Industrial |
51 Aikins |
Street |
Commercial |
Winnipeg, |
MB |
Equipment |
Canada, R2W 4E3 |
|
Manufacturing LTD. |
|
|
HTDM
INSTALLATION, OPERATION AND MAINTAINANCE MANUAL
ATTENTION: Read this manual, unit submittal sheets and all labels attached to the unit carefully before attempting to install, operate or service these units! Check unit data plates for type of gas, model number and serial numbers. Retain this document for future reference.
FOR YOU SAFTEY IF YOU SMELL GAS FOLLOW THESE
INSTRUCTIONS,
1)OPEN WINDOWS
2)DO NOT TOUCH ELECTRICAL SWITCHES
3)EXTINGUISH ANY OPEN FLAMES
4)CALL THE GAS SUPPLIER IMMEDIATLY
FOR YOUR SAFETY THE USE OF GASOLINE OR OTHER
FLAMMABLE VAPORS AND
LIQUIDS IN OPEN CONTAINERS IN THE VICINITY OF THIS APPLIANCE IS HAZARDOUS
Model:______________________ Serial Number:___________________
Job:________________________ Date of Installation:____________
WARNING
IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTAINACE CAN CAUSE PROPERTY DAMAGE OR DEATH. PLEASE READ THIS INSTALLATION, OPERATION AND MAINTAINANCE MANUAL THOUROUGHLY BEFORE INSTALLING OR SERVICING THIS EQUIPMENT
INSTALLERS RESPONSIBILITY
Installer please note: This equipment has been test fired and inspected. It has been shipped free from defects from our factory. However, during shipment and installation, problems such as loose wires, leaks or loose fasteners may occur. It is the installer’s responsibility to inspect and correct any problems that may be found.
INSTALLER/SERVICE CONTRACTOR
NAME:____________________________
ADDRESS:_________________________
TELEPHONE:_______________________
CONTACT:_________________________
Table of Contents
Receiving and Warehousing |
3 |
General Handling instructions |
3 |
General Installation Notes |
3 |
Clearance to Combustables |
4 |
Connecting the Flue |
5 |
Electrical Connections |
6 |
Gas Piping |
6 |
Gas Vent |
7 |
Duct Furnaces |
7 |
Cooling |
8 |
High Altitude |
8 |
Indoor Units |
8 |
General Operating Instructions |
8 |
Start Up Procedures |
8 |
Precautions |
8 |
Gas Units |
9 |
Start Up |
9 |
Shut Down |
10 |
Emergency Shut Down |
10 |
Service Shut Down |
10 |
Recommended Quarterly Maintenance |
10 |
Recommended Yearly Maintenance |
11 |
ICECON II Operators Manual |
12 |
ICECON II Controller |
13 |
Normal Start Up Sequence |
14 |
Heat Modes |
14 |
External Modulation Control |
15 |
How the ICECON II Controller Responds to External Control |
15 |
Switching From mA to VDC control |
16 |
Available Options (Software Control) |
17 |
Error Signals |
19 |
Trouble Shooting |
21 |
Tachometer Test Procedure |
23 |
Discharge Sensor/RSP Test |
24 |
Wiring |
25 |
Appendix A |
26 |
Programming the ICECON II Controller |
27 |
Setting Up the Software |
27 |
The Main Interface |
28 |
The System Tune Interface |
29 |
I/O View |
30 |
Set Points |
31 |
Altering Combustion Set Points |
32 |
Calibrating the Tachometer |
32 |
Adjusting combustion Points |
33 |
Saving an ICECON II Program |
34 |
Uploading an ICECON File |
34 |
Appendix |
36 |
ICECON I to ICECON II Upgrade |
37 |
2
RECEIVING AND WAREHOUSING
Inspect the unit upon arrival for any shipping damage. If any part is missing or damaged, Mark bill of lading as to damage and notify the carrier at once.
If the unit cannot be installed immediately, store it and its accessories in a clean and dry place.
GENERAL HANDLING INSTRUCTIONS
A qualified and experienced crane operator must do all rigging. General rigging methods should be followed in all cases:
a)Spreader bars must be used when lifting equipment.
b)Equipment must be lifted simultaneously by all “eye” bolts or channel slots provided on each section at the same time to distribute the loading properly. Damage or injury may result if all provisions for lifting are not utilized at time of lift. When multiple lifting eyes are furnished they are to share the weight of the lift evenly via spreader bar(s).
c)Lifting eyes and channel slots are designed to be lifted vertically. The MAXIMUM angle from a vertical lift, which is permitted, is 30 degrees. Single sections only are to be lifted at one time and stacked from the lowest section upward. Sections are designed to be self-supporting in compression only. Do not attempt to hang multiple sections from any structure. The total perimeter base and all frame structure must be supported, and levelled, on high-density concrete or sufficient I-beam steel.
d)For some models the heating and blower sections may be shipped separately. Assemble the sections by aligning the base frames and/or the pre-drilled flanges and secure the assembly with the fasteners provided. Use gasketing material to prevent infiltration at the joints.
WARNING
FAILURE TO COMPLY WITH THE GENERAL REQUIREMENTS MAY RESULT IN EXTENSIVE PROPERTY DAMAGE, SEVERE PERSONAL INJURY OR DEATH.
GENERAL INSTALLATION NOTES
a)In Canada the installation must conform with local building codes or, in the absence of local building codes, with the current CAN/CGA -BI49.1 or B149.2 “Installation Codes for Gas Burning Appliances and Equipment”. Indoor duct furnaces
3
have been designed for, and certified to comply with, CAN/CGA2.8.
b)Installation must be made in accordance with local codes or in absence of local codes with ANSI Standard Z223.1-1992 (N.F.P.A. No.54) “National fuel Gas Code” or the latest edition of all ANSI and NFPA standards. Standards referred to in these installation instructions are in effect at the time of certification. ANSI Standards are available from the American Gas Association 1515 Wilson Boulevard, Arlington, Virgina 22209. NFPA standards are available from the National Fire Protection Association, Batterymarch Par, Quincy, Massachusetts 02269. Heaters referred to in this manual are designed for use in airplane hangers when installed in accordance with ANSI/NFPA No.409 and in public garages when installed in accordance with the NFPA No. 88a and NFPA No.88b.
c)No alterations are to be made on this equipment.
d)For suspended appliances which are installed in air craft hangers, parking structures, and repair garages must be installed in accordance with the standard on air craft hangers, ANSl/NFPA 409, the standard for parking structures. ANSI/NFPA 88a, the standard for repair garages, ANSI/NFPA 88b, and with the CAN I-B149 codes,
CLEARANCE TO COMBUSTIBLE MATERIALS in inches (mm)
MODEL |
TOP |
FRONT |
BACK |
FLOOR |
SIDES |
FLUE |
HTDM 200 |
0 (0) |
0 (0) |
0 (0) |
3(76) |
0 (0) |
18(457) |
HTDM 400 |
6(152) |
6(152) |
4(102) |
3(76) |
4(102) |
18(457) |
HTDM 600 |
6(152) |
6(152) |
4(102) |
3(76) |
4(102) |
18(457) |
HTDM 1000 |
6(152) |
6(152) |
6(152) |
3(76) |
6(152) |
18(457) |
HTDM 1500 |
6(152) |
6(152) |
6(152) |
3(76) |
6(152) |
18(457) |
All units installed on the floor has a minimum clearance of 3" (76mm) provided by the base frames of each individual unit.
For service it is advisable to maintain a minimum 24' clearance on the side opposite the controls side (note: not valid for the HTDM 200), and 42" clearance on the control side. If this unit is to be operated within a confined space or within a building of unusually tight construction, air for combustion and ventilation must be obtained from outdoors or other spaces freely communicating with the outdoors. Refer to current United States and Canadian Fuel Codes.
4
Ducts connected to the furnace shall have removable access panels on both the upstream and downstream sides of the furnace. These openings shall be accessible when the furnace is installed and shall be sized to allow the observation of smoke or reflected light inside the casing to indicate the presence of leaks in the heat exchanger. The covers for the openings shall be attached in such manner as to prevent leaks.
The furnace must not be operated in the presence of chlorinated vapours. When such vapours mix with products of combustion, highly corrosive compounds result, which will result in the premature failure of the heat exchanger and other components. In such an event the warranty is void.
CONNECTING THE FLUE (VENTING)
When making flue connection to the unit, observe the following general recommendations. In addition, the HTDM series ofunits are approved and must use recognized type "8" vent and/or vent connector. All connections must conform to the requirements of current United States and Canadian codes (gas fires units), and be in accordance with local authorities, which include but are not limited to:
a)The flue must be securely attached to the unit with tight joints.
b)The pipe from the unit to the flue should rise at least If.." per foot, (76.2 mm).
c)The flue must be sized to have a cross-sectional area not less than that of the flue collar at the unit.
d)Other appliances must not be connected so as to vent through the flue of this unit.
e)Do not support the weight of the stack on the flue connection of the heating section.
f)Minimize connecting pip length and the number of bends by locating the unit as close to the flue pipe as possible.
g)Maintain clearances between the flue pipe and combustible material that are acceptable to the local authorities having jurisdiction.
h)For indoor/outdoor application the flues condensate deposal pipe, located on the unit, shall be piped to prevent accumulation of condensate on or around the unit.
The HTDM series are approved for use with type “B” venting. The venting must be of recognized type. For type “B” vent use with the HTDM 1000 and HTDM 1500 models a draft hood must be connected in series with the type “B” vent. The Drafthood must
5
be installed between the unit’s flue connection and the type “B” vent.
NOTE: For venting diagram see Appendix C.
ELECTRICAL CONNECTIONS
a)This unit has been examined and tested for compliance with CSA C22.2 no.0, CSA C22.2 no.3 and the NED code.
b)All electrical work must conform to the requirements of the current NEC and CSA standard C22.1, Canadian Electric Code part I, and local ordinances.
c)Control voltage is as indicted on the rating plate.
d)Follow the wiring diagram supplied with the unit.
e)If a space thermostat is used with the furnace, locate the thermostat so the cold drafts and hot discharge air streams do not affect the performance of the unit. Do no mount the thermostat on the casing of the unit, as it will be affected by radiated and conducted heat. Refer to the instruction furnished with the thermostat for further details.
f)If any of the original wires as supplied with the unit must be replaced, it must be replaced with type TEW 105 degrees or its equivalent except where noted.
g)Temperature controllers, limit controllers, remote selector switches, door switches or any other auxiliary electrical items must be connected to the terminals provided as shown on the wiring diagram.
h)For units shipped in multiple sections, electrical connections between sections are to be made by the installer in the field.
i)Field wiring to be done by the installer is denoted by doted lines on the wiring diagram. Solid lines on the wiring diagram indicate factory wiring by the manufacturer.
j)The unit must be electrically grounded in accordance with local codes, or in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70, and/or the CSA.C22.1 Canadian Electrical code.
NOTE: Due to the nature of transport check all bolts and fasteners for tightness.
GAS PIPING
All gas piping should be in accordance with NFPA, National Gas Code, and CAN 1-B149 with the regulation of local authorities having jurisdiction. An emergency manual shut down valve shall
6
be provided upstream of the piping to unit and should be labelled for quick identification. Colour coding of gas piping is also recommended.
In addition:
a)Carefully check the unit rating plate for fuel type and supply pressure.
b)If required, locate the high-pressure regulator at least five feet from the unit.
c)Gas lines must not be located in such a way as to hinder access to the unit.
d)A minimum 1/8" NPT plugged tapping, accessible for test gauge connection, must be installed immediately upstream of the gas supply connection to the appliance.
GAS VENT
High gas pressure regulator (if required), low pressure regulator, pilot pressure regulator, gas pressure switch (if supplied), and normally open vent valve (if supplied) must be vented outside of building for an indoor unit (check with authorities having jurisdiction).
DUCT FURNACES
a)A duct furnace shall be installed with an inlet duct, which will provide air distribution equivalent to a straight run of duct having the same cross-section area as the inlet connection and not less than two equivalent diameters in length.
b)The ducts connected to the duct furnace must have removable access panels on both upstream and downstream sides of the duct. The opening must be accessible, and shall be of such size, that smoke or reflected light may be observed inside the casing to indicate the presence of leaks in the heating element. The cover for the opening shall be attached in such a manner as to prevent leaks.
c)The installation of the duct furnace must be adjusted to obtain an air throughout within the range specified on the appliance rating plate.
d)If a duct furnace is connected to a return air duct or any other inlet air restoration; the duct furnace shall be installed on the positive pressure side of the aircirculating blower.
7
COOLING
When installed downstream from a refrigeration system. Condensation will form and provisions shall be made to dispose of condensate.
HIGH ALTITUDE
As per June I, 1998 all HTDM units are derated four percent of maximum input of each 1OOOft(305m) elevation above sea level.
INDOOR UNITS
Install an indoor unit in such that the gas ignition control system is not directly exposed to water spray, rain or dripping water.
GENERAL OPERATING INSTRUCTION
a)Refer to the rating plate for fuel input and supply pressures.
b)Do not attempt to start the burner if the unit is full of vapour gas, or if the combustion chamber is very hot.
c)Do not leave combustible material near the unit.
d)Shut off the manual fuel supply valve if the burner has been shut down for an extended period of time.
e)Ensure clean-out doors are in place before starting the burner.
f)Do not start the burner unless the blower access doors are securely in place.
g)Refer to literature regarding controls, gas valves and other components.
START-UP PROCEDURES
1.PRECAUTIONS
a)Ensure the main disconnect switch is in the “off” position.
b)Ensure the burner on-off switch is in the “off” position.
c)Check all electrical and gas connections and tighten if necessary
d)Check main fans (by rotating fan shaft by hand), bearing set screws, and pulley set screws. Ensure blowers are free to turn, vibration isolation shipping blocks are removed (if equipped), shipped loose items (if supplied), are removed from inside blower sections.
8
e)Lubricate (if necessary) the burner and main fan motors. The specification on the motors for grease and oil shall be adhered to.
f)Check heater outlets for obstruction.
g)Check all fuse blocks to determine that all fusing is insta11ed.
h)Set the operating controls (e.g. thermostat, remote panel switches) so as to allow heating operation of the unit.
i)Reset the motor starter by pushing the reset button, if so equipped. Ensure all blowers are rotating in the correct rotation.
j)Check building system gas supplies and be sure all lines are purged of air.
k)Check building system gas supply pressure.
2.CAUTION-GAS UNITS
At maximum input the supply gas pressure must fall within the range specified on the unit rating plate.
a)Check all piping for tightness and correct any signs of leaks.
b)Ensure purge timer is set to 70 seconds.
3.START-UP
a)Refer to start-up check list and field report for correct settings that are to be checked on the unit.
b)Check the supply fan motor thermal overload setting against the rating plate figure.
c)Ensure burner on-off switch is in the “off”
d)Verify units sequence of operation corresponds to sequence provided in the supplied literature.
e)Check supply fan motor amps against rating plate figure. If actual figure varies by +/-20% from rating plate value, take corrective actions with respect to duct work and accessories external to the unit or blower/motor drive adjustments making sure to follow manufactures rating for blower rotational speeds.
f)The thermal overloads must be set to appropriate motor performance after all adjustments have been make.
g)Follow sequence and perform necessary steps to intiate burner activation.
h)Once flame is detected the controller goes into "Power" and
“Heat” mode.
i)Check unit performance as described on the factory test report, (include items such as stack temperature. CO-2 level,
9
flame signals etc.) Readings obtained in the field should not deviate significantly from those obtained at the factory.
SHUT DOWN
1.EMERGENCY SHUT DOWN
a)Set disconnect switch to "off' position.
b)Close the manual main fuel valve.
c)Set the burner on-off switch to "off'.
2.SERVICE SHUT DOWN
a)Set the burner toggle switch to "off' position.
b)Close the manual main fuel valve.
c)Set the operating controls, (e.g. thermostat, remote panel switches), so as to prevent heating operation.
MAINTENANCE
Regular maintenance is necessary to ensure the efficient operation and long life of this unit. This maintenance should be preformed by or supervised by qualified service personnel. A maintenance schedule should be prepared for the unit based on its application and location.
1.RECOMMENDED OUARTERLY MAINTENANCE
a)Check for loose connections in the wiring.
b)Check the voltage at the unit while it is in operation.
c)Check motor amperage draws against rating plate values.
d)Inspect all contractors to ensure that they are clean and making good contact.
e)Check all fittings valves and lines for leaks.
f)Check for proper combustion. Adjust if necessary.
g)Check the flame sensor signal (1.5-6.0 mA), clean if necessary.
h)Check the fuel supply pressure to the unit.
i)On gas fired units check the manifold pressure.
j)Clean or replace air filters if necessary. Replace filters only with type equivalent to those supplied with the unit by the factory.
k)Check all dampers, linkages and damper actuators; adjust and tighten as required.
l)Check all belts. Adjust or replace as necessary.
m)Check all bearings and lubricate if necessary.
n)Check operation of all safety controls.
10
o)Oil burner fan.
p)Check all bearing to ensure tightness on shaft and lubricate if necessary.
q)Check ignition spark and adjust gap if necessary.
2.RECOMMENDED YEARLY MAINIENANCE
a)Perform the monthly quarterly maintenance recommended.
b)Inspect blower wheels and housing, clean if necessary.
c)Inspect all set screw on blower wheels and pulleys to ensure that they are secured to their respective shafts
d)Check flame supervisor controller.
e)Inspect all operating and safety controls. clean and replace if necessary.
f)Inspect and clean the collection and disposal systems to ensure proper drainage.
NOTE: If ignition controller is replaced ensure the control system is not exposed to water spray, rain or dripping water. Refer to individual manufacturer’s literature provided for maintenance requirements of optional equipment.
Power Venter Installation
The HTDM series may be equipped with a power vent system. Whnre installing ensure that the factory supplied diverter box is install on the unit, in series with the power venter.
a)Diverter box relief opening must be installed 10” from walls and restrictions.
b)Mount power venter in desired location. NOTE: Refer to manufactures installation instructions for vent length and sizing.
c)Power venter must operate for the individual unit only.
d)Wire power venter and safeties according to supplied diagram.
e)Verify all safeties. In the event of venter failure the burner must become in active.
NOTE: For venting diagram see Appendix C.
11
ICECON II
OPERATORS MANUAL
12
I. ICECON2 CONTROLLER
Figure 1
13
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