Price AW-I Series, AW-I-3, AW-I-4 Installation Manual

MANUAL – INSTALLATION
AW-I
Gas Fired Make-Up Air Series
v200 – Issue Date: 09/07/18
© 2018 Price Industries Limited. All rights reserved.
AW-I
TABLE OF CONTENTS
Overview
General Safety Information ............................................ 1
Safety Notices ............................................................... 1
Unit Description ............................................................. 2
Unit Nameplate ............................................................. 2
Unit Inspection .............................................................. 2
Installation Instructions
Mechanical Installation .................................................. 3
Vent Stack and Combustion Air Opening ....................... 7
Electrical Installation ...................................................... 9
Gas Piping Connection ................................................ 13
Hot Water and Chilled Water Coil Connections ............ 15
Safety Shut-off Valve Leak Check ................................ 17
Installation Checklist .................................................... 18
Supply Fan Start-Up .................................................... 20
Typical Sequence of Operation .................................... 23
Maintenance
Maintenance ............................................................... 24
Service and Warranty Procedure ................................. 25
AW-I Start-Up Report Form ......................................... 26
Quality Assurance Report ............................................ 28
Limited Warranty .........................................................29
Appendices
Appendix A: Assembly of Split Units ............................ 30
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow safety warning exactly could result in serious injury, death or property damage.
Be sure to read and understand the installation, operation and service instructions in this manual.
Improper installation, adjustment alteration, service or maintenance can cause serious injury, death or property damage.
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
Do not try and light any appliance.
Do not touch any electrical switch; do not use any phone in your building.
Leave building immediately.
Immediately call your gas supplier from a phone remote from the building. Follow the gas supplier’s instructions.
If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or the gas supplier.
MANUFACTURED BY
Price Industries Limited
404 Egesz Street Winnipeg, MB R2R 1X5
115 Turnbull Court Cambridge, ON N1T 1C6
ANSI Z83.8 Commercial Industrial Gas Heating Equipment
CSA 2.6-2009 Industrial Package Gas Fired Package Furnaces
AW-I
OVERVIEW
General Safety Information
This manual provides information on installation, start-up and maintenance for a gas fired unit. Improper installation can lead to unsatisfactory operation or dangerous situations. This unit should only be installed and maintained by qualified personnel. Qualified personnel should have a clear understanding of the contents of this manual prior to installation. Improper installation may lead to electric shock, possible injury from contact with moving parts and/or possible burns from contact with heating components. Additional safety concerns can arise from unit location such as a roof or inclement weather (outdoor installations). Additional safety precautions may be required.
Installer shall follow all national and local electrical code requirements such as the National Electrical Code (NEC) and the Canadian Electrical Code (CEC) in Canada. Where applicable, follow National Fire Protection Association (NFPA) requirements. The appliance 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 Canadian Electrical Code, CSA C22.1, if an external electrical source is utilized.
The appliance installation shall conform to local building codes or, in the absence of local codes, with the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or the Natural Gas and Propane Installation Code, CSA B149.1.
Safety Notices
Throughout this manual Caution and Warning notices are used where additional safety information may be required. Warnings are provided to alert personnel of a potential situation that could result in personal injury or death. Cautions are provided to alert personnel of a potential situation that could result in personal injury.
In addition to Warnings and Cautions, Notices are used to indicate a situation that may result in property damage.
WARNING
Indicates a potential situation that, if not avoided, could lead to serious personal injury or death.
CAUTION
Indicates a potential situation that, if not avoided, could lead to minor or moderate personal injury. Cautions may also be used to indicate unsafe practices.
NOTICE: Indicates a situation or action that may cause
damage to the unit or the facility.
In addition to this manual, start-up and commissioning videos are available at www.priceindustries.com. Additional information on this unit can be found by scanning the QR code sticker or by contacting Price Industries.
WARNING
The manufacturer’s warranty does not cover any damage or defect caused by modifications to the unit including unauthorized attachments of other components. Such activity may lead to unsatisfactory performance and may endanger life and property.
NOTE: This document is customer property and must be
retained by the unit’s owner for use by maintenance personnel.
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AW-I
OVERVIEW
UNIT DESCRIPTION TABLE
A B C D E F G H I
AW-I - 3 100 - S - AC DX - 010 - S - HR
Unit Description
The AW-I model is an indirect fired gas heating unit with a drum and tube type heat exchanger. The unit can be either indoor or outdoor and may include supplemental cooling and/or energy recovery.
A: Unit Model
B: Furnace Passes
2 = Two furnace passes
3 = Three furnace passes
4 = Four furnace passes
C: Nominal heating output in kBtu/h
D: Efficiency
S = Standard efficiency
H = High efficiency
E: Cooling type
AC = Air cooled
WC = Water cooled
EC = Evaporatively cooled
F: Refrigeration design
DX = Cooling
HP = Heat pump
G: Nominal cooling capacity in tons. This
is based on nominal condensing unit model.
H: Cooling efficiency
S = Standard efficiency
H = High efficiency
I: Single path heat recovery
Blank = None
HR = Heat Recovery
Unit Nameplate
Figure 1 shows a typical nameplate for an AW-I unit. The nameplate is generally located in the gas train weather housing. The nameplate includes model number, serial number, electrical characteristics and other pertinent data.
Unit Inspection
This unit has been inspected and test fired prior to shipment to make sure the unit is free from defects from the manufacturer. It is possible that damage may occur during shipping, rigging and installation.
Upon receiving the unit, check that all items have been delivered by comparing the Bill of Lading to the equipment received. If anything is missing or damaged, notify the carrier immediately. The carrier should note this on the packing slip or other form of documentation and provide a copy. Note: it is a good idea to take a photograph of any possible damage for record purposes.
Check the unit model number, heater size and electrical characteristics to make sure they are correct. If there are any issues, do not proceed with the installation. Contact your sales representative.
Storage
If the unit is to be stored, take precautions to prevent condensate from forming inside the unit’s electrical compartments. Make sure the equipment is protected from weather and dust from site conditions by temporarily
FIGURE 1: TYPICAL NAMEPLATE
sealing all openings to the air tunnel for outdoor units and completely covering indoor units.
Do not use the unit for temporary heat without first completing the start-up procedure. Price Industries will not assume any responsibility for equipment damage resulting from condensate accumulation on the unit’s electrical and / or mechanical components.
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ACCESS SIDE
30” (75 cm)
FLUE
9” (22 cm)
FLUE LOCATION
NO ACCESS SIDES 6” (15 cm) minimum
24” (60 cm) recommended
CONTROL CABINET 36” (1 m) minimum
48” (1.3 m) recommended
TOP 6” (15 cm) minimum
NO ACCESS BACK 20” (50 cm) minimum
24” (60 cm) recommended
ACCESS SIDE
30” (75 cm)
FLUE LOCATION
NO ACCESS SIDES 6” (15 cm) minimum
24” (60 cm) recommended
CONTROL CABINET 36” (1 m) minimum
48” (1.3 m) recommended
NO ACCESS BACK 20” (50 cm) minimum
24” (60 cm) recommended
ACCESS SIDE
30” (75 cm)
FLUE
9” (22 cm)
FLUE LOCATION
NO ACCESS SIDES 6” (15 cm) minimum
24” (60 cm) recommended
CONTROL CABINET 36” (1 m) minimum
48” (1.3 m) recommended
TOP 6” (15 cm) minimum
NO ACCESS BACK 20” (50 cm) minimum
24” (60 cm) recommended
ACCESS SIDE
30” (75 cm)
NO ACCESS SIDES 6” (15 cm) minimum
24” (60 cm) recommended
CONTROL CABINET 36” (1 m) minimum
48” (1.3 m) recommended
FLUE LOCATION
AW-I
INSTALLATION INSTRUCTIONS
Mechanical Installation
Location
Price AW-I units are approved for both indoor and outdoor installations. The installation must conform with local building codes or in absence of local codes, with the Natural Gas and Propane Installation Code, CAN/CSA-B149.1, or with the National Fuel Gas Code, ANSI Z223.1/NFPA 54.
The unit is suitable for use in aircraft hangars, parking structures and repair garages when marked and installed, as applicable, in accordance with:
Standard for Airport Hangars, ANSI/NFPA 409
Standard for Parking Structures, ANSI/NFPA 88A
Standard for Repair Garages, ANSI/NFPA 88B
Natural Gas and Propane Installation Code, CAN/CSA-B149.1
No alterations are to be made on this unit.
Unit Clearances
WARNING
COMBUSTIBLE PRODUCTS: The unit must not be operated
in the presence of hazardous atmospheres containing flammable vapors or combustible dust for risk of fire or explosion. The use and storage of any flammable material
in the vicinity of the appliance is hazardous.
CORROSIVE PRODUCTS: The unit must not be operated
in the presence of chlorinated vapors, halogenated hydrocarbons, cleaning solvents, refrigerants, swimming pool exhaust or in application with airborne substances containing silicone. When such vapor mixes with the products of combustion, highly corrosive compounds result causing premature failure of the heat exchanger and other components. In such event, the warranty is void. Exposure to these compounds can lead to personal injury
or death.
Before placing the unit, clearances to combustible materials and obstructions should be considered.
FIGURE 2: TYPICAL UNIT CLEARANCES FOR AW-I-3 UNITS
FIGURE 3: TYPICAL UNIT CLEARANCES FOR AW-I-4 UNITS
Maintain minimum clearances to combustible materials as indicated as shown in Figure 2 and 3.
For ease of service, it is also advisable to maintain a minimum of 48" (1.2 m) clearance to the control side of the unit and 24" (60 cm) or more on the side opposite of the controls.
If the unit is to be operated within a confined space or within a building of tight construction, air for combustion and ventilation must be obtained from outdoors or other spaces freely communicating with the outdoors.
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AW-I
INSTALLATION INSTRUCTIONS
Roof Curb or Base
Price AW-I units can be installed on a concrete housekeeping pad, sleepers or a roof curb. The entire perimeter base and frame structure must be continuously supported with either field supplied sleepers or structural steel. Make sure that the sleepers or structural steel supports are the correct dimensions for the unit and that it is flat and level.
NOTICE - CONTINUOUS STRUCTURAL SUPPORT REQUIREMENT:
The unit is designed to have continuous structural support around its entire perimeter. Failure to provide continuous structural support will damage the unit and void the warranty.
Check that the housekeeping pad is the correct dimensions for the unit and that it is flat and level. Check that there is enough trapping height and that a floor drain is nearby where the furnace condensate drain will be located.
Generally the curb is shipped in advance of the unit delivery. It should be installed along with any required ductwork prior to unit installation. Where a roof curb has been supplied in knocked-down condition, absolute care must be taken to make sure that all corners are square, and that finished dimensions exactly match those provided on the drawings. If this is not done, problems could arise with the seal of the unit to the curb.
CURB INSTALLATION DETAIL
NOTE: To minimize sound transmission, only cut openings in
roof deck for ductwork penetrations. Do not cut out the entire roof deck within in the curb perimeter.
If the unit is elevated, a field constructed cat walk around the unit is strongly recommended to provide access for service.
Check diagonal dimensions prior to securing the curb to ensure that dimensional integrity has been maintained during shipping. Shim the curb to the deck as required and complete roofing in accordance with accepted roofing practices.
Prior to the installation of the unit, check that the curb is the correct dimensions for the unit and that the curb profile is correct (this is especially important if the curb is not supplied by Price Industries). Check that the curb is both level and square. Curb ductwork that passes down through the curb must be installed by installing contractor prior to unit placement. Gasketing or other forms of sealant must be used around the curb perimeter and at the duct connections. When the curb is supplied by Price Industries, a neoprene gasket is included. Prior to the installation of the unit, secure the gasket to the mating surface of the curb by peeling the backing off the gasket material and applying adhesive-side down.
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AW-I
INSTALLATION INSTRUCTIONS
Unit Assembly
CAUTION
HEAVY COMPONENTS: The unit sections are very heavy
and significant force will need to be applied to cinch the sections together. Make sure everyone is clear of the sections prior to cinching to avoid injury.
SLIP UNITS: Price AW-I units may be shipped as a single
unit or in sections for field assembly by the installing contractor. For proper assembly of split units, refer to Appendix A of this manual. Failure to follow the instructions in this manual may void your warranty.
Figure 4: Split unit sections shall only be pulled together using the provisions on the base. Trying to pull sections together from the cabinet walls or roof will damage the cabinet and void the warranty. Refer to Appendix A.
Figure 5: Where sections join together, a flanged joining strip with bolt holes is provided. Refer to Appendix A for detailed instructions on how to attach these strips and all other components needed to properly seal between the unit splits.
FIGURE 4: TYPICAL BASE CINCH POINTS
FIGURE 5: TYPICAL FLANGE JOINTS
Figure 6: Mount any loose items such as intake hoods and
secure them to the unit with self-tapping fasteners.
Figure 7 (on the next page): Remove all shipping braces, packing etc. from the unit.
FIGURE 6: OUTDOOR AIR HOOD
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AW-I
INSTALLATION INSTRUCTIONS
Duct Connections
On outdoor units with ducting passing down through the curb, the ducting will be installed prior to unit placement and attached to the curb. For all other duct connections, the ductwork will be connected to the unit casing using sheet metal screws by the installing contractor. Unless indicated on the submittal drawings, the weight of the ducting should not be placed directly on the unit. The installing contractor should provide an external means to carry the duct weight.
Access panels in the ducting near the unit are recommended. Where no access to the unit inlet or discharge section is provided as part of the unit (for example an access door in the unit), access panels are strongly recommended for inspection and service.
Duct Furnace Installation
Where AW-I furnaces are supplied as duct furnaces, the following installation requirements apply:
1. Duct furnaces shall be installed on the positive pressure side of the fan.
2. Duct furnaces shall be installed with an inlet duct which will provide air distribution equivalent to a straight run of duct having the same cross-sectional area as the inlet connection and no less than two equivalent diameters in length.
FIGURE 7: TYPICAL FAN BASE SHIPPING BRACKET
3. Provide removable access panels on both upstream and downstream sides of the duct furnace. These openings shall be accessible when the appliance is in service, and shall be of such a size that smoke or light may observed inside the casing to indicate the presence of leaks in the heating element. The access panels shall be attached in such a manner as to prevent leaks.
4. High static packaged heaters must be adjusted to obtain temperature rise, manifold pressure and air flow within the range specified on the unit rating plate. Duct furnaces must be adjusted to obtain an air flow rate within the range specified on the appliance rating plate.
5. For altitudes of 2000 – 4500 feet (600 and 1350 m), derate the maximum rated input by 10%.
6. The appliance shall not be installed downstream from evaporative coolers, air washers or cooling units of refrigerating systems unless the following optional conditions are met.
a) if the heating element is made of corrosion resistant
material as per ANSI 83.8/CSA 2.6 clause 4.29.1 , it can be installed downstream for evaporative coolers or air washers.
DUCT FURNACE INSTALLATION
ACCESS
PANEL
2 diameters
DUCT FURNACE
HANG UNIT WITH ROD CONNECTED TO BASE
ACCESS PANEL
2 diameters
b) if the appliance complies with all of the optional provisions
outlined in ANSI 83.8/CSA 2.6 clause 4.29 and 5.30 the appliance may also be installed downstream from refrigerated units supplying air below the dew point of the ambient air surrounding the appliance.
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AW-I
INSTALLATION INSTRUCTIONS
Vent Stack and Combustion Air Opening
Outdoor Installation
AW-I units are certified as Category III appliances with positive vent pressure and stack temperature not exceeding 500°F (260 °C). Outdoor AW-I units are equipped with a factory mounted exhaust stack. This stack is made especially for the unit and should not be removed or altered in any way.
The gas train and burner vestibule is equipped with ventilation and combustion air openings. The appliance must be installed so that these openings are unobstructed. The unit must be installed in a location with adequate clearances to provide sufficient combustion air space, service, inspection and clearance from combustible material as marked on rating plate or as per local codes and authorities having jurisdiction.
Indoor Installation
WARNING
POISONOUS GASES: The products of combustion from any
gas appliance contain poisonous gases including Carbon Monoxide. Failure to properly install the chimney for an indoor installation could lead to dangerous gases being released within the building that in turn lead to death or serious injury. Follow the installation instructions carefully.
OUTDOOR EXHAUST STACK
NOTICE - CONDENSATE: Some chimney installations will
cause condensate to form in the chimney. Failure to properly drain the condensate from the chimney could lead to damage in both the chimney and the unit. This will void the warranty.
Vent installation shall conform with local codes or, in the absence of local codes, with the National Fuel Gas Code, ANSI Z223.1/ NFPA 54, or the National Gas and Propane Installation Guide, B149.1.
The unit must be installed in a location with adequate clearances to provide sufficient combustion air space, service, inspection and clearance from combustible material as marked on rating plate or as per local codes and authorities having jurisdiction. The appliance shall be located in such a manner that it does not interfere with the circulation of the air in the space being served.
Outdoor air must be introduced in accordance with National Fuel Gas Code, ANSI Z223.1/NFPA 54, or the National Gas and Propane Installation Guide, B149.1.
Install air openings that provide a total free area in accordance with the following;
1. Air from inside the building – Opening of 1 square inch per 1000 Btu/h ( 22 cm² per kW) input but not less than 100 square inches (650 cm).
2. Air from outside ducted – Opening of 1 square inch per 2000 Btu/h ( 11 cm² per kW) input.
3. Air from outside, direct opening - Opening of 1 square inch per 4000 Btu/h ( 6 cm² per kW) input.
The combustion products must be vented to the outdoors. All venting installation shall conform with local codes or, in the absence of local codes, the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or the National Gas and Propane Installation Guide, B149.1. Indoor AW-I units are supplied with a round flue connection as shown on the unit drawing. AW-I units are certified as Category III appliances, with positive vent pressure and stack temperature not exceeding 500°F (260 °C). Care must be taken to avoid flue products from entering the space. Only use vent material and components that are UL listed and approved for Category III appliances.
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AW-I
INSTALLATION INSTRUCTIONS
Before starting installation, examine all components for possible shipping damage.
1. Venting shall be installed in accordance with the appliance manufacturer's instructions. Venting shall conform with local codes or the National Fuel Gas Code, ANSI Z223.1/ NFPA S4, or the Natural Gas and Propane Installation Code, CSA B149.1.
2. AW-I units are approved with type “A” vents.
3. Each unit must have its own individual vent pipe and terminal. Do not common vent or connect more than one appliance to the venting system.
4. All vent pipe joints must be sealed to prevent leakage. The joints must be screwed with a minimum of five #10 stainless steel screws. Use approved high temperature sealant to seal the joints.
5. The total equivalent length of vent pipe must not exceed 50 feet (15.25 m). Avoid unnecessary turns and any other features that create resistance to the flow of flue gases.
6. Maintain the same vent diameter all the way to the end.
7. The vent shall be extended high enough above either a building or the neighboring obstructions so that wind from any direction will not create a positive pressure in the vicinity of the vent termination. The vent shall extend at least 18” (450mm) above the highest point where it passes through the roof surface and any other obstruction within a horizontal distance of 18” (450mm).
14. The vent shall terminate in accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA S4, or The Natural Gas and Propane Installation Code, CSA B149.1. Provide minimum vent termination clearances to the building as shown below:
Structure Min. Clearances
Public paved driveway 7’ above (2.1m)
Grade/snow level 1’ (300mm)
Mechanical air supply inlet 6’ (1.8m)
Window, door or any other opening 3’ (900mm)
Meter/regulator
15. All horizontal runs shall include ¼” per ft (21 mm per m) pitch and a maximum horizontal length of 10 ft. (3 m) without a power vent.
16. Do not connect into any portion of mechanical draft system operating under positive pressure.
3’ (900mm) horizontally
15’ (4.5m) vertically
TYPICAL CHIMNEY INSTALLATION
8. The venting system shall be firmly attached to flue collar with stainless steel screws.
9. The venting system shall be securely supported by noncombustible hangers suitable for the weight at a minimum of 36” (1m).
10. When a vent penetrates a floor or ceiling and is not running through the fire rated shaft, a fire stop and support is required.
11. The vent system must be installed to prevent collection of condensate. Use a condensation drain if necessary. The heat exchangers are equipped with condensate drain(s) and all the condensation must be disposed in accordance with local codes.
12. Maintain a minimum of 9” (22 cm) clearance between the vent pipe and combustible material. Insulate the pipe run longer than 10’ (3m) for pipe routed through unheated area with a minimum of ½” (12.5mm) thick foil face fiberglass, 1 ½ lb. (680,4 g). density insulation.
13. Venting system must be accessible for inspection.
NOTE: Do not intermix vent parts from different manufacturers in
the same vent system.
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AW-I
INSTALLATION INSTRUCTIONS
Electrical Installation
WARNING
ELECTRICAL SHOCK HAZARD: Disconnect all electric power,
including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power cannot be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.
NOTICE - USE COPPER CONDUCTORS ONLY: Unit terminals
are designed for copper conductors only. Failure to use copper conductors may result in unit damage.
Main Power Connection
All connections to the unit and the main disconnect switch must conform to the Canadian Electrical Code/National Electrical Code and local codes.
1. Before proceeding with electrical connections, ensure that the unit characteristics and the intended supply match. The proper voltage for connection is listed on the rating plate attached to the unit.
TYPICAL FACTORY SUPPLIED DISCONNECT
TYPICAL SPLITTER BLOCK TERMINATION
2. 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 Canadian Electrical Code, CSA C22.1, if an external electrical source is utilized.
3. Refer to the unit submittal drawing to determine the suggested location of the field wired power supply. Where a disconnect is supplied as part of the unit, the main power connection will be the line side of the disconnect.
4. If the unit is not supplied with a factory mounted disconnect, a field supplied disconnect must be installed in accordance with local codes, or in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70, and /or the Canadian Electrical Code, CSA C22.1. Where a disconnect is supplied by others, the main power connection to the unit will be the line side of the main splitter block. Refer to unit electrical wiring diagrams for details.
5. Ensure that the routing of the power supply wiring does not interfere with removal of any unit access door, or in any way hinder servicing of the unit.
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AW-I
INSTALLATION INSTRUCTIONS
6. Refer to the submittals for electrical service routing. Unless indicated on the submittals, DO NOT penetrate the floor of the unit to route electrical conduits to the unit control panel. Provide a pitch pocket in accordance with standard roofing practice.
7. For units that are shipped in multiple sections, some electrical connections may have to be made by the installer in the field. Field wiring to be done by the installer appears as a dotted line on the wiring diagram. Wiring to connect two sections of a unit will be marked by the factory and a terminal block will be provided for such connections.
8. Fuses are furnished and installed by the factory in accordance with the National Electrical Code, ANSI/NFPA 70, and /or the Canadian Electrical Code, CSA C22.1. Should the replacement of any fusing become necessary, the replacement MUST be of the same amperage as the original. Failure to use equivalent replacement fuses may result in damage to components within the electrical system of the unit and/or the building. If any of the original wires need to be replaced, they must be replaced with type TEW 105° or equivalent except where noted.
9. On units with three-phase power supplies, make sure that motor rotation is correct as connected.
ELECTRICAL INSTALLATION W/PITCH POCKET
CONVENIENCE OUTLET AND LIGHTS
Auxiliary Power Connections
A separate 120/1/60 power supply may be required on units with convenience outlets and lights. Refer to unit wiring diagrams for wiring sizing details and connection points.
Controls Installation
All field wiring must be in accordance with local codes, or in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70, and /or the Canadian Electrical Code, CSA C22.1.
Field controls wiring requirements will depend on the controls provided with the unit. A basic unit will require controls by others. Only the minimum safety controls are provided by Price Industries. A controller or thermostat must be provided by the installing contractor. Refer to unit electrical wiring diagrams for details.
Units supplied with controls may require field wiring to a remote sensor or control panel. Refer to unit electrical wiring diagrams for details.
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