 8.3 6 18 8.2 — 28.8 25.0 21.7 12.5 33.3 28.9 16.7 13.3 33.3** 28.9** 25.0 14.4** 11.5** 88 40 122 55 41.7 36.1** 20.8 16.7 29.1** 25.3** 21.9 12.6** 10.1** 93 42 139 63 20.0 93 42 139 63 8 24 10.9 — 38.5 10 30 13.6 — — 12 36 16.3 — — — 43.3 25.0 6.7 — 16.7** 14.4** 12.5 33.3 28.9 25.0 14.4 11.5 14 42 19.1 — — — — 29.2 23.3 38.9 33.7 29.2 16.8 13.5 93 42 139 63 16 48 21.8 — — — — 33.3 26.7 44.4 38.5 33.3 19.2 15.4 93 42 139 63 21 63 28.6 — — — — 43.8 35.0 — — 43.8 25.3 20.2 95 43 152 69 25 75 34.0 — — — — — 41.7 — — — 30.1 24.1 95 43 152 69 30 90 40.9 — — — — — — — — — 36.1 28.9 101 46 156 71 34 102 46.3 — — — — — — — — — 40.9 32.7 101 46 156 71 * On 208V/240V/single-phase/three-wire and on 208V/three-phase/four-wire supplies, the neutral line provides a separate 120V circuit for the SDU fan unit. ** For wire sizing, the highest leg draw is shown due to current imbalance. † Add the following to Vapormist weights if using an SDU option (these weights are for additional control components housed within the Vapormist cabinet): – SDU-I: 12 lbs (5.5 kg) (SDU-I operating weight is 58 lbs [26 kg]) – SDU-E: 9 lbs (4 kg) (SDU-E operating weight is 51 lbs [23 kg])) ‡ Add the following if using the SSR option: – For single-phase or three-phase models drawing less than 32.7 amps, add 2 lbs (1 kg) – For three-phase models drawing more than 32.7 amps, add 4 lbs (2 kg) All Vapormist models operate at 50/60 Hz. mc_042610_0900 FIGURE 4-1: STEAM OUTLET CONNECTIONS Table 4-2: Steam connection sizes Hose clamp (for steam hose) VM model Steam outlet 2, 4, 6, 8 1½" hose or NPT connection 10*, 12*, 14* ,16* 1½" or 2" hose or NPT connection 21, 25, 30, 34 2" hose or NPT connection The steam outlet is designed to connect to a steam hose or NPT connection. Tap/softened water Vapormist shown. * If using with an SDU-E (Space Dispersion Unit External Absorption), the Vapormist steam outlet must be 2" to match the SDU-E steam inlet. mc_052410_1705-VM 4 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL DC-1168 mc_052510_1531-VM SPECIFICATIONS Dimensions FIGURE 5-1: VAPORMIST DIMENSIONS Top view 24.2" (614 mm) 2" (50 mm) 10.9" (276 mm) 2" (50 mm) 1" (25 mm) Power wiring knockout 2.25" (57 mm) Steam outlet Control or SDU wiring knockout Venting Left side view Front view 18.6" (472 mm) 2.25" (57 mm) 1.50" (38 mm) 5.75" (146 mm) 16.1" (409 mm) 3/4" pipe thread (DN20) frame drain 3/4" pipe thread (DN20) tank drain Bottom view 0.50" (13 mm) hole in base for water fill line DC-1167 0.75" (19 mm) 0.63" (16 mm) 2.25" (57 mm) Power wiring knockout 1.50" (38 mm) 5.75" (146 mm) 24.2" (614 mm) Control or SDU wiring knockout VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 5 SPECIFICATIONS Dispersion options The duct dispersion options in Figure 6-1 and the open space dispersion options in Figure 6-2 are available for Vapormist humidifiers. For installation details, see “Dispersion” beginning on Page 18. FIGURE 6-1: VAPORMIST HUMIDIFIER DUCT DISPERSION OPTIONS FIGURE 6-2: SDU MOUNTING OPTIONS Ultra-sorb Remote from humidifier OM-636-1 Rapid-sorb OM-56-1 Directly above humidifier OM-637-1 Steam outlet Air intake vents Single dispersion tube OM-55-1 mc_052510_1620 OM-82-4-X 6 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL SPECIFICATIONS Selecting a location HUMIDIFIER FIGURE 7-1: INSTALLATION OVERVIEW When selecting a location for the humidifier, consider the following: • Proximity to the duct Install the humidifier near the air duct system where the dispersion assembly will be located. The maximum recommended length for steam hose connecting a single humidifier to a dispersion assembly is 10' (3 m). The maximum recommended developed length for tubing connecting a single humidifier to a dispersion assembly is 20' (6 m). Flexible steam hose or tubing connects to dispersion tube(s) or to an SDU Single dispersion tube with condensate return Supply water connection Electrical knockouts For more information about installing dispersion assemblies, see “Dispersion,” beginning on Page 18. • Elevation of the installed dispersion assembly Duct The recommended installation location for the dispersion assembly is at an elevation higher than the humidifier. However, if the dispersion assembly must be installed at an elevation lower than the humidifier, install a drip tee and drain. See “Drip tee installation” on Page 21. Electrical area Before installing a dispersion assembly or interconnecting piping, review all pitch requirements in the “Dispersion” section of this manual. Incoloy-sheathed immersion heaters • Required clearances (see Figure 9-1) Skimmer port Drain • Electrical connections Electrical power supply connections are at the lower or upper right rear corner of the unit. See “Wiring” on Pages 14 and 15. • Supply water and drain piping connections Water supply piping and drain connections are at the lower left rear corner of the unit. See the piping illustrations and instructions starting on Page 10. Removable evaporating chamber Mounting keyholes OM-82-4 mc_061610_1655-VM • Exterior wall insulation Install the humidifier on an exterior wall only if the wall is properly insulated. DISPERSION CONTROL DEVICES See Figure 17-1 for recommended installation locations for the dispersion assembly and associated control devices. mc_062810_0928-NA VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 7 INSTALLATION Mounting WALL MOUNTING THE HUMIDIFIER Mount the humidifier level and plumb, using the lag bolts provided. Follow the instructions below for mounting on a stud wall with wood studs 16" (406 mm) on center. See Figures 10-1 and 11-1. 1. Mark hole locations at centers of studs, and predrill 1/4" (6 mm) diameter pilot holes. 2. Secure cabinet to wall with lag bolts provided. See mounting keyholes in Figure 8-1. Note: Use the appropriate mounting methods and mounting hardware for other wall types. FIGURE 8-1: VAPORMIST MOUNTING KEYHOLE LOCATIONS AND DIMENSIONS 16" (406 mm) 3" (76 mm) Keyhole for 3/8" dia. (M10) fasteners 18.5" (470 mm) Vapormist chassis 24" (610 mm) 8 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL OM-282-7X WARNING Mounting hazard Mount humidifier per the instructions in this manual and to a structurally stable surface. Improper mounting of the humidifier can cause it to fall or tip, resulting in severe personal injury or death. mc_060110_1540 INSTALLATION Mounting FIGURE 9-1: VAPORMIST CLEARANCE RECOMMENDATIONS Maintain these clearances for service and maintenance. To dispersion assembly Top (when SDU is not mounted directly above the Vapormist): 18"(460 mm) Right side electrical controls: 36" (915 mm) Secured to supporting wall Supporting wall DC-1201 Left side: 12" (305 mm) Front 36" (915 mm) Floor: 24" (610 mm) mc_042710_1326-VM VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 9 INSTALLATION Piping: Tap/softened water FIGURE 10-1: VAPORMIST (TAP/SOFTENED WATER) FIELD PIPING OVERVIEW Steam hose (maximum run 10' [3 m]). May also use tubing. See the DriSteem Design Guide for maximum tubing lengths. Water supply line: • 1/4" NPT (DN8) connection size • 25 to 80 psi (175 to 550 kPa) required water pressure. • If water piping to humidifier is nonmetallic, the first 3' (1 m) of water supply piping from humidifier should be metallic. Unions by installer 2" (50 mm) water seal or loop in supply line to isolate steam from nonmetallic supply piping Install plumb Shock arrester recommended to reduce water hammer 3/4" pipe thread (DN20) tank drain, skimmer, and P-trap piping, rated for 212 °F (100 °C). If piping run is over 10' (3 m), increase pipe to 1¼" (DN32) after P-trap. 12" (300 mm) 2" (50 mm) DC-1136 1" (25 mm) air gap Cover Spill funnel. Plumb to floor drain. Frame drain Open drain required. See first note below. 3/4" pipe thread (DN20) frame drain and P-trap piping, rated for 212 °F (100 °C) Notes: • Locate air gap only in spaces with adequate temperature and air movement to absorb flash steam; otherwise, condensation may form on nearby surfaces. Refer to governing codes for drain pipe size and maximum discharge water temperature. • Offset humidifier from spill funnel or floor drain to prevent flash steam from rising into cabinet. • Dashed lines indicate provided by installer. • Water supply inlet is more than 1" (25 mm) above skim/overflow port, eliminating the possibility of backflow or siphoning from tank. No additional backflow prevention is required; however, governing codes prevail. • Install a union in water supply and drain lines as shown to allow tank removal. • Damage caused by chloride corrosion is not covered by your DriSteem warranty. mc_042710_1327-VM 10 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL INSTALLATION Piping: RO/DI water option FIGURE 11-1: VAPORMIST (RO/DI WATER OPTION) FIELD PIPING OVERVIEW Steam hose (maximum run 10' [3 m]). May also use tubing. See the DriSteem Design Guide for maximum tubing lengths. Water supply line: • ¼" NPT (DN8) connection size • 25 to 80 psi (175 to 550 kPa) required water pressure. Unions by installer Install plumb Strainer, by installer First 3' (1 m) of water supply line should be stainless steel tubing with a 2" (50 mm) water seal or loop in the supply line to isolate steam from nonmetallic supply piping. 3/4" pipe thread (DN20) tank drain, and P-trap piping, rated for 212 °F (100 °C). If piping run is over 10' (3 m) increase pipe to 1¼" (DN32) after P-trap. 12" (300 mm) 2" (50 mm) DC-1139 1" (25 mm) air gap Frame drain Spill funnel. Plumb to floor drain Open drain required. See first note below. Cover 3/4" pipe thread (DN20) frame drain and P-trap piping, rated for 212 °F (100 °C) Notes: • Locate air gap only in spaces with adequate temperature and air movement to absorb flash steam; otherwise, condensation may form on nearby surfaces. Refer to governing codes for drain pipe size and maximum discharge water temperature. • Offset humidifier from spill funnel or floor drain to prevent flash steam from rising into the cabinet. • Dashed lines indicate provided by installer. • The water supply inlet is more than 1" (25 mm) above the overflow port, eliminating the possibility of backflow or siphoning from the tank. No additional backflow prevention is required; however, governing codes prevail. • Install a union in the water supply and drain lines as shown to allow tank removal. • Damage caused by chloride corrosion is not covered by your DriSteem warranty. mc_042710_1328-VM VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 11 INSTALLATION Piping: Supply water and drain piping Supply water piping may be of any code-approved material (copper, steel, or plastic). The fill valve connection size is a 1/4" pipe thread (DN8) fitting except in Europe where it is a DN10 pipe thread fitting. In cases where water hammer may be a possibility, consider installing a shock arrestor. Water pressure must be between 25 psi and 80 psi (175 kPa and 550 kPa). If water piping to humidifier is nonmetallic, we recommend that the first 3' (1 m) of water supply piping from the humidifier be metallic with a 2" (50 mm) water seal or loop in the supply line to isolate steam from nonmetallic supply piping. Drain piping may be of any code-approved material (copper, steel, or plastic rated for 212 °F [100 °C] minimum). If drainage by gravity is not possible, use a reservoir pump rated for 212 °F (100 °C) water. The final connection size is 3/4" (DN20) copper for the tank and frame drains. Do not reduce this connection size. Pipe the tank and frame drains separately, as shown in Figures 10-1 and 11-1, to prevent backflow of drain water into the humidifier cabinet. If the equivalent length of pipe from the humidifier drain to the plumbing system drain is more than 10' (3 m), increase the pipe size to 1¼" (DN32). See Figures 10-1 and 11-1 for more piping instructions. Important: Install unions in the water supply and drain lines as shown in Figures 10-1 and 11-1 to allow tank removal. mc_062810_0930-VM FIGURE 12-1: DRANE-KOOLER WATER TEMPERING DEVICE DriSteem's Drane-kooler, shown mounted to a humidifier, tempers discharged water. For other Drane-kooler mounting options or for more information, contact your DriSteem representative/distributor, or view the Drane-kooler product data sheet in the literature section at www.dristeem.com OM-7398 mc_061710_1449 12 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL CAUTION Hot discharge water Discharge water can be as hot as 212 °F (100 °C) and can damage the drain plumbing. To prevent such damage from humidifiers without water tempering, allow the tank to cool before draining. Humidifiers equipped with a water tempering device such as a DriSteem Drane-kooler need fresh make-up water in order to function properly. Make sure the water supply to the water tempering device remains open during draining. Excessive supply water pressure Supply water pressure greater than 80 psi (550 kPa) can cause the humidifier to overflow. mc_030910_1440 INSTALLATION Piping: Drane-kooler FIGURE 13-1: DRANE-KOOLER FIELD PIPING CONNECTIONS Notes: • Dashed lines indicate provided by installer. • Total length of pipe between humidifier and Drane-kooler not to exceed 10' (3 m). Tank drain Field piping Frame drain Hot drain water inlet, 1" (DN25) Vacuum breaker Union Supply water shut-off valve Union Union Suppy water inlet, 3/8" (DN10) 25 to 80 psi (172 to 552 kPa) Maximum temperature 70 °F (21 °C) Tempered water overflow 12 gpm (45.4 lpm) 140°F (60°C) Floor DC-1160 Drane-kooler Part No. 902205 (NPT connections) Part No. 902206 (BSP connections) Tempered water outlet, 2" (DN50) mc_050610_1335-w/frame-drain FIGURE 13-2: LIFTING DRAIN WATER Frame drain Tank drain Discharge piping by installer Funnel Check valve DC-1138 Condensate pump Note: Use a condensate pump rated for your application. Pumps are rated by fluid temperature, head (pressure), and flow (gpm). Contact your local DriSteem representative for pump selection. mc_050610_1345 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 13 INSTALLATION Wiring HUMIDIFIER FIELD WIRING All wiring must be in accordance with all governing codes, and with the humidifier wiring diagrams. The diagrams are located inside the removable subpanel cover on the right side of the humidifier cabinet. Power supply wiring must be rated for 220 °F (105 °C). When selecting a location for installing the humidifier, avoid areas close to sources of electromagnetic emissions such as power distribution transformers. The fill valve, drain valve, probes, and temperature sensors use Class 2, 24 VAC power. The use of semiconductor fusing sized per the National Electric Code is recommended with the SSR option. GROUNDING REQUIREMENTS The approved earth ground must be made with solid metal-to-metal connections and must be a good conductor of radio frequency interference (RFI) to earth (multistranded conductors). Ground wire should be the same AWG (mm2) size as the power wiring or sized per NEC requirements (in Europe, IEC 60364 requirements). WARNING Electric shock hazard Only qualified electrical personnel should perform field wiring installation procedures. Improper wiring or contact with energized circuits can cause property damage, severe personal injury, or death as a result of electric shock and/or fire. Do not remove the humidifier electrical panel cover or the heater terminal cover until electrical power is disconnected. Contact with energized circuits can cause property damage, severe personal injury, or death as a result of electrical shock. mc_062310_0629 FIGURE 14-1: FIELD WIRING REQUIREMENTS PROPER WIRING TO PREVENT ELECTRICAL NOISE Electrical noise can produce undesirable effects on electronic control circuits, which affects controllability. Electrical noise is generated by electrical equipment such as inductive loads, electric motors, solenoid coils, welding machinery, or fluorescent light circuits. The electrical noise or interference generated from these sources (and the effect on controllers) is difficult to define, but the most common symptoms are erratic control or intermittent operational problems. Important: • For maximum EMC (electromagnetic compatibility) effectiveness, wire all humidity, high limit, and airflow controls using multicolored shielded/ screened plenum-rated cable with a drain wire for the shield/screen. Connect the drain wire to the shield/screen ground terminal with wire less than 2" (50 mm) in length. • Do not ground shield at the device end. mc_061610_0625-NA OM-1007 Fused disconnect (provided by installer) Vapormist humidifier Notes: • Control wiring and power wiring must be run in dedicated or separate earthed metal conduit, cable trays, or trunking. • Separate the line voltage wiring from low voltage control circuit wiring when routing electrical wiring inside the humidifier cabinet. • Do not use chassis or safety grounds as current-carrying commons. Never use a safety ground as a conductor or neutral to return circuit current. mc_062310_0630-VMHT 14 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL Power supply (provided by installer) INSTALLATION Wiring FIGURE 15-1: SHIELDED/SCREENED CABLE DRAIN WIRE CONNECTION TO LUG Humidifier side view Vapor-logic keypad/display Microprocessor board OM-1505 Shield/screen ground lug Note: For maximum EMC effectiveness, all humidity, temperature, and airflow controls should be wired using multicolored shielded/screened plenum-rated cable with a drain wire for the shield/screen. The drain wire should be connected to the shield/screen ground terminal with its length kept to less than 2" (50 mm). Table 15-2: European breaker requirements I max. A Breaker size 0 - 8.0 10 8.1 - 10.4 13 10.5 - 12.8 16 12.9 - 16 20 16.1 - 20 25 20.1 - 25.6 32 25.7 - 32 40 32.1 - 40 50 40.1 - 50.4 63 50.5 - 64 80 64.1 - 80 100 80.1 - 100 125 100.1 - 128 160 128.1 - 160 200 mc_062310_0616 mc_062310_0634 Table 15-1: European wiring requirements 230 volt single phase 400 volt three phase Amps Wire size mm Ground wire size mm Amps Wire size mm2 Ground wire size mm2 0 - 18 2.5 2.5 0 - 15.7 2.5 2.5 18.1 - 24 4 4 15.8 - 21 4 4 24.1 - 30.7 6 6 21.1 - 27 6 6 30.8 - 42.7 10 10 27.1 - 37.5 10 10 42.8 - 57 16 16 37.6 - 51 16 16 57.1 - 75.7 25 16 51.1 - 66.7 25 16 75.8 - 93.7 35 16 66.8 - 82.5 35 16 93.8 - 113.2 50 25 82.6 - 100.5 50 25 113.3 - 144 70 35 100.6 - 128.2 70 35 144.1 - 174 95 50 128.3 - 155.2 95 50 174.1 - 201.7 120 70 155.3 - 179.2 120 70 2 2 mc_062310_0615 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 15 INSTALLATION Sensor placement SENSOR LOCATION IS CRITICAL Other factors affecting humidity control Sensor location has a significant impact on humidifier performance. See the recommendations below and Figure 17-1. Humidity control involves more than the controller’s ability to control the system. Other factors that play an important role in overall system control are: Note: DriSteem recommends that you do not interchange room and duct humidity devices. Room humidity devices are calibrated with zero or little airflow, whereas duct humidity devices require air passing across them. Recommended humidity control (transmitter/humidistat) locations: A. Ideal. Ensures the best uniform mix of dry and moist air with stable temperature control. B. Acceptable, but room environment can affect controllability, such as when sensor is too close to air grilles, registers, or heat radiation from room lighting. C. Acceptable. Provides uniform mixture of dry and moist air. If extended time lag exists between humidity generation and sensing, extend sampling time. D. Acceptable (behind wall or partition) for sampling entire room if sensor is near an air exhaust return outlet. Typical placement for sampling a critical area. E. Not acceptable. These locations might not represent actual overall conditions in the space. F. Not acceptable. Do not place sensors near windows, door passageways, or areas of stagnant airflow. Recommended safety (airflow and high limit) sensor location: G. Best sensing location for high limit humidistat or humidity sensor and airflow proving switch. mc_072011_1655 16 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL • Size of humidification system relative to load • Overall system dynamics associated with moisture migration time lags • Accuracy of humidistats and humidity transmitters and their location • Dry bulb temperature accuracy in space or duct • Velocities and airflow patterns in ducts and space environments • Electrical noise or interference mc_072011_1656 INSTALLATION Sensor placement FIGURE 17-1: RECOMMENDED SENSOR LOCATIONS 8' to 12' (2.4 m to 3.7 m) min. Outside air Damper control Relief air Return air sC Window Air handling unit sG High limit humidistat or high limit transmitter (set at 90% RH maximum) for VAV applications Airflow switch or differential pressure switch (sail type recommended for VAV applications) Vapor absorption has taken place Wall or partition Point of vapor absorption sD sE Es Humidifier dispersion assembly Turning vanes sB As DC-1084 mc_060508_0750 F E s Doorway F Window Temperature compensation option: Place a temperature compensation sensor on the lower corner of the inside surface of double-pane window glass on north- or northeast-facing window. VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 17 INSTALLATION Dispersion: Selecting the dispersion assembly location DriSteem humidifiers operate with several types of dispersion assemblies for open spaces and for ducts and air handling units. FIGURE 18-1: ULTRA-SORB WITH THE HIGH-EFFICIENCY TUBE OPTION Dispersion assemblies in ducts and air handling units must be positioned where the water vapor being discharged is carried off with the airstream and is absorbed before it can cause condensation or dripping. • Non-wetting distance is the dimension downstream from the leaving side of the steam dispersion assembly to the point where wetting will not occur, although wisps of steam may be present. This distance was calculated during humidification system design and is dependent on several application parameters. To determine your dispersion assembly’s non-wetting distance, consult your system’s design engineer or project documentation. Non-wetting distance can also be calculated using DriSteem’s DriCalc sizing and selection software, available at www. dristeem.com. Note that your current design conditions may vary from conditions used for system design. • In general, the dispersion assembly is best placed where the air can absorb the moisture being added without causing condensation at or after the unit. This normally will be after the heating coil or where the air temperature is highest. • Place the dispersion assembly such that absorption will occur – before the intake of a high efficiency filter, because the filter can remove the visible moisture and become waterlogged; – before coming in contact with any metal surface; – before fire or smoke detection devices; – before a split in the duct; otherwise, the dispersion assembly can direct more moisture into one duct than the other. • When draining dispersion condensate to an open drain, provide a 1" (25 mm) air gap between the condensate drain piping and the drain. Locate the gap only in spaces with adequate temperature and air movement to absorb flash steam; otherwise, condensation may form on nearby surfaces. mc_060210_0838 18 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL High-efficiency Tube option Dispersion assemblies with the High-efficiency Tube option are designed to produce significantly less dispersion-generated condensate and airstream heat gain, which reduces wasted energy by up to 85%. These improvements are accomplished by reducing the thermal conductivity of the tubes with 1/8" of polyvinylidene fluoride (PVDF) insulating material on the outside of the tubes. These assemblies require careful unpacking, installation, and handling. If your dispersion assembly has the High-efficiency Tube option, be sure to read this section carefully. mc_060208_1320 INSTALLATION Dispersion: Interconnecting piping requirements Important: The steam outlet on the humidifier is sized to the output of the humidifier. DO NOT use steam hose or tubing with an inside diameter smaller than the humidifier steam outlet. See note at left. Reducing the inside diameter of the steam hose or tubing will result in the internal humidifier system pressure exceeding the parameters for acceptable performance. • See maximum steam carrying capacities in Table 19-1. mc_060210_0847 • If the humidifier must be located higher than the dispersion assembly, use the recommended installation shown in Figure 21-1. Important: CONNECTING TO HUMIDIFIER WITH STEAM HOSE • Support steam hose to prevent sags, or low spots, and to maintain a minimum pitch of 2"/ft (15%) back to the humidifier. • Use DriSteem steam hose. Other manufacturers of steam hose may use unacceptable release agents or material mixes that can affect humidifier system performance adversely. Using hose from alternative manufacturers increases the possibility of tank foaming and accelerated aging. Foaming causes condensate discharge at the dispersion assembly. Failure to follow the recommendations in this section can result in excessive back pressure on the humidifier. This will result in unacceptable humidification system performance such as leaking gaskets, blown water seals, erratic water level control, and spitting condensate from dispersion tubes. mc_060210_0843 • Do not use steam hose in outdoor applications. • Do not insulate steam hose. Insulation causes accelerated heat aging, causing the steam hose to become hard and susceptible to failure due to cracks. • For single dispersion tube applications, see hose kit sizes in Table 29-1. Table 19-1: Maximum steam carrying capacity and length of interconnecting steam hose or tubing Steam hose1 Hose I.D. Maximum capacity Copper or stainless steel tubing Maximum length2 Tubing size Maximum capacity 3 Maximum developed length4 inches DN lbs/hr kg/h ft m inches DN lbs/hr kg/h ft m 1½ 40 150 68 10 3 1½ 40 150 68 20 6.1 2 50 250 113 10 3 2 50 220 100 30 9.2 3. Insulate tubing to minimize loss of capacity and efficiency. 1. When using steam hose, use DriSteem steam hose for best results. Field-supplied hose may have shorter life and may cause 4. Developed length of tubing equals measured length plus 50% of measured length, to account for fittings. foaming in the evaporating chamber resulting in condensate discharge at the dispersion assembly. Do not use steam hose for Longer tubing lengths are possible at capacities lower than listed maximums. Consult factory. outdoor applications. 2. Maximum recommended length for steam hose is 10' (3 m). Longer distances can cause kinking or low spots. Note: Capacities and lengths in this table are based on total maximum pressure drop in hose or tubing of 5" wc (1250 Pa) mc_091410_1050-VM VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 19 INSTALLATION Dispersion: Interconnecting piping requirements CONNECTING TO HUMIDIFIER WITH TUBING • See Figures 28-1 and 29-1 for interconnecting tubing pitch requirements for single dispersion tube applications. See Table 31-1 for interconnecting tubing pitch requirements for Rapid-sorb applications. WARNING Excessive moisture hazard DriSteem strongly recommends installing a duct airflow proving switch and a duct high limit humidistat. These devices prevent a humidifier from making steam when there is low airflow in the duct or when the RH level in the duct is too high. Failure to install these devices can result in excessive moisture in the duct, which can cause bacteria and mold growth or dripping through the duct. • Support tubing between the humidifier steam outlet and the dispersion system with pipe hangers. Failure to properly support the entire tubing weight may cause damage to the humidifier tank and void the warranty. • 90° elbows are not recommended; use two 45° elbows, 1' (0.3 m) apart. • Insulate tubing to reduces the loss in output caused by condensation. mc_060310_1145-NA mc_060310_0725 Table 20-1: Steam loss of interconnecting steam hose or tubing Steam loss Description Steam hose Tubing Nominal hose or tubing size Noninsulated Insulation thickness Insulated inches DN lbs/hr/ft kg/h/m lbs/hr/ft kg/h/m inches mm 1½ 40 0.15 0.22 N/A N/A N/A N/A 2 50 0.20 0.30 N/A N/A N/A N/A 1½ 40 0.11 0.16 0.020 0.030 2 50 2 50 0.14 0.21 0.025 0.037 2 50 Note: These data are based on an ambient air temperature of 80 °F (27 °C), fiberglass insulation, and copper tubing. mc_051310_1215 20 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL INSTALLATION Dispersion: Drip tee installation Install a drip tee as shown below when the humidifier is mounted higher than the dispersion assembly, when interconnecting hose or tubing needs to go over an obstruction, or when interconnecting piping runs are long. Important: Steam hose must be supported to prevent sagging or low spots. WARNING Hot surface and steam hazard Dispersion tube, steam hose, or tubingcan contain steam, and surfaces can be hot. Discharged steam is not visible. Contact with hot surfaces or air into which steam has been discharged can cause severe personal injury. mc_060110_1555 FIGURE 21-1: DRIP TEE INSTALLATION 90° long sweep or two 45° elbows Pitch Obstruction DC-1450 Insulate tubing to reduce steam loss Vapormist humidifier To dispersion assembly 6" (150 mm) recommended 8" (200 mm) minimum Tubing drip tee, by installer. DriSteem part numbers for 304 stainless steel inline tees: • 1½" (DN40): Part No. 162710 • 2" (DN50): Part No. 162712 3/4" (DN20) 1" (25 mm) air gap Open funnel or floor drain. See first note below. Notes: • Locate air gap only in spaces with adequate temperature and air movement to absorb flash steam; otherwise, condensation may form on nearby surfaces. Refer to governing codes for drain pipe size and maximum discharge water temperature. • Support steam hose so there are no sags or low spots. • Dashed lines indicate provided by installer. mc_062810_0645-VM VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 21 INSTALLATION Dispersion: SDU-I and SDU-E SDU-I is available for Vapormist humidifier models VM-2 through VM-10. SDU-I: Instant, internal absorption SDU-E is available for all Vapormist humidifiers except VM-2 and models using 240V, 277V, and 480V three-phase power with the SSR control option and drawing more than 32.7 amps. SDU-I (Space Distribution Unit Internal Absorption) disperses humidity with no visible vapor trail or wetness, making it ideal for use in finished spaces. The SDU-I fan mixes room air and steam to ensure complete absorption before discharge as humidified air. Note: SDUs ship separate from the Vapormist. mc_052510_1525-VM MOUNTING SDU-I AND SDU-E Both SDUs can be mounted on a wall directly above the Vapormist cabinet or mounted on a wall remote from the Vapormist (see Figure 6-3). Use the mounting template on the box for correct placement. Two lag bolts are provided with each SDU. • Installation must comply with governing codes. • See interconnecting piping requirements in Table 19-1, and the drip tee installation instructions on Page 21. Important: For visible vapor to be absorbed completely within the SDU-I unit before being discharged as humidified air, room air must be 45% RH or less. Trying to maintain greater than 45% RH will cause visible vapor and potential for moisture collection on the discharge grille. SDU-E: Higher capacity SDU-E (Space Distribution Unit External Absorption) is designed for higher capacity dispersion. SDU-E requires an installed condensate drain line and water seal, provided by installer. mc_052510_1610 • Provide at least 6" (150 mm) clearance on each side of the SDU. • Field wiring is required to connect the SDU fan and airflow proving switch terminals to Vapormist electrical panel terminals. Refer to the external connections diagram in the package shipped with your unit. See Figure 22-1. Minimum wire size for field wiring is 18-gauge (1.5 mm2) stranded wire. FIGURE 22-1: SDU FIELD WIRING SDU-E • For wall mounting, use the mounting template on the box for correct placement. Two 3/8" lag bolts (M10 × 50 mm coach screws) are provided with each fan unit. Field wiring for fan and airflow proving switch • When mounting on a stud wall (studs 16" [406 mm] on center), locate studs and position lag bolts (coach screws) in place so that each of the two lag bolts (coach screws) centers on a stud. Mark hole locations and predrill ¼" (6 mm) diameter pilot holes for a 3/8" × 2" lag bolt (M10 × 50 mm coach screw). • For hollow block or poured concrete wall mounting, position template in place and mark the holes. Drill appropriate pilot hole for two 3/8" (M10) toggle bolts or two 3/8" (M10) machine bolt lead anchors (expansion bolts). Secure SDU frame in place. WHEN PERFORMING VAPORMIST MAINTENANCE If the SDU-E or SDU-I is installed immediately above the Vapormist, disconnect both hose clamps on the steam hose, grip the hose and rotate it to break it loose from the tubing, and then slide the hose up onto the SDU steam tube until sufficient clearance is provided to move the tank. mc_062810_1005-VM 22 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL Vapormist electrical panel, right side view VLC-OM-031 INSTALLATION Dispersion: SDU-I and SDU-E FIGURE 23-1: WALL-MOUNTED VAPORMIST AND SDU-I Keyhole for 3/8" dia. (M10) fasteners 16" (406 mm) SDU chassis 3" (76 mm) 17.75" (451 mm) 18.02" (458 mm) 16" (406 mm) 0.25" (6.4 mm) 3" (76 mm) Keyhole for 3/8" dia. (M10) fasteners 18.50" (470 mm) Vapormist chassis 24" (610 mm) OM-282-4 mc_052610_1505-VM FIGURE 23-2: WALL-MOUNTED VAPORMIST AND SDU-E Keyhole for 3/8" dia. (M10) fasteners 16" (406 mm) SDU chassis 3" (76 mm) 18.02" (458 mm) 16" (406 mm) 16" (406 mm) 2" (51 mm) 3" (76 mm) Keyhole for 3/8" dia. (M10) fasteners 18.5" (470 mm) Vapormist chassis 24" (610 mm) OM-282-7 mc_052610_1506-VM VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 23 INSTALLATION Dispersion: SDU-I and SDU-E Table 24-1: SDU specifications Maximum capacity Shipping weight Amps at 120V Horsepower (50/60 Hz) SDU model lbs/hr kg/h lbs kg SDU-I 30 13.6 68 31 3.20 SDU-E 102 46.3 61 28 2.07 cfm m3/s dB* 1/5 760 0.36 58 1/8 545 0.26 64 * Measurement taken 6.5' (2 m) in front of SDU cabinet. mc_042710_1440-NA FIGURE 24-1: SDU-I MECHANICAL DETAIL Front view 24.2" (615 mm) Side view Humidified air discharge grille 16.1" (409 mm) 18.6" (472 mm) DC-1076 10.9" (276 mm) 1½" (DN40) steam inlet Air intake grille 2.25" (57 mm) mc_052510_1700-NA FIGURE 24-2: SDU-E MECHANICAL DETAIL Front view Steam outlet Side view 16.1" (409 mm) 24.2" (615 mm) DC-1078 3/4" (DN20) pipe thread drain nipple (see note below) 18.6" (472 mm) 3.2" (82 mm) 10.9" (276 mm) 1½" (DN40) or 2" (DN50) steam inlet Steam inlet 2.25" (57 mm) Note: SDU-E dispersion box requires an installed condensate drain line and water seal, provided by installer. See Figure 25-1. mc_052510_1701-NA 24 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL INSTALLATION Dispersion: SDU-I and SDU-E SDU-E CONDENSATE DRAIN CONNECTION Mounting SDU-E 1. Piping must be minimum 3/4" I.D. (DN20) and rated for 212 °F (100 °C) minimum continuous operating temperature. • SDU-E requires an installed condensate drain line and water seal (provided by installer). See Figure 25-1 and instructions at left. 2. Drain line must be piped as shown in Figure 25-1. Provide a 6" (152 mm) drop prior to a 4" (102 mm) water seal to ensure condensate drainage from the SDU-E, and to keep steam from blowing out of the drain line. • Spread dimensions greater than 3' (1 m) may require additional clearance. See Table 27-1). 3. After the water seal, run the drain line to an open drain with a 1" (25 mm) vertical air gap. Cut the drain line at a 45 degree angle on the end above the drain to permit a direct stream of water into the drain pipe while maintaining a 1" (25 mm) air gap. 4. All drain lines must be installed and sized according to governing codes. 5. The drain line should have a union installed directly on the dispersion box ¾" nipple to accommodate future removal of the SDU-E shroud. 6. A drain line and water seal must be connected to the SDU-E fan unit dispersion box ¾" nipple. If the condensate is not drained from the dispersion box, standing water will accumulate. See Warning at right. 7. The dispersion box is constructed with a pitch toward the drain; however, the SDU-E frame must be installed plumb and level for the dispersion box to drain properly. mc_052610_1720-NA WARNING Hazards of standing water in SDU-E If standing water is allowed to accumulate in the dispersion box, it can: • Cause bacteria and mold growth, which can cause illness. • Affect SDU-E fan unit performance. • Cause 212 °F (100 °C) water to discharge from the SDU-E fan unit, which can cause severe personal injury. FIGURE 25-1: SDU-E DRAIN LINE PIPING Install SDU-E frame plumb and level mc_052610_1725 OM-1245 Union Elbow Drain 4" (102 mm) Dispersion box 1" (25 mm) air gap 3/4" pipe thread (DN20) dispersion box drain and P-trap piping, rated for 212 °F (100 °C) Spill funnel. Plumb to floor drain. mc_042710_1445-NA Open floor drain. Refer to governing codes for drain pipe size and maximum temperature requirements. VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 25 INSTALLATION Dispersion: SDU-I and SDU-E SDU-E RISE, SPREAD, AND THROW As steam is discharged from the SDU-E, it quickly cools and turns to a visible fog that is lighter than air. As this fog is carried away from the SDU-E by the airstream, it tends to rise toward the ceiling. If this fog contacts solid surfaces (columns, beams, ceiling, pipes, etc.) before it disappears, it could collect and drip as water. The greater the space relative humidity, the more the fog will rise, throw and spread. Table 27-1 lists the minimum rise, throw and spread non-wetting distances for SDU-E at 40%, 50% and 60% RH in the space. Surfaces cooler than ambient temperature, or objects located within this minimum dimension, can cause condensation and dripping. To avoid steam impingement on surrounding areas, observe the minimum non-wetting distances in Table 27-1. The SDU-E contains a blower (120 V, single-phase, 60 Hz) and an airflow proving switch (field-wired to the humidifier electrical panel). A wiring diagram of the SDU-E is included with the unit. On a call for humidity, the humidifier begins producing steam, and the start relay energizes the SDU-E blower. When the call for humidity is satisfied, the Vapor-logic controller keeps the blower running to disperse residual moisture using a time delay. mc_042710_1255 FIGURE 26-1: SDU-E RISE, SPREAD, AND THROW Air intake grille Steam outlet Rise Spread 26 DC-1027 mc_042710_1435 Throw VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL INSTALLATION Dispersion: SDU-I and SDU-E Table 27-1: SDU-E minimum nonwetting distances kW 40% RH @ 70 °F (21 °C) Maximum steam capacity Rise Spread 50% RH @ 70 °F (21 °C) Throw Rise Spread 60% RH @ 70 °F (21 °C) Throw Rise Spread Throw lbs/hr kg/h ft m ft m ft m ft m ft m ft m ft m ft m ft m 2 6 2.7 1.0 0.3 1.0 0.3 5.0 1.5 1.5 0.5 1.5 0.5 6.5 2.0 2.5 0.8 2.5 0.8 7.5 2.3 4 12 5.4 1.0 0.3 1.0 0.3 5.0 1.5 1.5 0.5 1.5 0.5 6.5 2.0 2.5 0.8 2.5 0.8 7.5 2.3 6 18 8.2 1.0 0.3 1.0 0.3 5.0 1.5 1.5 0.5 1.5 0.5 6.5 2.0 2.5 0.8 2.5 0.8 7.5 2.3 8 24 10.9 1.0 0.3 1.0 0.3 5.5 1.7 1.5 0.5 1.5 0.5 6.5 2.0 2.5 0.8 2.5 0.8 7.5 2.3 10 30 13.6 1.5 0.5 1.5 0.5 6.0 1.8 2.0 0.6 2.0 0.6 7.0 2.1 3.0 1.0 3.0 1.0 8.0 2.5 12 36 16.3 1.5 0.5 1.5 0.5 6.0 1.8 2.0 0.6 2.0 0.6 7.0 2.1 3.0 1.0 3.0 1.0 8.0 2.5 14 42 19.1 2.0 0.6 2.0 0.6 7.0 2.1 2.0 0.6 2.0 0.6 7.0 2.1 3.0 1.0 3.0 1.0 9.0 2.7 16 48 21.8 2.0 0.6 2.0 0.6 7.0 2.1 2.0 0.6 2.0 0.6 7.0 2.1 3.0 1.0 3.0 1.0 9.0 2.7 21 63 28.6 2.0 0.6 2.0 0.6 7.5 2.3 2.5 0.8 2.5 0.8 10.0 3.0 3.0 1.0 3.0 1.0 12.0 3.7 25 75 34.0 2.0 0.6 2.0 0.6 8.0 2.5 2.5 0.8 2.5 0.8 10.5 3.2 3.5 1.1 3.5 1.1 12.5 3.8 30 90 40.9 2.0 0.6 2.0 0.6 8.0 2.5 2.5 0.8 2.5 0.8 10.5 3.2 3.5 1.1 3.5 1.1 12.5 3.8 34 102 46.3 2.0 0.6 2.0 0.6 8.0 2.5 2.5 0.8 2.5 0.8 10.5 3.2 3.5 1.1 3.5 1.1 12.5 3.8 Notes: • Surfaces or objects directly in the path of steam discharge may cause condensation and dripping. • To avoid steam impingement on surrounding areas, observe the minimum nonwetting dimensions in this table. • Rise: The minimum nonwetting height above the steam outlet of the SDU-E. • Spread: The minimum nonwetting width from the steam outlet of the SDU-E. • Throw: The minimum nonwetting horizontal distance from the steam outlet of the SDU-E. mc_042710_1300-NA VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 27 INSTALLATION Dispersion: Single dispersion tube FIGURE 28-1: SINGLE DISPERSION TUBE WITHOUT CONDENSATE DRAIN Duct Single dispersion tube without condensate drain Steam hose or tubing. Insulate tubing to reduce steam loss. Do not insulate steam hose. See Table 19-1 for maximum piping lengths. Mounting nut 3/8" - 16 (M10) Pitch* See the first bullet in Installation notes. Secure and seal escutcheon plates Vapormist humidifier Tube pitch: 2"/ft (15%) 90° long sweep or two 45° elbows * Pitch steam hose or tubing toward humidifier: – 2"/ft (15%) when using steam hose – 1/2"/ft (5%) when using 1½" tubing – 1/4"/ft (2%) when using 2" tubing Dispersion tube escutcheon plate A DC-1447 Dashed lines indicate provided by installer. A Dimension A: • 3.25" (82.5 mm) for 1½" tubes • 5" (127 mm) for 2" tubes OM-351-1 mc_062810_0720-VM INSTALLATION NOTES • Use a hose clamp to connect the steam outlet to steam hose. Use a hose cuff and clamps to connect the steam outlet to tubing. • Tubing diameter must match Vapormist steam outlet size 1½" (DN40), 2" (DN50), or NPT connection. • See the steam carrying capacity and steam loss tables on Pages 19 and 20. Important: Failure to follow the recommendations in this section can result in excessive back pressure on the humidifier. This will result in unacceptable humidification system performance such as leaking gaskets, blown water seals, erratic water level control, and spitting condensate from dispersion tubes. mc_060210_0843 • Orient dispersion tube with tubelets (steam orifices) pointing up. • If mounting the humidifier above the level of dispersion tube, see “Drip tee installation” on Page 21. • Table 28-1 lists hose kit sizes by humidifier model. Note that the capacities of Models 30 and 34 require multiple tube assemblies and cannot use a hose kit. For multiple tube assemblies, see “Rapid-sorb,” beginning on Page 30. mc_062810_1030-NA WARNING Hot surface and steam hazard Dispersion tube, steam hose, or tubing can contain steam, and surfaces can be hot. Discharged steam is not visible. Contact with hot surfaces or air into which steam has been discharged can cause severe personal injury. mc_060110_1555 28 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL INSTALLATION Dispersion: Single dispersion tube FIGURE 29-1: SINGLE DISPERSION TUBE WITH CONDENSATE DRAIN Single dispersion tube with condensate drain Duct Secure and seal escutcheon plates Steam hose or tubing. Insulate tubing to reduce steam loss. Do not insulate steam hose. See Table 19-1 for maximum piping lengths. Mounting nut 3/8" - 16 (M10) Pitch* 90° long sweep or two 45° elbows Pitch tube toward drain 1/8"/ft (1%) 6" (150 mm) recommended See the first bullet in Installation notes. 1/4" NPT (DN8) 1/2" O.D. (DN15) condensate drain tube. Pitch 1/4”/ft (2%) toward escutcheon plate. 3/4" (DN20) (minimum) condensate drain tube by installer. Must be suitable for 212 °F (100 °C) water. Water seal 5" (125 mm) Vapormist humidifier Open drain required. Locate air gap only in spaces with adequate temperature and air movement to absorb flash steam; otherwise, condensation may form on nearby surfaces. Refer to governing codes for drain pipe size and maximum discharge water temperature. 1" (25 mm) air gap DC-1449 Escutcheon plates * Pitch steam hose or tubing toward humidifier: – 2"/ft (15%) when using steam hose – 1/2"/ft (5%) when using 1½" tubing – 1/4"/ft (2%) when using 2" tubing Dispersion tube Condensate drain A Dimension A: • 3.25" (82.5 mm) for 1½" tubes • 5" (127 mm) for 2" tubes A Dashed lines indicate provided by installer. A mc_062810_0725-VM A OM-351-1 Table 29-1: Single dispersion tube capacities Insulated (High-Efficiency Tubes) Tube size Without drain Uninsulated With drain Without drain With drain inches DN lbs/hr kg/h lbs/hr kg/h lbs/hr kg/h lbs/hr kg/h 1½ 40 29 13.2 65 29.5 28 12.7 62 28.2 2 50 65 29.5 97 44.1 62 28.2 93 42.3 Notes: • Single dispersion tube available with face width between 6" (152 mm) up to 120" (3048 mm) in 1" (25 mm) increments. • If face width is <19" (483 mm), tube capacity may be reduced. Consult DriSteem or see DriCalc for the correct capacity. • Hose kits are available that include dispersion tube, 10 ft (3 m) of steam hose, and hardware VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 29 INSTALLATION Dispersion: Rapid-sorb Read all dispersion instructions in this manual, and follow the installation instructions below: • Unpack shipment and verify receipt of all Rapid-sorb components with packing list. Report any shortages to DriSteem immediately. The components typically include the following: – Multiple dispersion tubes – Header – 3/4" × 2" (19 mm × 51 mm) L-bracket WARNING Hot surface and steam hazard Dispersion tube, steam hose, or tubing can contain steam, and surfaces can be hot. Discharged steam is not visible. Contact with hot surfaces or air into which steam has been discharged can cause severe personal injury. mc_060110_1555 Note: Dispersion tubes, header, and L-bracket are each tagged with the customer requested identification number. – A single duct escutcheon plate the size of the header – Slip couplings or hose cuffs and clamps – Accessories such as duct plates, slip couplings, or hose cuffs – Bolts and washers for mounting the dispersion tubes to the bracket • L-bracket mounting holes (see note at left): – L-bracket 50" (1270 mm) long or shorter has a mounting hole 4" (100 mm) from each end for mounting the L-bracket to the duct or air handler wall. – L-bracket longer than 50" (1270 mm) has an additional mounting hole in the center. Note: Hardware for mounting the L-bracket to the duct or air handler wall and the hardware for the header support bracket is not provided. • Select an installation location that provides necessary access in and around the ductwork or air handler. • The Rapid-sorb typically is installed centered side to side in a duct, or is installed across the face of a coil in an air handler. • The center line of the outer dispersion tubes should never be closer than 4.5" (114 mm) from the side of the ductwork or air handler wall. • The following instructions are for a typical Rapid-sorb installation — horizontal-airflow duct with Rapid-sorb header either inside or outside the duct. See the DriCalc Installation Guides library or contact your representative/distributor or DriSteem for installation instructions for air handler or vertical airflow applications. mc_060210_0945-NA 30 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL Important: Before marking and drilling holes in the duct or air handler, refer to ALL pitch requirements for the Rapid-sorb assembly you received (see Table 31-1). The size, quantity, and location of penetrations are determined by the dimensions and configuration of the Rapid-sorb assembly you received. mc_060210_0937 Important: Failure to follow the recommendations in this section can result in excessive back pressure on the humidifier. This will result in unacceptable humidification system performance such as leaking gaskets, blown water seals, erratic water level control, and spitting condensate from dispersion tubes. mc_060210_0843 INSTALLATION Dispersion: Rapid-sorb Pitch requirements • For Rapid-sorb with the header outside a horizontal-airflow duct, consider the following: – 1½" (DN40) dispersion tubes: Use a fastener of sufficient length to accommodate the 1/8"/ft (1%) pitch requirements toward the 3/4" pipe thread (DN20) header drain fitting. – 2" (DN50) dispersion tubes: The bracket can be mounted flush to the ductwork. The 1/8"/ft (1%) pitch typically can be accomplished in the length of the hose cuffs used to connect the tubes to the header. • See Table 31-1 and the drawings on the following pages for pitch requirements. mc_060210_0953-NA Table 31-1: Pitch of interconnecting piping, dispersion tubes, and headers for Rapid-sorb evaporative dispersion units Airflow Type of interconnecting piping Diameter of interconnecting piping Pitch of interconnecting piping Steam hose 1½" (DN40) 2" (DN50) 2"/ft (15%) toward Rapid-sorb Tubing 1½" (DN40) 2" (DN50) 1/8"/ft (1%) toward Rapid-sorb Steam hose 1½" (DN40) 2" (DN50) 2"/ft (15%) toward Rapid-sorb Tubing 1½" (DN40) 2" (DN50) 1/8"/ft (1%) toward Rapid-sorb Horizontal Vertical Pitch of dispersion tubes Pitch of header Vertically plumb 1/8"/ft (1%) toward condensate drain 2"/ft (15%) toward header 1/8"/ft (1%) toward condensate drain mc_060310_1000 Table 31-2: Rapid-sorb tube capacities* Table 31-3: Rapid-sorb header capacities Tube capacity Tube diameter Insulated (High-Efficiency Tubes) Header capacity Uninsulated Header diameter lbs/hr kg/h inches DN ≤ 250 ≤ 113 2 50 inches DN lbs/hr kg/h lbs/hr kg/h 251-500 114-227 3 80 1½ 40 43.0 19.5 40.0 18.2 501-800 228-363 4 100 2 50 80.0 36.4 77.0 35.0 801-1300 364-591 5 125 1301-2100 592-955 6 150 * Capacities shown are for horizontal airflow. See DriCalc for vertical airflow capacities. If face height is <22" (559 mm), tube quantity per panel may need to increase to compensate for reduced capacity of short tubes. Consult DriSteem or see DriCalc for the correct calculation. mc_060210_0936- mc_060210_0935 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 31 INSTALLATION Dispersion: Rapid-sorb FIGURE 32-1: RAPID-SORB IN A HORIZONTAL AIRFLOW WITH HEADER OUTSIDE THE DUCT Position L-bracket so that flange is upstream of dispersion tubes. Drawing shows L-bracket positioned for airflow back to front. Dashed lines indicate provided by installer. L-bracket Air Dispersion tube flow Duct Point tubelets perpendicular to airflow 90° long sweep or two 45° elbows Steam hose or tubing. Insulate tubing to reduce steam loss. Do not insulate steam hose. See Table 19-1 for maximum piping lengths. DC-1448 Secure and seal escutcheon plates Slip coupling or hose cuff Support bracket that has 0.421" (11 mm) mounting holes at top, bottom and end Pitch (see Note 1) Header pitch: 1/8" /ft (1%) minimum See Note 2 Condensate drain 3/4" pipe thread (DN20) copper 3/4" pipe thread (DN20) copper 1" (25 mm) air gap Vapormist humidifier Notes: 1 Pitch steam hose or tubing toward Rapid-sorb: – 2"/ft (15%) when using steam hose – 1/8"/ft (1%) when using tubing 2 Use a hose clamp to connect steam outlet to steam hose. Use a hose cuff and clamps to connect steam outlet to tubing. 6" (150 mm) recommended 5" (125 mm) recommended Open drain required: Locate air gap only in spaces with adequate temperature and air movement to absorb flash steam; otherwise, condensation may form on nearby surfaces. Refer to governing codes for drain pipe size and maximum discharge water temperature. Dispersion tube escutcheon plates A A mc_062810_0815-VM Dimension A: • 3.25" (82.5 mm) for 1½" tubes • 5" (127 mm) for 2" tubes OM-351-1 HEADER OUTSIDE OF DUCT, HORIZONTAL AIRFLOW 1. Mark and cut holes in the ductwork for the dispersion tubes. Use the L-bracket as a template to mark the holes on the duct floor. 2. Temporarily, loosely suspend or support the header below the final location. Vertical balance point of the dispersion tube length dictates where the header should be suspended or temporarily supported. 3. Mount the dispersion tubes to the header with the slip coupling or hose cuff (provided). • When installing slip couplings for 1½" (DN40) dispersion tubes, take care not to shear the O-rings. • Set the slip coupling on the header stub or dispersion tube so the O-ring is resting on the face of the tubing. • Rotate the slip coupling as you push it onto the tubing. • The O-rings are lubricated at the factory. If additional lubrication is necessary, DO NOT use a petroleum-based lubricant. 32 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL INSTALLATION Dispersion: Rapid-sorb 4. Position the flange of the L-bracket so it is upstream of the tubes when the assembly is raised and fastened into position. Fasten the L-bracket to the end of the dispersion tubes with the provided bolt, lock washer, and flat washer. Note: See Page 36 for steam supply and condensate drain line connection instructions. 5. Before tightening the L-bracket bolts to the dispersion tubes: • For 1½" (DN40) dispersion tubes: – Dispersion tube will rotate in slip coupling. Verify that dispersion tube orifices are directed perpendicular to airflow. – Dispersion tube and slip coupling must be fully engaged on header stub for O-rings to provide a seal. • For 2" (DN50) dispersion tubes: Before securing hose cuff in place with hose clamps on dispersion tube and the header stub, verify that dispersion tube orifices are directed perpendicular to airflow. 6. Slide the assembly up until the L-bracket aligns with the mounting holes in the duct. • For 1½" (DN40) dispersion tubes: – Header pitch is duplicated in the L-bracket. – Dispersion tube and slip coupling must be fully engaged on header stub for O-rings to provide a seal. – High end of L-bracket can be fastened tight to duct or air handler. – Fastener on low end of L-bracket must be long enough to compensate for pitch. Use a nut on both sides of L-bracket and duct or air handler for stability. • For 2" (DN50) dispersion tubes: – Fasten bracket to top of duct and use hose cuffs to compensate for header pitch. – Before securing hose cuffs with hose clamps on dispersion tube and header stub, verify that header pitch, 1/8"/ft (1%) toward drain, is maintained. 7. Permanently secure both ends of header, and verify that header pitch, 1/8"/ft (1%) toward drain, is maintained. 8. Verify that all fasteners are secure: • L-bracket to duct • Dispersion tubes to L-bracket • Hose clamps on 2" (DN50) tubes 9. Secure and seal the dispersion tube escutcheon plate and condensate drain tube escutcheon plate around the respective tubes, if applicable. mc_060210_1015-NA VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 33 INSTALLATION Dispersion: Rapid-sorb FIGURE 34-1: RAPID-SORB IN A HORIZONTAL AIRFLOW WITH HEADER INSIDE THE DUCT Position L-bracket so that flange is upstream of dispersion tubes. This drawing shows the L-bracket positioned for airflow back to front Dispersion tube Air Point tubelets (steam orifices) perpendicular to airflow w flo Duct Slip coupling or hose cuff 90° long sweep or two 45° elbows Support bracket Pitch* Steam hose or tubing. Insulate tubing to reduce steam loss. Do not insulate steam hose. See Table 19-1 for maximum piping lengths. Secure and seal escutcheon plate Pitch header toward drain 1/8"/ft (1%) 3/4" pipe thread (DN20) drain 3/4" (DN20) copper 6" (152 mm) 5" (127 mm) 1" (25 mm) air gap OM-7399 Vapormist humidifier * Pitch steam hose or tubing toward Rapid-sorb: – 2"/ft (15%) when using steam hose – 1/8"/ft (1%) when using tubing Open drain required: Locate air gap only in spaces with adequate temperature and air movement to absorb flash steam, or condensing on nearby surfaces may occur. Refer to governing codes for drain pipe size and maximum discharge water temperature. Dashed lines indicate provided by installer. mc_062810_0820-VM HEADER INSIDE OF DUCT, HORIZONTAL AIRFLOW 1. Mark and cut holes in ductwork or air handler for steam header penetration, condensate drain piping, and header support bracket fastener. Allow 1/8"/ft (1%) header pitch toward the support bracket when you drill the hole for the header support bracket fastener. 2. Loosely fasten the header in place. 3. Rotate the header 90° so the header stubs point horizontally in the duct. 4. When installing in an air handler, the rotation of the header is often less than 90°. Typically, due to the condensate drain piping requirements, the header can be set on the floor of the air handler, assembled in the vertical position, and then raised and mounted in place. 34 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL WARNING Hot surface and steam hazard Dispersion tube, steam hose, or tubing can contain steam, and surfaces can be hot. Discharged steam is not visible. Contact with hot surfaces or air into which steam has been discharged can cause severe personal injury. mc_060110_1555 INSTALLATION Dispersion: Rapid-sorb 5. Mount the dispersion tubes on the header with the slip couplings or hose cuffs: • When installing slip couplings for 1½" (DN40) dispersion tubes, take care not to shear O-rings. Note: See Page 36 for steam supply and condensate drain line connection instructions. • Set slip coupling on header stub or dispersion tube so O-ring is resting on face of tubing. • Rotate slip coupling while pushing it onto the tubing. • O-rings are lubricated at factory. If additional lubrication is necessary, DO NOT use petroleum-based lubricant. 6. Allow the dispersion tubes to rest against the bottom of the duct. 7. Position the flange of the L-bracket so it is upstream of the tubes when the assembly is rotated into position. Fasten the L-bracket to the end of the dispersion tubes with the provided bolt, lock washer, and flat washer. 8. Rotate the assembly up until the L-bracket aligns with the mounting holes in the duct or air handler. • For 1½" (DN40) dispersion tubes: – Header pitch is duplicated in the L-bracket. – Dispersion tube and slip coupling must be fully engaged on header stub for O-rings to provide a seal. – High end of L-bracket can be fastened tight to duct or air handler. – Fastener on low end of L-bracket must be long enough to compensate for pitch. Use a nut on both sides of L-bracket and duct or air handler for stability. • 2" (DN50) dispersion tubes – Fasten bracket to top of duct and use hose cuffs to compensate for header pitch. – Before securing hose cuffs with hose clamps on dispersion tube and header stub, verify that dispersion tube orifices are directed perpendicular to airflow. 9. Verify that all fasteners are secure: • L-bracket to duct • Dispersion tubes to L-bracket • Hose clamps on 2" (DN50) tubes • Header support bracket fastener 10. Secure and seal the header escutcheon plate around the header. mc_060210_1050 -NA VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 35 INSTALLATION Dispersion: Rapid-sorb STEAM SUPPLY CONNECTIONS TO RAPID-SORB HEADER Connect the steam supply interconnecting piping from the humidifier to the Rapid-sorb. The steam supply piping requires a minimum of 1/8"/ft (1%) pitch toward the header. If multiple humidifiers are supplying one Rapid-sorb, a multiple steam supply connector is needed. Typically, the multiple steam supply connector attaches to the Rapid-sorb header supply end with hose cuff and clamps: 1. Route the necessary number of steam supplies from the humidifiers to the steam supply connector. 2. Position the steam supply connector to accept the steam supplies while maintaining the necessary pitch. 3. Make sure the hose clamps on the steam supply connector and header are tight. CONDENSATE DRAIN CONNECTIONS TO RAPID-SORB HEADER Piping must be minimum 3/4" I.D. (DN20) and rated for 212 °F (100 °C) minimum continuous operating temperature. The condensate drain line must be piped as shown in Figures 32-1 and 34-1. Provide a 6" (152 mm) drop prior to a 5" (127 mm) water seal to: • Ensure drainage of condensate from the header • Keep steam from blowing out of the drain line After the water seal, run the drain line to an open drain with a 1" (25 mm) vertical air gap. • Cut the drain line at a 45° angle on the end above the drain to permit a direct stream of water into the drain pipe while maintaining a 1" (25 mm) air gap. • Locate air gap only in spaces with adequate temperature and air movement to absorb flash steam, or condensing on nearby surfaces may occur. All drain lines must be installed and sized according to governing codes. ULTRA-SORB For Ultra-sorb steam dispersion panel instructions, see the installation, operation, and maintenance manual shipped with the Ultra-sorb. mc_060210_1300-NA Ultra-sorb 36 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL CAUTION Operate Rapid-sorb within rated steam capacity Excessive steam flow to the Rapidsorb steam dispersion assembly can cause condensate to exit the tubelets, which can cause water damage and standing water in the duct or air handler. To avoid condensate exiting the tubelets, do not operate the Rapid-sorb beyond its rated capacity. mc_072010_0930 OPERATION Principle of operation FIGURE 37-1: VAPORMIST PRINCIPLE OF OPERATION Tap/softened water Vapormist (shown with cover removed) 4 1 3 2 OM-2000 mc_022112_0952 1. When the system is first activated, the fill valve opens and the evaporating chamber fills with water to the operating level. 2. On a call for humidity, the heating elements are energized, causing the water to boil. The fill valve opens and closes as needed to maintain the operating water level. 3. During refill in tap/softened water systems, a portion of the surface water is skimmed off, carrying away precipitated minerals. 4. RO/DI water systems (systems using deionized water or water that has been treated using reverse osmosis) do not require skimming. 5. Steam created in the evaporating chamber flows through vapor hose or piping to the dispersion assembly, where it is discharged into the airstream. mc_022112_0953 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 37 OPERATION Start-up checklist If an item in the Start-up checklist below does not apply to your system, skip to the next item and continue the process. ☐ Read this manual and all other information that was provided with your humidifier. ☐ Verify that all field wiring is done according to the instructions in this manual and in the humidifier wiring diagram. ☐ Confirm that the input signal is consistent with the Vapor-logic controller's expected input signal. Input signals are listed in the Vapor-logic Setup menu. See “Installation Step 2: Setup” in the Vapor-logic version 5 Installation and Operation Manual. ☐ Confirm that proper grounding and an approved earth ground are provided. ☐ Turn on the water supply, and confirm that the drain valve is closed. ☐ Turn on power to the humidifier, and confirm the Main menu is displayed on the keypad/display. The display may take several seconds to appear as the controller powers up. ☐ Confirm in the Main Menu that the mode is “Auto” and that tank status is “Filling.” ☐ When “Filling” appears in main menu, confirm that the tank is filling with water. ☐ In the Status screen, confirm that the Duct Airflow Switch is closed. ☐ In the Status screen, confirm that the high limit humidistat input is closed or the high limit transmitter is connected. ☐ Make sure the tank has filled with water. See the “Damage from dry startup” Caution on Page 39. ☐ With sufficient water in the tank, the airflow switch closed, the high limit closed, and the humidifier getting a call for humidity, verify that the heater outputs are activated. ☐ Check the amp draw of the heaters. Refer to the humidifier wiring diagram for the proper rating. ☐ If you experience difficulties, have the keypad/display information available along with the serial number and humidifier Model, and call DriSteem Technical Support at 800-328-4447. mc_060210_1355-VM 38 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL OPERATION Start-up procedure After the system is installed and connected properly: 1. Verify that the humidifier, controls, piping, electrical connections, steam supply, and dispersion units(s) are installed according to the following: • Installation instructions in this manual The Vapor-logic version 5 Installation and Operation Manual is a comprehensive operation manual. Refer to it for information regarding the following features: • Keypad/display setup and menu information • Control input signals and functions • Vapor-logic version 5 Installation and Operation Manual • Drain, flush, and skim features – Installation section • Safety features – Pre-installation checklist • Alarm screens and fault messages • Ladder style wiring diagram (inside humidifier electrical panel cover) • External connections wiring diagram (inside humidifier electrical panel cover) The manual was shipped with your humidifier and is available at our Web site: www.dristeem.com mc_052410_1340 • All governing codes 2. Verify that all electrical connections are secure before applying power. 3. Make sure all electrical covers are in place and secure. See Warning at right. 4. Verify that the humidifier is mounted level and securely supported before filling with water. See operating weights in Table 4-1. 5. Verify that the humidifier is level front to back and side to side after it is full of water. 6. Read the “Operation” section of the Vapor-logic version 5 Installation and Operation Manual. Note: During start-up, do not leave the humidifier unattended. 7. Perform all applicable “Start-up checklist” items. See Page 38. WARNING Electric shock hazard Only qualified electrical personnel should perform start-up procedure. Contact with energized circuits can cause property damage, severe personal injury or death as a result of electrical shock or fire. Make sure that all electrical covers are in place and secure before turning on electrical power. These include the heater terminal cover, electrical panel cover, and subpanel access panels. 8. Monitor humidifier operation through multiple fill cycles. The humidifier operating status appears on the keypad/display. 9. On tap/softened water units, water skims from the humidifier after every fill cycle. Adjust the amount of skim by increasing or decreasing the skim time (see the Vapor-logic version 5 Installation and Operation Manual). At start-up, DriSteem recommends initially running the humidifier with the factory default setting for skim time. See “Maintenance," beginning on Page 40. mc_060210_1400 CAUTION Damage from dry startup In the event the humidifier tank does not contain water and the heaters are energized, turn main power off. Operation of the heaters without water will cause damage to the humidifier. Before turning main power on, verify that all wiring has been completed per the wiring instructions in this manual and the unit wiring diagrams. mc_052410_1325 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 39 MAINTENANCE Tap/softened water The best way to determine how often your humidifier needs maintenance is to remove the tank cover and inspect it for mineral deposits after three months of duty. Hours of operation and duty cycle will determine your maintenance schedule, as will water quality. WATER QUALITY AND MAINTENANCE Maintenance requirements vary with water quality, because tap and softened water carry a variety of minerals and other materials in a mix that varies from location to location. Very hard (high mineral content) water requires more frequent cleaning and drain/flush cycles than water with low mineral content. Softened water significantly reduces mineral accumulation inside the humidifier. WARNING Electric shock hazard Contact with energized circuits can cause severe personal injury or death as a result of electric shock. To prevent shock, disconnect electrical power before performing service or maintenance procedures on an part of the humidification system. When performing maintenance on the humidifier: Note: Solids, like silica, are not removed in the softening process. • Always switch the keypad control mode to Standby. SKIM DURATION • Place all power disconnects in OFF position and lock in OFF position. Skim duration determines the quantity of water skimmed with each fill cycle and is field adjustable using the Vapor-logic keypad/display. Skimming reduces the need for frequent humidifier cleaning. Each time the tank refills, it fills to a level just above the lip of the skim/overflow fitting. A portion of the fill water flows out of the skim/overflow fitting to the drain, which flushes minerals left by the previous evaporating cycle and skims away surface residue. Both humidifier cleaning and heated water flowing to the drain are operational costs. DriSteem recommends that the user observe and adjust the skim duration to achieve a balance between reducing mineral buildup and conserving heated water. mc_060210_1430 • Close the field-installed manual supply water shut-off valve. mc_031110_0444 WARNING Hot surface and hot water hazard Do not touch the tank or drain piping until the unit has had sufficient time to cool, or serious injury can occur. Opening the drain valve when the tank is hot can discharge water with a temperature up to 212 °F (100 °C) into the plumbing system. This can cause damage to the plumbing system if the humidifier is not properly connected to a water tempering device such as a DriSteem Drane-kooler™. mc_060110_1640 40 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL MAINTENANCE Tap/softened water COOL DOWN HUMIDIFIER Before performing any maintenance, allow the tank to cool down. Fresh makeup water is used to speed up cooling. Do not close the manual water supply before cooling down the humidifier; otherwise the tank could stay hot for several hours. FIGURE 41-1: COVER ENCLOSURE SCREW CAP DETAIL • Insulated and uninsulated tanks will have hot surfaces. • Verify that there is no call for humidity and that the aquastat set point (adjusted using the keypad/display Setup screens) is less than room temperature (default setting is 40 °F [4 °C]) so that the heaters do not energize while cooling down the tank. • Models with a standard drain valve: – Manually open the drain valve by moving the valve lever located on the back of the drain valve to the manual open position. The fill valve eventually opens. OM-778-3 – Let the fill water run until the tank is cooled, then shut off the fieldinstalled manual supply water shut-off valve. – Let the tank drain, then manually close the drain valve. Humidifier De-scaling Solution • Models with optional drain valves: – For drain valves without the manual open lever, use the keypad to perform the cool down process. – Go to the control modes screen and select Manual Drain. – Allow approximately half the water to drain out of the tank. – In the Control Modes screen select Auto; the fill valve opens and the humidifier cools down. – When the fill valve closes, select Manual Drain in the Control Modes screen and let the tank drain dry. The humidifier should be cool enough to work on. – For more information about using the keypad, see the Vapor-logic version 5 Installation and Operation Manual. Scale buildup on humidifier heaters acts as an insulator, reducing humidifier performance while increasing energy costs. To keep humidifiers operating as efficiently as possible, remove scale with DriSteem's Humidifier Descaling Solution, available for purchase from your DriSteem representative or distributor. The De-scaling Solution cleans without risk of corroding humidifier tanks or welds. The De-scaling Solution also cleans surfaces unreachable by hand scraping. DriSteem's Humidifier De-scaling Solution is the only approved cleaner/de-scaler for use with DriSteem humidifiers. Use of other cleaners/descalers may void your DriSteem warranty. mc_021908_1410 mc_060210_1715 INSPECTION AND MAINTENANCE 1. Annually (also recommended when maintenance is performed) • Inspect tank and gaskets for leaks. • Measure current draw of heaters and verify amp values per stage by comparing to the wiring diagram located inside the subpanel cover. This identifies any burned out heaters. Only qualified electrical personnel should perform this task. • All safety devices in the control circuit should be cycled on and off to verify they are functioning. These include: – High limit switch – Airflow proving switch – Low water level probe. Pull out probe plug; fill valve should energize. VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 41 MAINTENANCE Tap/softened water 2. Seasonally (or as required, depending on water quality) • Remove the evaporating chamber: – Remove the two fasteners on each side of the cover enclosure (see Figure 41-1). – Remove the enclosure. See “Electric shock hazard” Warning at right. Note: If the humidifier has an SDU mounted directly above it, remove the SDU cover before removing the humidifier cover. – If the tank is hot, cool it down first. See “Cool down humidifier” on Page 41. – Shut off the water supply. – Allow the tank to drain completely. – Shut off the electrical supply. – Disconnect the fill line at the supply side of the fill valve. – Disconnect the electrical plugs between the tank components and the back of the electrical panel (includes: power plug, fill plug, drain plug, water level control plug, tank temperature sensor plug, and thermal trip plug). Important: Disconnect by pulling on plug housing. Do not disconnect by pulling on cord or wires. WARNING Electric shock hazard Do not remove humidifier electrical panel cover, heater terminal cover, or subpanel access panels until electrical power is disconnected. Improper wiring or contact with energized circuits can cause property damage, severe personal injury, or death as a result of electric shock and/or fire. Only qualified electrical personnel should perform maintenance procedures. mc_060310_0840 FIGURE 42-1: PROBE TOOL – Disconnect the drain union on the back left corner of the frame. – Disconnect the steam supply hose from the top of the tank. – Lift the tank foot above the frame flange, and slide the tank assembly forward to remove. • Loosen the four cover bolts and remove the cover assembly from the tank. Probe tool • Clean the tank interior using a putty knife or similar flat instrument. • Clean and inspect probe rod assembly: – Unplug the probe plug assembly, and leave ground wire connected to tank. – Unscrew probe rod assembly using the probe tool (see Figure 42-1), and clean plastic probe housing, ensuring that all passageways for water flow are clear. – Clean probe rods using steel wool or similar mild abrasive material. – Inspect composite plastic probe housing. If any signs of cracking, roughness, or deterioration, replace assembly. – When sliding probe housing into bracket from which it hangs, orient housing so neither water flow slot directly faces tank wall at back end of bracket. mc_061610_1500 42 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL OM-7395X Remove and install probe assembly with supplied probe tool. Attach a 3/8" square drive to the probe tool. When installing, torque probe assembly to 120 in-lbs (10 ft-lbs; 13.6 N-m). Probe tools can be ordered from your DriSteem representative (Part No. 185101). mc_060310_0735-NA MAINTENANCE Tap/softened water • Install the probe and probe plug assembly. Verify ground wire is solidly connected to tank. • Secure the chamber cover, making sure the cover gasket is seated and the chamber is sealed. • Re-install evaporating chamber: – Reconnect the fill line. – Reconnect electrical plugs (the plugs are color coded). – Reconnect the drain union. – Reconnect the steam hose. • Verify electrical connections: – Verify that all DIN rail-mounted components are securely fastened to DIN rail. – Verify that all power terminal screws and lugs are tight from power block to heaters. – Verify that all plugs under the humidifier cover are completely plugged in. • Move the drain valve lever back to the auto position. • Turn on the water supply. • Turn on the electrical power. 3. Off-season maintenance • Perform complete inspection and cleaning of the following: – Heaters – Probe rods – Skimmer port and water seal – Humidifier tank • After cleaning, the humidifier should remain empty until humidification is required. OFF-SEASON SHUT-DOWN PROCEDURE 1. Switch off electrical power. 2. Remove the enclosure. 3. Shut off the water supply to the makeup valve. 4. Drain the evaporating chamber, and clean if necessary following the instructions in this manual. 5. Replace the enclosure. 6. Leave the evaporating chamber dry, the power off, and the water shut-off valve closed until the next humidification season. VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 43 MAINTENANCE RO/DI water option RO/DI humidifiers use RO/DI water. Because these water types are mineral free, cleaning the evaporating chamber should not be necessary. However, there are some maintenance steps that should be followed to ensure all parts of the unit are in working order. Important: Verify regularly that water processing equipment is operating correctly. The presence of chlorides in improperly processed deionized water will eventually cause pitting and failure of the humidifier tank and its components. Damage caused by chloride corrosion is not covered by your DriSteem warranty. COOL DOWN HUMIDIFIER If the tank is hot, cool it down by opening the manual ball valve on the side of the tank. The float valve will open allowing cool water to run into the tank until it is cool enough to handle. Then shut off the water supply, and allow the tank to drain completely. WARNING Electric shock hazard Do not remove humidifier electrical panel cover, heater terminal cover, or subpanel access panels until electrical power is disconnected. Improper wiring or contact with energized circuits can cause property damage, severe personal injury, or death as a result of electric shock and/or fire. Only qualified electrical personnel should perform maintenance procedures. mc_060310_0840 INSPECTION AND MAINTENANCE 1. Remove the evaporating chamber: • Remove the two fasteners on each side of the cover enclosure. See Figure 41-1. • Remove the enclosure. See “Electric shock hazard” Warning at left. Note: If the humidifier has an SDU mounted directly above it, remove the SDU cover before removing the humidifier cover. • If the tank is hot, follow the instructions in “Cool down humidifier” above before proceeding. • Shut off the water supply. • Allow the tank to drain completely. • Shut off the electrical supply. • Disconnect the fill line at the fill fitting. • Disconnect the electrical plugs between the tank components and the back of the electrical panel (includes: power plug, low water switch plug, tank temperature sensor plug and thermal trip plug). Important: Disconnect by pulling on plug housing. Do not disconnect by pulling on cord or wires. • Disconnect the drain union on the back left corner of the frame. • Disconnect the steam supply hose from the top of the tank. • Lift the tank foot above the frame flange and slide the tank assembly forward to remove. 44 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL WARNING Hot surface and hot water hazard Do not touch the tank or drain piping until the unit has had sufficient time to cool, or serious injury can occur. Opening the drain valve when the tank is hot can discharge water with a temperature up to 212 °F (100 °C) into the plumbing system. This can cause damage to the plumbing system if the humidifier is not properly connected to a water tempering device such as a DriSteem Drane-kooler™. mc_060110_1640 MAINTENANCE RO/DI water option 2. Loosen the four cover bolts and remove the cover assembly from the tank. WARNING 3. Inspect the tank interior for debris or pitting. 4. Inspect the valve inlet for debris. 5. Check the operation of the float valve and the condition of the float seat. 6. Check the low water switch to make sure the float slides freely on the stem. 7. Secure the chamber cover making sure the cover gasket is seated and the chamber is sealed. 8. Reinstall the evaporating chamber. Electric shock hazard Contact with energized circuits can cause severe personal injury or death as a result of electric shock. To prevent shock, disconnect electrical power before performing service or maintenance procedures on an part of the humidification system. When performing maintenance on the humidifier: • Reconnect the fill line. • Reconnect electrical plugs (the plugs are color coded). • Always switch the keypad control mode to Standby. • Reconnect drain union. • Reconnect steam hose. • Place all power disconnects in OFF position and lock in OFF position. 9. Verify electrical connections: • Verify that all DIN rail-mounted components are securely fastened to DIN rail. • Verify that all power terminal screws and lugs are tight from power block to heaters. • Close the field-installed manual supply water shut-off valve. mc_031110_0444 • Verify that all plugs under the humidifier cover are completely plugged in. 10. Close the drain valve. 11. Turn on the water supply. 12. Turn on the electrical power. OFF-SEASON SHUT-DOWN PROCEDURE 1. Switch off electric power. 2. Remove the enclosure. 3. Shut off the water supply to the makeup valve. 4. Drain the evaporating chamber by opening the drain valve. For units with an end-of-season drain, refer to the Vapor-logic version 5 Installation and Operation Manual. 5. Replace the enclosure. 6. Leave the evaporating chamber dry, the power off, and the water shut-off valve closed until the next humidification season. mc_061610_1520 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 45 REPLACEMENT PARTS Humidifier FIGURE 46-1: VAPORMIST HUMIDIFIER REPLACEMENT PARTS Tap/softened water Vapormist RO/DI water Vapormist OM-768 46 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL REPLACEMENT PARTS Humidifier Table 47-1: Vapormist humidifier replacements parts No. Description Qty. Part No. No. Description Qty. Part No. 1 Head bolt, large Phillips, ¼ - 20 × 1" 4 700300-013 19 Washer, No. 8 external tooth, pltd 2 700200-003 2 Thermo cut-out 1 409560-001 20 Nut, 8-32 hex, pltd 6 700200-002 3 Cover, heater terminal 1 * 21 Cover, humidifier electrical panel 1 120277 4 Hose clamp, 2" 2 700560-200 Fill adapter, VM-2 through VM-4 1 160226-041 Hose cuff, 1½" 1 305390- * 1 160224-041 Hose cuff, 2" 1 305391- * 1 160224-052 6 Cover, tank 1 * 23 Insulation, panel 1 309845-003 7 Heater element * * 24 Sensor, temperature 1 197000-025 8 Probe assembly with cord and plug 1 406050-100 25 Screw, Phillips head, 8-32 × ½" 8 700170-007 9 Gasket, 2.50" OD × 1.90" ID 1 309750-004 26 Frame assembly, chassis 1 165541 Probe assembly, VM-2 through VM-4 1 406303-005 27 Clip, wire harness 1 405892-001 Probe assembly, VM-6 through VM-34 1 406303-006 28 Clip, temperature sensor 1 408251 Valve, ¾" electric, 24V 1 505400-001 29 Valve assembly, float 1 505310 Valve, ½" SST ball 1 505000-003 30 Switch, float, 1/8" NPT 1 408420-002 Drain, ¼" NPT E.O.S., 24V solenoid SST w/ DIN plug (not shown) 1 505086-003 31 Ring, seal, ¼"-18 NPT 1 306365 12 Tank weldment 1 * 32 Gasket, bulkhead, 1.60 OD × 1.15 ID 1 309750-005 13 Fill valve 1 197000-010 33 Probe housing, nylon 1 308500 14 Cabinet enclosure 1 330001-001 34 Nut, heater .475 1 409601-001 15 Hose, ¾" ID 2 307020-002 35 O-ring, 5/8" EPDM No. 016 1 300400-009 16 Hose clamp, ¾" 4 700560-075 DI orifice, VM-2 through VM-16 1 160229-041 DI orifice, VM-21 through VM-34 1 160229-052 1 162721-002 Tube weld, low water, short, VM-2 through VM-4 1 167787 Tube weld, low water, long, VM-6 through VM-34 1 167788 22 Fill adapter, VM-6 through VM-16 5 Fill adapter, VM-21 through VM-34 10 11 37 Nut assembly, ¼-20, VM-2 through VM-4 4 700650 Nut assembly, ¼-20, VM-6 through VM-34 2 700650 Cover, tank gasket, VM-2 through VM-4 1 160695-001 Cover, tank gasket, VM-6 through VM-34 1 160695-002 17 18 38 Bulkhead nut 39 * Specify humidifier model and serial numbers when ordering. VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 47 REPLACEMENT PARTS SDU-E FIGURE 48-1: SDU-E REPLACEMENT PARTS OM-1503 mc_062810_1110 Table 48-1: SDU-E replacement parts No. Description Qty. Part No. 1 Shroud 1 330002-001 2 Blower, SDU external assembly 1 * 3 Switch, airflow 1 406190 4 Screw, 8-32 × ½" Phillips, black 4 700170-007 5 Nut retainer, 8-32 4 409593-001 Dispersion chamber for SDU with 1½" outlet 1 160445-003 Dispersion chamber for SDU with 2" outlet 1 160445-004 6 * This is an assembly of multiple parts. mc_062810_1112 48 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL REPLACEMENT PARTS SDU-I FIGURE 49-1: SDU-I REPLACEMENT PARTS OM-1504 mc_062810_1111 Table 49-1: SDU-I replacement parts No. Description Qty. Part No. 1 Shroud 1 330001-002 2 Blower, SDU external assembly 1 * 3 Switch, airflow 1 406190 4 Screw, 8-32 × ½" Phillips, black 6 700170-007 5 Nut retainer, 8-32 6 409593-001 6 Tubelet, 0.375" × 0.375" molded 44 310280-006 * This is an assembly of multiple parts. mc_062810_1113 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 49 REPLACEMENT PARTS Subpanel FIGURE 50-1: VAPORMIST SUBPANEL WITH SSR OM-213-4 mc_062810_1120-VM Table 50-1: Vapormist subpanel with SSR No. Description Qty. Part No. 1 Subpanel, barrier 1 120801 2 DIN rail, 11" long 1 167765-011 3 Lug wire 2 4 Ground lug, medium 5 6 7 8 Board, Vapor-logic main microprocessor Qty. Part No. 408495-001 10 Board, Vapor-logic keypad/display 1 408495-002 409250-003 11 Plug, 4-prong female 4 409585-008 2 409250-027 12 Terminal block, 3-pole 1 408300-002 Block, DIN rail terminal end 3 408252-006 13 Fan, cooling 1 408677-001 Transformer 120/208/240/480 V 1 408965-001 14 Housing, 75 Amp white connector 4 409585-001 Transformer 600 V 1 408986 15 Plate, plug retainer 2 409585-009 SSR, 50 Amp, 1-pole * 408679-001 SSR, 50 Amp, 2-pole * 408679-003 Wire channel, 1" × 1" 12.5" 408999-001 Wire channel cover 12.5" 408999-002 Contactor, 35 A 1 407010-001 Contactor, 55 A 1 407010-002 VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 9 Description 1 * Refer to model for correct selection and quantity. 50 No. 16 REPLACEMENT PARTS Subpanel FIGURE 51-1: VAPORMIST SUBPANEL WITH SDU Table 51-1: Vapormist subpanel with SDU No. Qty. Part No. 1 Subpanel, barrier 1 120801 2 DIN rail, 11" long 1 167765-011 3 Lug wire 2 409250-003 4 Ground lug, medium 2 409250-027 5 Block, DIN rail terminal end 2 408252-006 Transformer 120/208/240/480 V 1 408965-001 Transformer 600 V 1 408986 Transformer, 240/480 V, 300 VA 1 408991 Transformer, 230/460/575 V, 300VA 1 408992 Transformer, 480 V, 500 VA 1 408996-008 Transformer, 600 V, 500 VA 1 408996-009 Plug, 4-prong female 4 409585-008 Terminal block, 3-pole 1 408300-002 Terminal block, 4-pole 1 408300-003 10 Fan, cooling 1 408677-001 11 Housing, 75 Amp white connector 4 409585-001 12 Plate, plug retainer 2 409585-009 13 Board, Vapor-logic main microprocessor 1 408495-001 14 Board, Vapor-logic keypad/display 1 408495-002 15 Terminal, DIN rail mount 9 408252-001 16 Terminal, ground 1 408252-010 17 End cap, DIN rail mount 2 408252-005 18 Jumper, marathon terminal 2 408252-009 19 Relay, 24V DPDT finder * 407900-016 20 Relay socket * 407900-019 * 406775-007 * 406775-009 Circuit breaker, 600V, 1.5 A, 1-pole * 407010-002 Contactor, 55 A 1 407010-002 Contactor, 35 A 1 407010-001 Channel, wire cover 6" 408999-002 Channel, wire 6" 408999-001 6 7 8 9 OM-1506a mc_062810_1121-VM Description Circuit breaker, 1.6 A, 1-pole 21 Circuit breaker, 4 A, 1-pole 22 23 24 Channel, wire cover 12.5" 408999-002 Channel, wire 12.5" 408999-001 * Refer to model for correct selection and quantity. VAPORMIST INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 51 WARRANTY Expect quality from the industry leader Two-year Limited Warranty For more than 45 years, DriSteem has been leading the industry with creative and reliable humidification solutions. Our focus on quality is evident in the construction of the Vapormist humidifier, which features cleanable, stainless steel construction. DriSteem also leads the industry with a Two-year Limited Warranty and optional extended warranty. DriSteem Corporation (“DriSteem”) warrants to the original user that its products will be free from defects in materials and workmanship for a period of two (2) years after installation or twentyseven (27) months from the date DriSteem ships such product, whichever date is the earlier. For more information www.dristeem.com [email protected] For the most recent product information visit our Web site: www.dristeem.com DriSteem Corporation An ISO 9001:2000 certified company U.S. Headquarters: 14949 Technology Drive Eden Prairie, MN 55344 800-328-4447 or 952-949-2415 952-229-3200 (fax) European office: Marc Briers Grote Hellekensstraat 54 b B-3520 Zonhoven Belgium +3211823595 (voice) +3211817948 (fax) E-mail: [email protected] Continuous product improvement is a policy of DriSteem Corporation; therefore, product features and specifications are subject to change without notice. DriSteem, DriCalc, Rapid-sorb, Ultra-sorb, Vapor-logic, and Vapormist are registered trademarks of Research Products Corporation and are filed for trademark registration in Canada and the European community. Drane-kooler is a trademark of DriSteem Corporation. Product and corporate names used in this document may be trademarks or registered trademarks. They are used for explanation only without intent to infringe. © 2013 Research Products Corporation Form No. VM-IOM-0913 Part No. 890000-201 Rev 8FC If any DriSteem product is found to be defective in material or workmanship during the applicable warranty period, DriSteem’s entire liability, and the purchaser’s sole and exclusive remedy, shall be the repair or replacement of the defective product, or the refund of the purchase price, at DriSteem’s election. DriSteem shall not be liable for any costs or expenses, whether direct or indirect, associated with the installation, removal or reinstallation of any defective product. The Limited Warranty does not include cylinder replacement for electrode steam humidifiers. DriSteem’s Limited Warranty shall not be effective or actionable unless there is compliance with all installation and operating instructions furnished by DriSteem, or if the products have been modified or altered without the written consent of DriSteem, or if such products have been subject to accident, misuse, mishandling, tampering, negligence or improper maintenance. Any warranty claim must be submitted to DriSteem in writing within the stated warranty period. Defective parts may be required to be returned to DriSteem. DriSteem’s Limited Warranty is made in lieu of, and DriSteem disclaims all other warranties, whether express or implied, including but not limited to any IMPLIED WARRANTY OF MERCHANTABILITY, ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE, any implied warranty arising out of a course of dealing or of performance, custom or usage of trade. DRI-STEEM SHALL NOT, UNDER ANY CIRCUMSTANCES BE LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES (INCLUDING, BUT NOT LIMITED TO, LOSS OF PROFITS, REVENUE OR BUSINESS) OR DAMAGE OR INJURY TO PERSONS OR PROPERTY IN ANY WAY RELATED TO THE MANUFACTURE OR THE USE OF ITS PRODUCTS. The exclusion applies regardless of whether such damages are sought based on breach of warranty, breach of contract, negligence, strict liability in tort, or any other legal theory, even if DriSteem has notice of the possibility of such damages. By purchasing DriSteem’s products, the purchaser agrees to the terms and conditions of this Limited Warranty. Extended warranty The original user may extend the term of the DriSteem Limited Warranty for a limited number of months past the initial applicable warranty period and term provided in the first paragraph of this Limited Warranty. All the terms and conditions of the Limited Warranty during the initial applicable warranty period and term shall apply during any extended term. An extended warranty term of an additional twelve (12) months or twenty four (24) months of coverage may be purchased. The extended warranty term may be purchased until eighteen (18) months after the product is shipped, after which time no extended warranties are available. Any extension of the Limited Warranty under this program must be in writing, signed by DriSteem, and paid for in full by the purchaser. mc_051308_0630