Titan Air User Manual

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18349

Rohner

360-885-7641

24 MONTH WARRANTY

Titan Air hereby warrants its products against defects in material and workmanship for a period

of (24) twenty four months from date of shipment.

Start up checklist is due back within (30) thirty days of start-up or 120 days from date of delivery for 24 month warranty to be effective. After (30) thirty days, and up until (60) sixty days, a (13) thirteen month warranty will be observed. All warranties are null and void if start up checklist is not received within (60) sixty days from start-up or 120 days from date of delivery. NO EXCEPTIONS WILL BE MADE.

Titan Air reserves the right at Titan Air’s option, to replace or repair free of charge, any part proven by Titan Air to be defective. Prompt notification of defective part must be given to Titan Air and defective part must be returned freight prepaid within (30) thirty days of notification.

WARRANTY INCLUDES ONLY PARTS SUPPLIED BY TITAN AIR INCIDENTAL COSTS AND LABOR CHARGES SHALL BE THE RESPONSIBILITY OF OTHERS. This warranty does not cover fuses, belts, filters, refrigerant or water damaged parts which are the result of improper storage or installation.

This warranty is void in event the product is improperly installed and/or operated under conditions other than normal published ratings, improperly maintained, misused or not in compliance with applicable codes or not in accordance with Titan Air’s operating instructions.

This warranty is void if attempts to correct or repair any alleged defective part or parts are made by unauthorized personnel without Titan Air’s written approval.

In no event shall Titan Air be held liable for any damage, incidental or consequential, arising from the installation, performance or operation of the product.

This warranty supersedes, voids, and/or is in lieu of any other verbal or written understanding

which may not be in total accordance with this expressed warranty.

Warranted parts must be returned to Titan Air within 60 days to receive credit.

Purchased components such as Steam Generators Systems, Electric Coils, Refrigerant Condensers, Chillers, Coils, Heat Exchangers are covered under the original equipment manufacturer’s warranty.

PURPOSE/ APPLICABILITY

This manual is intended to provide installation, operating and service information on Titan Air’s TA Series H.O.T.™ (High Outlet Temperature) air make-up units. Other types of equipment including TAP Series H.O.T. ™ units are covered in other manuals.

A packet of reference materials for a specific unit (tracked by its Serial Number) is generally included with this Operating and Service Manual. The reference materials include Unit Specifications, Parts Lists, Gas Train and Burner Specifications, Electrical Schematic, and a Sequence of Operation. A start up checklist is also included in this packet. Review the reference materials for a specific unit and note any optional equipment or controls which are not specifically addressed in this manual prior to attempting start-up or service work.

The information and recommendations contained in this publication are based on general observation and are not intended to supplant requirements of federal, state or local codes having jurisdiction. These codes should be reviewed before installation of equipment. All units must be installed in accordance with national, state or local codes.

It is the responsibility of the purchaser at the time of order, to specify any and all code or insurance requirements that may dictate the addition of components to the equipment in order to comply with those requirements.

Only qualified personnel who have experience with the installation and operation of industrial/ commercial direct fired equipment should attempt to service Titan Air equipment..

GENERAL INFORMATION PAGE #

24 MONTH WARRANTY ........................ 3

PURPOSE/ APPLICABILITY ................... 4

EQUIPMENT ARRIVAL ........................... 6

STORAGE ................................................ 6

COMPONENTS ..................................... 7-9

AIR FLOW SWITCH OPERATION ........ 10

INSTALLATION

PRE-INSTALLATION ....................... 11-12

POSITIONING THE HEATER ................ 12

CLEARANCE ......................................... 12

CURBING (OUTDOOR MOUNTING) .... 13

INSTALLATION SAFETY ...................... 13

GAS PIPING ..................................... 13-14

DUCTWORK ..................................... 14-15

SOUND AND VIBRATION CONTROL .. 15

DISCHARGE TEMP SENSOR BULB

INSTALLATION & WIRING ......................... 15

FIELD WIRING ....................................... 15

UNIT AND ACCESSORY INSTALLATION

UNIT & ACCESSORY SUPPORTING

OPTIONS...................................................... 16

SECTION ASSEMBLY-HORIZONTAL17-18

SECTION ASSEMBLY-VERTICAL .. 19-21

ACCESSORY INSTALLATION ........ 22-23

INTAKE DAMPER MOUNTING ............. 24

DISCHARGE DAMPER MOUNTING ..... 24

VERTICAL DISCHARGE DIFFUSER

MOUNTING .................................................. 25

MAINTENANCE

GENERAL MAINTENANCE .................. 26

FILTERS ................................................ 26

BURNER ................................................ 27

GENERAL V-BELT DRIVE TIPS ...... 28-29

BLOWER BEARINGS ........................... 30

MOTOR BEARINGS .............................. 30

BLOWER WHEEL .................................. 30

FLAME FAIL DIAGNOSTICS ............ 31-32

GENERAL START-UP INFORMATION . 33

VALVE LEAK TEST ............................... 34

SPECIFIC EQUIPMENT DETAILS

................................ pages not numbered

UNIT SPECIFICATION

UNIT DRAWING

SEQUENCE OF OPERATION

PARTS/ LEGEND SHEET

SCHEMATIC

GAS TRAIN / BURNER SPECIFICATION

COIL PERFORMANCE REPORTS (IF

APPLICABLE)

START-UP PROCEDURE

TROUBLESHOOTING (OPTIONAL)

SUPPLEMENTAL MANUALS

DX, CW, HW AND STEAM COIL

INSTALLATION & MAINTENANCE (IF APPLICABLE)

EVAPORATIVE COOLER (IF APPLICABLE)

Note that operating and service manuals are occasionally requested prior to production of a unit. These manuals will be marked “PreProduction Release” on the front cover.

The final copy of the operating and service manual for a specific unit will be sent with the unit. Additional copies of the manual for a

specific unit are available.

A detailed unit specification sheet, parts/ legend sheet, schematic, sequence of operation and start-up procedure are provided in the startup section of each operating and service manual generated for a specific unit. Selected vendor cut sheets on components will also be included.

EQUIPMENT ARRIVAL

When the air make-up unit arrives, be sure to inspect for shipping damage. The equipment was thoroughly inspected before leaving the factory. Also upon receipt check the shipment for items which shipped loose such as a remote box and remote sensors. Consult the Bill of Lading to identify the potential shipped loose items. It should be noted that these items may have been placed inside unit cabinet in multiple locations; however, more often than not, shipped loose items can be found in the blower section of the unit. Any damaged or missing items should be reported to the transporter immediately. DO NOT SEND DAMAGED FREIGHT BACK TO TITAN AIR! All claims must be filed with the transporter. Be sure to take photographs and get the driver’s signature to confirm the damage. The driver will have a number for you to call to file a claim. Request a written inspection

report from the carrier claims inspector to substantiate any necessary claim. Be sure to open the

unit access doors and inspect for internal damage.

STORAGE

If for some reason you are unable to install the equipment immediately, be sure that the equipment is protected from the elements. Water damaged parts are not covered by Titan Air’s warranty. If the equipment is stored for an extended length of time, be sure to completely check the unit for any internal damage which may have been caused by excessive condensation. Also check for damage caused by rodents, and be sure to eliminate any dust that may have built up on the components while the unit was in storage.

LONG TERM STORAGE

Please observe the following precautions if the unit is to be stored for an extended period of time. (NOTICE: The time elapsed during storage still counts against the warranty period.)

 Best place to store the equipment is on a clean level surface, in a dry location

where the temperature can be controlled, if possible.

 Isolate equipment from shock and vibration or damage may occur to the

stationary blower bearings.

 At least once a month enter the blower vestibule and slowly rotate the blower

wheel about 30 times to redistribute the grease inside the bearings to help prevent corrosion from occurring.

 Reduce belt tension by at least 50% or remove belts completely.

 Do not allow coverings to trap moisture against unit casing.

CAREFULLY AND THOROUGHLY READ TITAN AIR’S PRODUCT WARRANTY

Each unit is tested at the factory prior to shipping. Because we are not able to simulate exact field conditions and sometimes actual conditions are different than what was stated on the order, you may need to make some adjustments in the field. This is why it is very important that only qualified personnel start-up and service Titan Air equipment. The start-up checklist (provided in packet with this manual) must be filled out and returned to Titan Air in order to validate equipment warranty.

For a fee, Titan Air personnel will travel to the job site, supervise start-up and provide operation and maintenance training for the equipment.

COMPONENTS

BLOWERS

The typical blower(s) used in Titan Air equipment are AMCA rated industrial type forward curve D.W.D.I. fans. Backward incline, backward airfoil, and plenum/plug fans are used occasionally. Models TA-109 through TA-136 utilize a single blower while models TA-215 through TA-242 utilize twin blowers. All blower wheels are mounted on a solid, turned, ground and polished shaft. 9” and 12” blowers are supported with permanently lubricated ball bearings. Larger blowers are supported by relubricatable pillow block ball bearings.

MOTOR & DRIVE

Rigid base, T-Frame, motors are utilized. The motor is mounted on an adjustable slide base.

Equipment furnished with a supply VFD will typically have a fixed motor sheave. However, some equipment may still utilize a variable pitch sheave.

DIRECT FIRED HEATING

BURNER OPERATING PRINCIPLES

The direct fired burner is designed to operate in a cabinet of flowing fresh air. Fuel gas is fed directly to the burner; kinetic energy of the airstream furnishes combustion air. It will function properly at the design velocity and pressure associated with ventilating systems.

Two speed H.O.T.™ units feature a damper with actuator and controls to maintain proper velocity across the burner profile as air volume changes. Single speed H.O.T.™ units have slide plates on either side of the burner to allow manual adjustment of the burner profile area.

The burner must be installed to fire with, and parallel to, the air flow. By virtue of velocity impact and suction generated by the diverging shape of the combustion baffles, air is induced through the air ports into the combustion zone. Although the air supply to the burner combustion zone is constant, only some of the air is actually

mixing with the gas to produce combustion.

When a very small quantity of gas is admitted to the burner, sufficient mixing takes place in the low fire slot where combustion takes place. Since the low fire zone is contained within the burner casting it is effectively shielded from uncontrolled air entry.

As the gas supply is increased the flame progresses into the intermediate fire zone where an additional supply of air is available. At higher or full capacity, mixing occurs at the larger air ports of the high fire zone augmented by air flowing over the end of the baffles.

On a reduction of gas supply the reverse sequence takes place, the flame recedes to a location of lesser air supply until the low fire zone is reached. The burner is suitable for a turndown range of approximately 30 to 1.

AIR SUPPLY

The supply fan is typically positioned to draw air across the burner. Air flow across the burner must be substantially straight (laminar) and velocity must be within the proper range to develop the desired turndown and capacity.

The direct fired burner is designed to operate in an air make-up heater with all air crossing the burner taken directly from outdoors. Rare exceptions involve equipment that serves an unoccupied space.

Total pressure rating of the blower includes allowance for the pressure drop through the primary air handling unit including the burner, together with pressure losses at the inlet screen, inlet damper,

filters, outlet damper if used, plus the external pressure rating of the system.

BURNERS

Burners are purchased in 6” and 12” straight lengths and 12” tee sections and are assembled to meet the BTU requirements of each piece of equipment.

According to national safety standards, the following factors could influence safe operation of a direct fired air make-up unit and must be interlocked to either prevent the burner from firing or shut it down if unsafe conditions occur.

1. AIR SOURCE – If a damper is used, it must be interlocked to prove it is open before the blower can start.

2. BLOWER STARTER/VFD INTERLOCK – A contact proving that the blower starter is energized or VFD is operating must be incorporated to prevent burner operation when

the blower is not operating.

3. AIR FLOW SWITCHES – Monitor the air flow (pressure drop) across the burner. The switches (one high differential and one low differential) will not allow burner to operate if air pressure drop across burner is outside of the high and low set points.

4. HIGH TEMPERATURE LIMIT – A manual reset high temperature limit control must be utilized to prevent high temperature situations caused by excessive fuel pressure or lack of air flow.

5. FLAME SAFEGUARD – Monitors the combustion process during ignition and operation for safe conditions.

6. HIGH GAS PRESSURE SWITCH – Monitors gas pressure to the burner. This deenergizes the burner in the event gas pressure increases above its set point.

GAS CONTROLS

Titan Air H.O.T.™ equipment is constructed to meet ANSI Z83.25/CSA 3.19 standards. Components in the gas delivery manifold on standard equipment include: two manual shut-off valves, gas pressure regulator, two safety shut-off valves and an electronic gas modulating valve. The pilot control includes a shutoff valve, gas pressure regulator and a pilot solenoid.

ELECTRIC /ELECTRONIC CONTROLS

Titan Air H.O.T.™ units typically come standard with the following items: disconnect switch, starter and overload assembly(s) or variable frequency drive(s), control power transformer (if a 3 wire system), air proving switches, high temperature limit, electronic flame safeguard and electronic flame modulation with remote setpoint adjustment. Control systems can be designed to meet specific requirements. Numerous temperature controls are available. Since H.O.T. units usually temper outside air to replace the air exhausted from a paint booth, modulating discharge temperature control is typical. At least one additional setpoint is usually included for the high outlet temperature mode.

H.O.T.™ units are typically supplied with a remote control panel. This panel will include switching for blower & burner operation and temperature setpoint(s). Timers are often included to

automate the bake cycle. Other options common for H.O.T.™ units include controls to interlock with

paint booth lights and compressed air solenoid as well as control a paint booth exhaust fan. Some units feature operating lights, discharge temperature display, custom controls or contacts by others to enable blower and/or burner operation.

Refer to the unit specification sheets, parts list, schematic, sequence of operation and start-up procedure for a specific unit to determine the control options included.

IMPORTANT: If the malfunction of the heater creates a hazard to other fuel burning equipment in the served building (i.e. supplying make-up air to boiler room) it is to be interlocked to open an inlet air damper in case of failure.

NOTICE: The operating temperature control system must limit the discharge air temperature from exceeding 250°F in the process air heater mode and 160°F

ventilation air heater mode.

AIR FLOW SWITCH OPERATION

BURNER PROFILE AIR PRESSURE DROP

ANSI standards, Z83.25/CSA 3.19, require manufacturers to monitor air moving across the burner for both high and low conditions. Titan Air utilizes air pressure drop across the burner to satisfy this requirement.

Certification testing demonstrated that the burner will function properly between a low pressure drop of 0.2" w.c. and high pressure drop of 0.95" w.c. The standards also mandate that the switches cannot be adjustable. This makes air pressure drop across the burner profile a very important factor at initial start up.

The design burner pressure drop at standard air conditions is 0.60” w.c. and will change as the

temperature of outside air increases or decreases from 70°F. In order for the burner to operate within the range of the air flow monitoring switch set points, the pressure drop should be as close to

0.60” w.c. as possible.

Air pressure drop across the burner profile is dependent on OA temperature. When the burner is off, pressure drop will climb significantly during cold weather. The burner is always off on initial start

-up. Therefore, if the burner profile air pressure drop is above 0.70” w.c. during a warm weather start-up, it may exceed 0.95” w.c. during a cold weather start-up in northern regions. Such a high air pressure drop would open the high airflow switch and prevent burner ignition.

The following chart will aid in equipment set up at outside air temperatures different from 70°F when the unit is operating with the burner off. The chart gives pressure drops, at various

temperatures, equivalent to 0.60” w.c. at 70°F.

Note that two speed H.O.T. units feature controls to maintain pressure drop across the burner as air volume changes. Either high speed and low speed mechanical adjustments of damper actuator travel or a dual pressure switch assembly are used to control burner air pressure drop. Burner profile air pressure drop should be measured on high speed with the burner profile dampers near the full open position. If the burner profile dampers open less than 50% on high speed, the unit is probably delivering less than full rated airflow.

Burner Profile Air Pressure Drop at Various OA Temperatures (Burner Off)

Temp

(˚F)

Burner

Profile Drop

(w.c.)

Temp

(˚F)

Burner

Profile Drop

(w.c.)

Temp

(˚F)

Burner

Profile Drop

(w.c.)

-40 0.76 10 0.68 60 0.61

-35 0.75 15 0.67 65 0.61

-30 0.74 20 0.66 70 0.60

-25 0.73 25 0.66 75 0.59

-20 0.72 30 0.65 80 0.59

-15 0.71 35 0.64 85 0.58

-10 0.71 40 0.64 90 0.58

-5 0.70 45 0.63 95 0.57

0 0.69 50 0.62 100 0.57

5 0.68 55 0.62 105

0.56

PRE-INSTALLATION

Inspect the equipment making sure all parts and accessories are on the job site. Check equipment against order and packing list. If the equipment has been sitting in storage for some time, inspect it for moisture (from condensation, rain or snow) and/or dust accumulation. Both can cause damage to electrical and electronic components as well as bearings and insulation.

INSTALLATION CODES

Care taken during the installation and start-up is vital to the longevity and reliability of the equipment. Confirm that gas and electric utilities match the rating on the equipment name plate.

 This heater shall be installed in accordance with local codes or, in the absence of

local code, according to National Fuel Gas Code, ANSI Z223.1/ NFPA 54, or the

CAN/ CSA B149.1 Natural Gas and Propane Installation Code.

 If the heater is to be installed in an aircraft hangar, refer to ANSI/NFPA 409.

 If the heater is to be installed in a parking garage, refer to ANSI/NFPA 88A.

 If the heater is to be installed in a repair garage, refer to ANSI/NFPA 30A.

 For installations in Canada, refer to CAN/CSA B149.1 National Gas and Propane

Installation Codes.

INSTALLATION PREREQUISITES

 The heater inlet shall be located in accordance with the applicable building or

mechanical code provisions for ventilation air.

 Adequate exhaust and/or relief must be provided to prevent over pressurizing the

served space when the heater is operating at its rated capacity. It should be noted that this can be accomplished by taking into account, through standard engineering methods, the structure’s designed infiltration rate; by providing properly sized relief openings; or by interlocking a powered exhaust system; or by a combination of these methods.

 Heaters installed with intake ductwork must purge at least four air changes the

volume of the intake ductwork prior to an ignition attempt.

 Ventilation air to the heater shall be ducted directly from outdoors when heater is

operated in the ventilation air mode.

 An electric disconnect switch having adequate ampacity (see name plate on the

heater for voltage and ampacity), if not provided as part of the heater shall be installed in accordance with the National Electric Code, ANSI/ NFPA 70.

 If in doubt regarding the application of the direct fired heater, contact the sales

representative or the factory.

PAINT BOOTH HEATER INSTALLATION PREREQUISITES

 Access opening(s) to the heated space must be equipped with door interlock

switch(es) to prevent the operation of the heater during a bake cycle when an access door is open.

 It is recommended to post the following warning marking at each access opening.

“Do not enter this space until the cool down cycle is complete.”

 A post purge timer to purge contaminants from the space and cool the products to

avoid a burn hazard must be provided following a bake/ drying cycle.

PAINT BOOTH HEATER INSTALLATION PREREQUISITES Contd.

 An interlock must be provided to:

 Lock out paint spraying equipment unless process heater is operating in

ventilation mode.

 Lock out facility lighting with-in the heated space during bake cycle.

 Ensure equipment has been operated in the ventilation mode for three

minutes or a minimum of four air changes of the paint booth volume, whichever is greater at the start of the bake or drying cycle.

 Initiate the heater fan in conjunction with the operation of the exhaust fan.

POSITIONING THE HEATER

Locate the heater exactly level, making certain minimum clearance required by local codes is maintained between the heater and any combustible materials. See name plate on unit for minimum recommended clearances.

When the makeup air equipment is located on a roof or at ground level on a concrete pad, the unit intake needs to be a minimum of 24” above the roof and/ or ground to prevent the intake of snow or splashed rain. The unit should be located in such a way to prevent prevailing winds from blowing directly into the unit intake. If the application is critical, provisions must be made to protect the unit inlet from the driving winds.

CLEARANCE

Select the installation location and support system (curb, stand or other) that meets or exceeds all of the minimum safety clearance requirements.

BOTTOM

Unit should be installed to allow clearance for proper condensate trap (If applicable). Do not install unit on combustible surfaces.

SIDES

The minimum recommended clearance on all sides of the unit except for the service side and bottom is 6 inches.

SERVICE

The service side should have a minimum of 24 inches of clearance; however it is recommended

that the clearance be at least the width of the widest door.

Also, if the unit includes any coils or has twin blowers more clearance should be provided for removal of those components.

The minimum clearances listed above are set, in place, by the standard in which Titan Air builds their equipment to meet; however, one should consult with all authorities having jurisdiction to ensure they don’t require larger clearances. Furthermore, the unit must be installed in such a way to facilitate smooth operation and maintenance of all built in sections and components. Also, it should be noted that the coil pull could be located on either side of the unit. Review the unit submittal drawing for the correct direction of the coil pull.

CURBING (OUTDOOR MOUNTING)

The use of a full perimeter curb or mounting rails under the heater is recommended. The only openings in the roof should be for the supply air duct, return air duct (if required), gas and electrical connections (if applicable). These openings must be sealed properly after installation. Titan Air ships all curbs unassembled and un-insulated. Installing contractor supplies gaskets, cant strips, insulation, etc.

INSTALLATION SAFETY

RIGGING

DANGER: Never enlarge lifting lug hole to accommodate larger anchor shackle.

WARNING: Never assemble unit sections or sub-assemblies together before rigging.

Always rig unit the way it was shipped from the factory.

CAUTION: It is the installer’s responsibility to confirm that the lifting equipment capacity exceeds unit weight by an adequate safety factor. Never stack inlet hoods or other components onto the unit as the unit is being lifted.

IMPORTANT: Apply appropriate sealant to roof curb and duct adapter(s) prior to setting the unit in place (If applicable).

Lifting Requirements:

 Protect coil connections, extending through unit casing, from damage by the

rigging cables through the use of plywood or other suitable materials.

 Exercise care when moving the unit.

 Rig the unit using ALL the lifting points, in a fashion that holds it level and

prevents it from tipping, falling and/ or twisting.

 Spreader bars of sufficient width MUST be used across the top of the unit, to

ensure that the lifting cables clear unit cabinetry.

 Utilize the same rigging and lifting methods as the ones applied to the unit, for

lifting the accessories.

 Remove all wooden shipping blocks before setting unit(s) onto curb (If applicable).

 After sections are set in place, assemble according to Unit Section Assembly (If

applicable).

 NOTICE: Warranty does not cover damage from the unit being severely

twisted or dropped during handling.

GAS PIPING

Gas piping must be sized and installed in accordance with applicable codes. It must be able to deliver the specified CFH and gas pressure at full flow. Refer to unit nameplate or unit specification sheets for specified CFH and gas pressure.

NOTICE: A manual emergency fuel shut off valve is required to be installed in a location which is accessible to personnel in case of a fire or explosion at the equipment. This is the responsibility of the installing contractor.

Care must be taken with the gas piping to prevent problems at start-up and later during operation. Before the union between the supply line and the unit is connected, the supply line should be cleaned out to remove any foreign material (dirt, rust, metal shavings, etc.) and a drip leg should be utilized.

GAS PIPING Contd.

Refer to unit nameplate to determine the minimum gas supply pressure required to attain the maximum specified gas capacity.

Suitable gas controls, regulators and valves (equipped with a diaphragm) in this unit are furnished with an ANSI approved add-on vent limiter or have an integral vent limiter, if available. However, final vent limiter approval will always be up to state, city or local codes. If local code requires these components to be vented to outside, it is the responsibility of the installing contractor.

CAUTION: The heater and its individual shut off valve must be disconnected from the gas supply piping system during any pressure testing in excess of ½ PSIG.

CAUTION: The heater must be isolated from the gas supply piping system by closing

its individual shut off valve during any pressure testing of the supply system at pressures equal to or less the ½ PSIG.

During start-up, the technician should perform a gas leak check on all components and piping during

the heater’s normal operation. (See page 34)

DUCTWORK

Ductwork must be sized and installed in accordance with applicable codes and standards. As a recommendation follow SMACNA guides for proper ductwork design, size and installation. A size variation may exist from recommended duct size to unit or accessory flange size. Accessories on the unit intake or discharge may be larger than the openings on the unit. Be sure to check the unit

submittal drawing for the correct equipment connection size. Recommended duct size applies to the

size of the duct at the connection to the equipment. Factory also recommends 2 1/2 times the equivalent duct diameters of straight ductwork off the discharge outlet of the blower. A properly designed duct transition from the blower outlet to a larger duct is recommended for long ducts or ducts with numerous elbows. The unit was designed for a specific CFM and ESP (External Static Pressure) stated on unit rating plate. The ductwork attached to the unit will significantly affect its performance.

NOTICE: When the heater is operated as a process air heater with airborne particulate matter in a recirculation mode, filters must be installed in the return air duct. The particulate removal filters shall be approved by the authority having jurisdiction. The return air duct system must also have doors/ access panels for inspection and cleaning. The filters and duct require periodic inspection and cleaning.

NOTICE: The duct to a process air heater which will allow recirculation must be

designed to prevent recirculation of insufficiently diluted products of combustion. A minimum amount of ventilation air must be supplied to exceed 200 CFM per 1000 CFH of natural gas based on maximum capacity of the heater plus an allowance to sufficiently dilute the VOC’s created by the process to maintain the lower explosive level (LEL) below a 25 percent threshold value.

On heaters mounted outdoors, discharge ductwork should be insulated to minimize condensation during the “off” cycle in cold weather. A fresh air intake hood with bird screen is required. Discharge ductwork on a twin blower unit must be common to both blowers.

On a heater mounted indoors with through the roof intake, a “mushroom” type intake hood is recommended to prevent moisture entrainment. When using “through the wall” intake duct, the intake louver should have adequate moisture baffling characteristics. All intake ductwork exposed to

the heated space should be insulated. Also any ductwork passing through unconditioned spaces must be insulated and covered with a vapor barrier.

Factory not responsible for field retro fits due to difference of the actual ESP from the designed ESP.

SOUND AND VIBRATION CONTROL

Use of flex coupler between building ductwork and air makeup unit is highly recommended. Vibration isolators that mount between the unit and support structure are optional and can be supplied with the equipment for installation by others. Another option is internal isolation of the blower/motor assembly with internal flexible connections between the blower housing and the unit structure.

Appropriate insulation on the interior of ductwork significantly reduces sound levels.

DISCHARGE TEMPERATURE SENSOR BULB INSTALLATION & WIRING

The installing contractor may be responsible for field installation of the discharge temperature sensor. Field installation of the discharge temperature sensor in the discharge ductwork results in a better measurement of the average supply air temperature. For paint booth applications, the sensor should typically be located as close to the booth’s supply air plenum as possible. Utilize shielded cable for field installed discharge sensor wiring.

FIELD WIRING

Power supply wiring should be routed from a dedicated branch circuit per schematic. Depending upon how the equipment was ordered, a single point power connection may be subdivided to individual loads or multiple power supply circuits may be required.

If an intake or discharge damper was ordered as a loose accessory, it will have to be mounted as specified in the Damper Installation Instructions found on page 24 and the actuator must be wired. The remote panel must be mounted in a convenient location and wired to the unit. Interlocks between the exhaust, unit and possibly spray booth will have to be connected by field wiring.

Carefully review the schematic and associated schematic symbol legend. Note that legend may be on the parts/legend sheet rather than on the schematic.

Many codes require that low voltage wiring be routed in separate conduit from line voltage wiring. If low voltage wiring is routed with 120 VAC control voltage wiring, it must be placed in shielded cable(s) with appropriate insulation rating. Even if low voltage wiring is routed in separate conduit, very low voltage sensor outputs and actuator control signals should be routed in shielded cable.

NOTICE: All field wiring must conform to N.E.C. and/or any state or local codes.

POST INSTALLATION

Sealing integrity should be rechecked on a yearly basis. Most of the unit will likely be under a negative pressure when the blower is operating. Dirt and moisture can be drawn into the unit. Check for water in outdoor units after operation during a rain shower. Water damaged parts are not covered

by Titan Air’s warranty.

Horizontal Unit-Supporting Options

Curb

Curbs are to be assembled in the field.

Assemble according to the letters marked on the top of each curb piece using factory supplied fasteners.

Caulking or Gasket material (supplied by others)

Accessory-

Horizontal Unit Supporting Options

Recommended option for supporting

accessories on a flat roof:

Other method of installation using sheet

metal support legs.

IMPORTANT: Not recommended for any unit larger than 125 model.

Typical Equipment Support (by others)

Attach support brace to accessory seam using field supplied fasteners.

Bent, 16 gauge (if supplied by factory), sheet metal support brace.

6 X 6 inch sheet metal pad welded to the support brace (if supplied by factory)

Wood Block (supplied by others)

MULTI-SECTION EQUIPMENT

Horizontal Configuration

Before beginning:

Be sure to check the tightness of all bolts, nuts and setscrews, which could have loosened during shipping.

Rotate blower fan shaft(s) by hand to make certain there is no interference or rubbing between components.

Verify installation surface is level before proceeding with unit installation.

Locate mounting hardware:

Items included: Caulk, Caulk Tape, Fasteners

Check all sections, of the unit, thoroughly for assembly hardware. The assembly hardware will be found packaged in either a clear plastic bag or corrugated box.

NOTICE: There may be more

than one package of assembly

materials provided.

1. Apply provided caulk tape to the face of the joint to be bolted together, on one side only as shown below, before assembly. Ensure there are no gaps in the caulk tape when applying. Do not cover bolt holes with caulk tape.

2. Locate and match each section letter on the service side of the unit with the corresponding letter on the other section. In addition, also refer to the unit submittal drawing for proper assembly order.

3. Pull sections together at the lifting lugs using, two, half inch rods w/ nuts and large washers as shown below.

Caulk Tape

Caulk

Tape

4. Use the provided fasteners to secure the seam at the top and bottom before setting the next section into place.

IMPORTANT: Use all of the bolt holes in the seam for joining the unit sections together and then tighten

accordingly.

Trim off the excess caulk tape squeezed out of the joint at each unit joint to provide a clean appearance.

5. After all of the sections are bolted together, caulk the external section seam(s) to provide a water tight seal.

IMPORTANT: Check all external sheet metal seams for caulk

shrinkage and re-caulk if

necessary. Titan Air. does not warranty water damage units. Unit seam sealing integrity should be rechecked on a yearly basis.

NOTICE: Access door swings MUST be kept free of installation piping and wiring to allow for service and maintenance.

8. Roof Cap Installation

Apply caulk to section roof tee before

placing on the splice cap.

Fasten splice cap to roof tee using the

provided self tapping screws from the top.

Caulk around all edges of the splice cap.

Caulk

MULTI-SECTION EQUIPMENT

Vertical Configuration

Before beginning:

Be sure to check the tightness of all bolts, nuts and setscrews, which could have loosened during shipping.

Rotate blower fan shafts by hand to make certain there is no interference or rubbing between components.

Verify installation surface is level before

proceeding with unit installation.

Locate mounting hardware:

Items included: Caulk, Caulk Tape, Fasteners

Field Supplied Hardware: Anchoring studs along with nuts and washers

Check all sections, of the unit, thoroughly for assembly hardware. The assembly hardware will be found packaged in either a clear plastic bag or corrugated box.

NOTICE: There may be more

than one package of assembly

materials provided.

1. Anchor the stand on a level concrete pad using studs or by other means. Each stand foot pad needs to be secured.

NOTICE: For indoor units, the

stand must be enclosed

(sometimes height is increased.) A transition (by others) must be made from enclosed stand intake opening to the intake damper or louver (a size variation may exist.)

Flat & Level Concrete Pad

Set in Place Stud or Wedge Type Anchor

Flat Washer

Hex Nut

2. Apply provided caulk tape to one side of the joint to be assembled. Apply tape toward the outside of the bolt pattern as seen below. Ensure there are no gaps in the caulk tape when applying. Do not cover the bolt holes with caulk tape.

3. Locate and match each section letter on the service side of the unit with the corresponding letter on the other section. In addition, also refer to the unit submittal drawing for proper assembly order.

4. Lift blower section and center it over burner section with the unit section letters lined up. After blower section is set in place use drift punches to line up seam bolt patterns. Fasten sections together using the provided bolts, nuts and washers filling all of the seam holes.

Caulk Tape

5. Caulk around the outside of each section seam.

IMPORTANT: Re-caulk unit lifting lugs after assembly. Check all external sheet metal seams for caulk shrinkage and re-caulk if necessary. Titan Air. does not warranty water damage units. Unit seam sealing integrity should be rechecked on a yearly basis.

Caulk

Accessory Installation

NOTICE: Unit accessories may be larger than unit intake and discharge opening or flanges. Due to infinite installation possibilities, a section of ductwork or transition may be required for proper accessory mounting (by others).

IMPORTANT: Installer MUST SUPPORT accessory items

from a rigid point or points to

ensure solid mounting using field or factory supplied hardware.

DESIGN CONSIDERATION: Titan Air strongly recommends using a flex coupler between the AMU and Ductwork.

Refer to Field Wiring section, under the installation section, for instructions on wiring the damper actuators.

Design Requirement: If intake accessories are supplied by others, the design shall minimize entry of snow/ rain and include an intake screen to meet ANSI standards.

Accessories on large equipment may be shipped in two pieces for field assembly. As a result, two damper actuators may need to be field wired.

Horizontal Unit

Before beginning:

Verify with roofing manufacture the method of installation preferred for supporting accessories (Rooftop Units Only).

Locate assembly supplies:

Items included: Support Brackets (optional)

Field supplied hardware:

Caulk, Caulk Tape, Fasteners (Self tapping screws and ¼ inch bolts/ nuts/ washers)

1. Match serial number on the accessory to

unit name plate inside control vestibule door.

2. Check unit submittal drawings to verify if unit accessories need a transition to match up with the air handler unit intake or discharge opening.

Support (by others)

Transition may be required to interconnect accessories and the AMU (by others)

HOOD

FILTER RACK

AMU

3. Apply caulk tape (field supplied) directly to the flange, below the screw pattern of the joint to be fastened together.

4. Hoist accessory using all lifting lugs, if provided; otherwise, a sling, to lift accessory and center it over the panel opening.

5. Affix the accessory to the unit using (field supplied) self tapping screws. Make certain every pre-punched hole in the flange is used in

fastening.

6. Repeat steps three through five to attach

the hood to the filter section; except in step five

substitute ¼ inch bolts in for self taping screws to attach the hood to the filter section.

7. After all of the accessories are installed,

caulk each seam to provide a water tight seal.

IMPORTANT: Re-caulk

accessory lifting lugs after

assembly (if applicable). Check all external sheet metal seams for caulk shrinkage and re-caulk if necessary. Titan Air. does not warranty water damage units. Seam sealing integrity should be rechecked on a yearly basis.

NOTICE: Access door swings MUST be kept free of installation piping and wiring to allow for service and maintenance.

Caulk Tape

Caulk

Intake Damper Mounting

Follow the Horizontal Accessory Installation instructions for proper installation and the diagrams below for mounting location of the intake damper.

Indoor Installation Location:

Outdoor Installation Location:

Discharge Damper Mounting

Follow the Horizontal Accessory Installation instructions for proper installation and the diagram below for mounting location of the discharge damper.

NOTICE: If the Discharge Damper is being mounted within two to three duct diameters from the unit

discharge opening

Titan Air highly recommends the discharge damper be mounted so the blades are orientated vertically. (If possible)

IMPORTANT: Titan Air also highly recommends the discharge damper be mounted at the wall or ceiling indoors. However, if the damper cannot be mounted indoors the damper actuator MUST BE PROTECTED from the outdoor elements (if applicable).

BOTTOM VIEW

IMPORTANT: Intake damper should be mounted at the building wall or ceiling.

INTAKE DAMPE

FILTER RACK

(SIDE VIEW)

UNIT

IMPORTANT: Titan Air recommends the intake damper be mounted with the damper actuator facing the service side of the unit. Make certain the damper actuator is PROTECTED from the outdoor elements with a sheet metal cover.

INTAKE DAMPER

FILTER RACK

HOOD UNIT

Vertical Unit Discharge Diffuser Mounting and Supporting

Ductwork between AMU and diffuser or discharge damper and diffuser is supplied by others.

Support diffuser at two points using field supplied materials (See example below).

Square Tubing

DISCHARGE DAMPER

Secure turning vanes once adjusted in the field (by others)

Mount discharge diffuser after discharge damper (if applicable).

Accessory Supporting

Example

Threaded Rod (by others)

GENERAL MAINTENANCE

Visit http://www.titan-air.com/ and click on “Tools & Resources” for more detailed maintenance information.

As with any equipment or machinery, a maintenance program should be implemented.

Equipment maintenance should include the following:

 Check filters and clean or replace as needed.

 Check burner and flame rod - clean if necessary.

 Check belts, belt tension and sheave alignment. (Do not over tension.)

 Confirm smooth operation of dampers.

 Lube bearings.

 Check all hardware (bearings, etc.) for tightness.

 Check settings for all controls.

 Check duct connections for leaks.

 Re-caulk seams if needed.

 Perform complete start-up procedure once per year (prior to heating season).

FILTERS

Dirty or clogged filters will restrict air flow which in turn affects the equipment performance. Therefore, it is necessary to check filters on a regular basis. Several standard filter types are available including 2" pleated 30% efficient, 2" disposable fiberglass, 2" linked panel, and 1" or 2" cleanable filters.

Cleanable filters should be removed from the filter rack and sprayed with a low pressure water. Always spray these filters in the opposite direction to air flow and apply new coating to filters when dry.

Note that cleanable filters alone may not adequately protect a coil from dust and dirt accumulation.

Filters in an unheated outdoor airstream can “freeze-up” when the humidity is high (foggy)

and temperatures are near freezing.

Method of Prevention:

Install pre-filters in the outdoor airstream that can be removed during such weather.

BURNER

NOTICE: Vertical Unit Burner Access: Filter rack can be slid out through the unit door to allow access to the backside of the burner.

Maintaining the pilot assembly is essential to reliable operation. During pre-heating season maintenance, the burner should be lit numerous times to confirm reliability. If ignition system components require servicing, pay attention to the following:

 Handle porcelain spark rod and flame rod with care. Small cracks lead to

intermittent ignition problems.

 Midco burners utilize the pilot gas tube as a ground point for the ignition rod.

Keep this grounding point free from scale or other contaminant build-up.

 Ignition wire routing should remain separated from sheet metal cabinet to

maintain optimal spark strength.

 Dielectric grease is utilized inside of the ignition and flame sensor connection

boots to limit potential for moisture in the connection.

 Maintaining low pilot regulator output pressure typically produces reliable ignition.

Excess pilot pressure creates a gas rich region that will not ignite consistently.

 The pilot solenoid is disabled following main flame ignition. The low fire setting

must be high enough to maintain a proper amplified flame rectification signal.

Check that burner baffles are firmly attached to each other and to burner casting. Do not use excessive force on screws in casting. Clean baffles with wire brush if needed.

Burner orifices may need to be re-drilled due to rust or other build-up. Burners with aluminum castings will rarely require orifice cleaning. Use drill bit sizes listed below.

Fuel Type Burner Model Orifice Size

Natural Gas Eclipse AH-MA 2.4 mm Bit

Natural Gas Midco HMA-2 or 2A 1/8” Bit

LP Gas Eclipse AH-MA 2.0 mm Bit

LP Gas Midco HMA-2 or 2A 1/8” Bit

Low Fire Air Ports Midco HMA-2 or 2A

#43 Bit

GENERAL V-BELT DRIVE TIPS

 Keep the belts and sheaves free from foreign materials that may cause slippage

or damage to the belt and sheave surfaces.

 Maintain sheave alignment.

 Inspect the V-belt drive periodically. Re-tension the drive belts if they are slipping.

 NOTE: Optimal belt tension is the lowest tension at which the belts will

not slip under peak load. Peak load typically occurs at start-up.

 Over tensioning belts can cause premature bearing, sheave and belt failure.

 Particular attention should be given to these conditions:

 Worn groove sidewalls

 Shiny sheave groove bottom

 Wobbling sheaves

 Damaged sheaves

BELT TENSION

Proper sheave alignment and belt tension are critical to belt and bearing service life. Incorrect

belt tension or misalignment of sheaves can cause any of the following:

 Premature failure of bearings.

 Premature failure of belts.

 Reduced air volume.

 Noise and vibrations.

Each Titan Air unit has as standard equipment an adjustable motor base. To adjust the belt tension, loosen the motor hold down bolts and adjust the slide base with adjusting bolt(s) on the end of the base (larger bases will have 2 adjustment bolts). Use a belt tension tester and associated tables to determine proper tension. Re-tension after the first day of operation with new belts and periodically thereafter.

Common belt tension gauges will specify a force required to produce a deflection of 1/64” per inch of span. The force required to achieve this deflection is typically in the range of 3 lbs for Abelts, 5 lbs. for B-belts, and 15 lbs. for 5V belts. See Figure below.

SHEAVE ALIGNMENT

With the use of a straight edge, sheave alignment can be checked quickly and accurately. One of the sheaves will have to be loose on its shaft in order to make adjustment. Adjust until all 4 points are in contact with the straight edge (see Figure below). Repeat on the other side of sheaves and then re-tighten.

If a face width variation exists, measure the difference between each side of the narrowest sheave and adjust until both sides are an equal distance from the straight edge.

BELT REPLACEMENT CONSIDERATIONS

IMPORTANT: Do not force belts onto sheaves by using a pry bar or by rolling the sheaves.

NOTICE: Match the size of the new belts to existing ones, except if the sheave groove size was adjusted. Replace drive belts in complete sets. Purchase set of belts from the same manufacture.

BLOWER BEARINGS

Bearings must be checked during each periodic maintenance inspection. Bolts and set screws

should be checked for tightness and the bearings may need lubrication. Refer to website for specific

manufacturer cut sheets pertaining to bearing maintenance.

Bearing Lubricate: 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 (100-250 cSt at 40˚C) may be used for re-lubrication.(Only applicable if unit blower bearings are Browning AH (Air Handler))

IMPORTANT: The following table is intended only as a guide to aid you in setting up your own schedule.

LUBRICATION GUIDE FOR BLOWER BEARINGS

MOTOR BEARINGS

Motor bearings in a clean environment should be lubricated every 2 to 3 years. Under more severe conditions of dirt or moisture, lubrication may be required every 6 months to 1 year. Refer to website for specific manufacturer cut sheets pertaining to motor bearing maintenance.

Typical motor bearing lubrication procedure follows:

 Remove fill and drain plugs.

 Clean drain port of hard grease (with wire if necessary).

 Add grease (cavity should be no more than ½ full.).

 Start motor and let run for 10 minutes.

 Wipe off any drained grease and replace fill and drain plugs.

IMPORTANT: Avoid adding an excessive amount of grease since this a common cause of motor failure.

BLOWER WHEEL

Ensure that blower hub is securely fastened to shaft. Inspect blower wheel and blades for signs of damage or cracks. Clean blades if necessary to maintain proper balance and performance. Avoid use of excessive grease on blower bearings that can coat fan blades and attract dirt.

Operating Conditions Bearing Temp. (˚F) Grease Interval

Clean 32 – 120 6 – 10 ,months

120 – 150 1 – 3 months

150 – 200 1 – 4 weeks

32 – 150 1 – 4 weeks Dirty

150 – 200 Daily – 1 week

Moisture 32 - 200

Daily – 1 week

FIREYE MICRO M SERIES LED INDICATING LIGHTS – STANDARD OPERATION

 Operating Control - Energized whenever the burner control switch is on and

power is applied to terminal #7 in the flame safeguard.

 Interlock - Illuminated solid when power is applied on terminal # 6 in the flame

safeguard to indicate that the air flow switch and other control & limit switches are closed. This light flashes once per second if the user has selected the fan-only mode (summer) or if an airflow switch or other safety circuit switch is open.

 PTFI - Illuminated only during the pilot trial for ignition period.

 Flame - Illuminated when flame signal is detected.

 Alarm - LED will flash once per second when an alarm condition is detected.

Symbol Legend

Flashing Light

Solid Light Light Off

Lockout Description OPR CNTL INTRLK PTFI FLAME ALARM

Line Frequency Noise Detected

Flame Fail – PTFI

Fault Unknown

Amplifier High Count Fail

Flame Fail – MTFI

False Flame – Standby

Interlock Open

Interlock Closed

Chassis Opto

Flame Fail – Auto

Check Chassis

Check Programmer

Amplifier Auto Check Fail

Check Blown Fuse

Check Sensor

FIREYE MICRO M SERIES LED INDICATING LIGHTS – ALARM MODE

Line Frequency Noise Detected - At start up, the MICRO M measures the AC line to determine if the input is 50 Hz or 60 Hz and set its flag accordingly. As the system is running, line frequency is constantly monitored. Outside interference causing a momentary shift in line frequency could be from SCR controls, VFD’s, etc.

Flame Fail - PTFI - No flame signal present at the end of pilot trial for ignition period.

Fault Unknown - A catch all message when, under certain high noise conditions, the lockout message may become garbled and not translatable into any existing message

Amplifier Count Fail - A message used to detect a failed amplifier module that would

generate an inordinate amount of pulses to micro computer, usually due to a shorted

transistor or oscillating electronic filter.

Flame Fail - MTFI - No flame signal present during main burner trial for ignition period.

Flame Fail - Standby - Flame signal present, for a constant 60 seconds, while control is in standby or off condition.

Interlock Open - Interlock safety circuit (terminal #6) has been detected open for longer than ten minutes during the purge cycle or during main flame period on MEP

562.

Interlock Closed - If selected by dip switches, air flow or interlock switch (terminal #6) is closed 30 seconds after the start of a cycle or when terminal #7 is closed. Titan Air does not use this function.

Chassis Opto - Opto coupler located on chassis has been found to be defective. Opto couplers are checked every 1/2 cycle of the AC main(s) to ensure they are off during the negative 1/2 cycle.

Flame Fail Auto - If dip switches selected for non-recycle, no flame is detected during the run cycle or main flame period.

Check Chassis - At beginning of cycle terminal #5 is energized.

Check Programmer - At beginning of cycle terminal #3 is energized or an internal diagnostics test for the Micro controller has failed.

Check Amplifier - Diagnostic problem with amplifier has been found.

Amplifier Auto Check - The amplifier is checked every 8 seconds by the micro computer to assure it is responding properly.

Check Blown Fuse - At the end of pilot try for ignition, no flame is detected and no power is present on terminal #3, indicating the fuse, located on chassis, is blown.

Check Scanner - The UV self check scanner (UV equipped units only) is producing flame pulses during the shutter closed period due to a malfunctioning shutter or a runaway UV tube.

GENERAL START-UP INFORMATION

Even though Titan Air equipment is tested prior to leaving the factory, a complete field start-up is essential for proper operation of the equipment. Qualified individuals should perform installation, start-up and maintenance tasks.

The factory cannot duplicate the conditions the equipment will see in the actual installation (i.e. gas pressure, static pressure, desired control settings, etc…). For this reason there are field adjustments that have to be made. Performing a complete start-up procedure will help ensure that correct adjustments are made and correct operation is verified. A step-by-step start-up procedure is provided on subsequent pages. While working through the start-up procedure, record information on the start-up checklist and return to Titan Air to validate the equipment warranty. The start-up

checklist is provided on cardstock with Titan Air’s address pre-printed on one side.

Because most component failures occur during start-up, it is very important that the function of every component be checked out during start-up. It is just as important that the start-up technician realize the malfunction of a component may be caused by other factors (i.e. air flow, gas pressure, field wiring, etc…) and should fully investigate a component malfunction and its cause before replacing the component.

Titan Air checks out all returned components and has found approximately 70% of returned parts are in full operational condition. This history has proven that a little extra time invested in troubleshooting will often save the considerable investment in parts, time, and paperwork associated with replacing components.

SUGGESTED TOOLS AND INSTRUMENTS NEEDED FOR START-UP:

 Volt/Ohm Meter

 Ammeter

 Tachometer (preferably non-contact style)

 Thermometer (preferably digital with remote probes and sufficient lead lengths)

 Gas pressure gauge (-10” to 0 to +10” of water column typical scale)

 Air differential pressure gauge (-2” to 0 to +2” of water column typical scale)

 Standard Hand Tools

Additional items for Maxitrol Series 14 or 44 temperature controls:

 10,000 Ohm potentiometer

 ½ watt, 10,000 Ohm resistor

 ½ watt, 2,000 Ohm resistor

Additional items for temperature controls using Digital Programmable Controller:

 1,070 Ohm resistor (supplied)

VALVE LEAK TEST

This is a test for checking the closure tightness of the gas safety shutoff valve. It should be performed by trained and experienced technicians. This test should be part of the scheduled inspections and maintenance procedures.

 Close the upstream manual gas valve.

 Make sure manual test cock on leak test assembly is closed.

 Remove the test plug on leaving side of gas valve.

 Close the downstream manual gas valve.

 Open the upstream manual gas valve.

 Through the safety system enable the gas valve momentarily.

 Immerse a ¼” tube vertically into a jar of water.

 Slowly open the test cock on the leak assembly.

 Once the rate of bubbles through the test assembly stabilizes, count the number

of bubbles appearing during the ten second time frame. Each bubble is approximately 0.001 cfh.

 Do this test for each shut off

valve.

Reference below leak test assembly and leakage rate chart.

Pipe Size (in) Medium

Allowable

Leakage SCCH

Max. # of

Bubbles in 10 Sec.

Min. # of sec.

for 10 bubbles

3/8 & 1/2

.64 gas 294 7 13

1.57 LP 188 4 20.4

3/4 & 1

.64 gas 301 7 12.7

1.57 LP 192 5 19.9

1-1/4 & 1-1/2

.64 gas 532 13 7.2

1.57 LP 341 8 11.2

.64 gas 578 15 6.6

1.57 LP 370 9 10.3

1-1/2

.64 gas 752 19 5.1

1.57 LP 481 12 8

.64 gas 925 24 4.1

1.57 LP 592 15 6.5

UNIT SPECIFICATIONS

Rep Job # Serial #

Sales Rep

Rohner

Quote #

16847

Revision

Job Name

R20200704.0

Date

01/20/21

18349

Tag #

Airhandling Specifications

Model:

CFM:

ESP ("w.c.):

Function:

Systems:

Location:

Configuration:

Elevation (ft):

TSP ("w.c.):

Fan Type:

Fan Model:

Fan RPM:

Fan BHP

TA-125 NG HLH H.O.T

20800 (20800)

High Outlet Temperature | HOT

HOT | Recirculating Cure

Indoor

HLH

2.82

FC DWDI

Lau A25-25H

660

16.7

Unit Control Summary

Controls:

BMS Comm.:

Enclosure:

Remote Panel:

Booth Manufacturer Temp Control

Remote Panel | None

Voltage and Supply Motor Specifications

Power Supply:

Motor HP:

Motor Type:

NEC Motor FLA:

Unit FLA:

SCCR:

480V, 3PH

20 HP

1750 rpm ODP Premium E

35.6

5 kA RMS Symmetrical at 480 VAC Maximum

Exhaust Fan Motor VFD Specifications

Power Supply:

Motor HP: VFD Control:

VFD Location: NEC Exh. FLA:

480V, 3PH 1 @ 5 HP

By Booth Manufacturer

Mounted in Unit Vestibule

7.6

Unit Construction

Exterior: Casing Type: Insulation:

Liner: Ins./Liner Loc.:

None

Single Wall Insulated Entire Airstream

1" 1.5#G-90

Gas Heat Source

Heating Type: Gas Type: Gas Pressure: Agency: Temp Rise: BTU/HR Min:

BTU/HR Max:

Direct-Fired 14" - 1# STD-ANSI 2288000

NG 100 (100) 91520

2/16/2021 1:46:07 PMTitan Air, LLLP. - Kyle Kittelson

Model: TA-125 NG HLH H.O.T

UNIT SPECIFICATIONS

Rep Job # Serial #

Sales Rep

Rohner

Quote #

16847

Revision

R20200704.0

Date

01/20/21

18349

Tag #Job Name

Optional Equipment Included:

- Mixing Box (By Titan Air)*

- 20 Percent Cure Mode Outside Air

- Intake Damper & Actuator*

- Type: Standard

- Finish: G-90

- Mixed Air V-Bank Filter Section*

- Filters: Linked Panel MERV-8

- Finish: G-90

NOTE: Options Ending With * Are Shipped Loose For Job Site Installation

Optional Controls Included:

- ETL Label (ANSI Z83.25 / CSA 3.19)

- HOT Package: Spray Booth | Controls by Booth Manufacturer

- Door Interlocked Non-Fused Disconnect

- Low Fire Start

- High Gas Pressure Switch

- Clogged Filter Switch | Switch Only

- Electronic High Temp. Limit

- VFD by Booth Manufacturer

- Supply/Exhaust Motor Circuits Sub-fused

- Air Handler Ducted Directly to Paint Booth

- OA Proving Switch

- RA Blade Switch

- Rohner PLC & VFD installed by Titan

- 160° F Maximum Discharge Temperature

2/16/2021 1:46:09 PMTitan Air, LLLP. - Kyle Kittelson

FILTER

ACCESS

12) 20x25x2

20x30x1

DAMPER/

ACTUATOR

ACCESS

40x40x1

BLOWER/

MOTOR ACCESS

40x40x1

ELEC./

GAS TRAIN

ACCESS

NTS

SERVICE ELEVATION

NTS

PLAN VIEW

NOTE: ACCESSORIES ARE LARGER THAN OPENINGS AND ARE SUPPORTED BY OTHERS

REV DATE DESCRIPTION INITIALS

- 10/22/20

ORIGINAL SN-18349 FROM Q-16847

- 10/22/20

MOVE RA FROM BACK TO BOTTOM OF MIXING

BOX, CHANGE FROM HRD TO HRH

- 12/14/20

UPDATE FROM HRH TO HLH; AND MOVE RA

FROM BOTTOM TO BACK PER CUSTOMER

- 1/21/21 SUBMITTAL APPROVED AF

QUOTE NUMBER:

SERIAL NUMBER:

NOTICE:

REP. NAME:

JOB NAME:DRAWING NAME:

DESCRIPTION:

DRAWN BY:

DRAWN DATE:

SHEET #:

ISSUE #:

SCALE:

DRAWING NUMBER:

CONFIDENTIAL PROPERTY OF TITAN AIR

LLLP. INFORMATION CONTAINED

ON THIS DRAWING IS CONFIDENTIAL IN

NATURE, IT MAY NOT BE REPRODUCED OR

RELEASED WITHOUT PRIOR WRITTEN

CONSENT OF TITAN AIR INCORPORATED.

WL/AF

TA-125 HLH HOT

CUSTOM

18349

16847-4

ROHNER

R20200704.0

0-00-000-00001/25/2021

- = - - OF -

ACCESSORY

SIZE

ACCESSORY

SIZE

GAS INLET

VESTIBULE VENT W/FAN

POWER ENTRY LOCATION (OPTIONAL)

INTAKE DAMPER MOUNT AT INSIDE WALL (DUCT BY OTHERS)

20% OA OPENING (7

1 2

X50)

4)25X60 LP

ROHNER PLC

CONTROL PANEL

ACCESSORY

SIZE

ACCESSORY

SIZE

ACCESSORY

SIZE

RA OPENING

ON OPPOSITE

SIDE

ACCESSORY

SIZE

AIR MAKE-UP UNITS WITH DISCHARGE TEMPERATURE CONTROL VIA PLC BY ROHNER AND RECIRCULATION IN BAKE MODE

SUMMER-PAINT MODE:

1. Start interlock (by others) closed and burner enable interlock (by others) open (see schematic).

2. Damper (optional discharge or intake) will open. Note that this optional damper is separate from the dampers on the recirculation mixing section.

3. Damper interlock switch closes, sending signal to PLC (by others).

4. PLC will energize the supply motor VFD (by others).

WINTER-PAINT MODE:

1. Start interlock and burner enable interlock (both by others) closed (see schematic).

2. Damper (optional discharge or intake) will open. Note that this optional damper is separate from the dampers on the recirculation mixing section.

3. Damper interlock switch closes, sending signal to PLC (by others).

4. PLC will energize the supply motor VFD (by others).

5. Air Flow switch (P-1) makes when pressure drop across burner profile is sensed.

6. Air Flow switch (P-1A) monitors pressure drop across burner profile and will open in the event the pressure drop increases above set point.

7. Manual reset high temperature limit (TL-1) is a normally closed safety switch and will trip when discharge temperature increases above its set point (typically 225°F).

8. High (P-3) and low (P-2) gas pressure switches protect against abnormal gas pressure and are manual reset safety switches.

9. Pre-purge (built into FS-1) clears cabinet of combustible gases before ignition.

10. Flame safeguard relay (FS-1) monitors the ignition and burn process. If abnormal conditions exist, the control will shut down the unit. FS-1 is a manual reset control.

11. Discharge air temperature is controlled by the PLC with an output to the modulating gas valve actuator (VM-1). PLC will keep VM-1 in the minimum position until the flame is proven.

12. When the unit is shut off there is a fifteen second post purge (built into FS-1). The blowers will operate for fifteen seconds after start interlock is opened.

BAKE MODE:

1. Unit operating in paint mode described above.

2. Bake mode interlock (by others) closed.

3. Following purge cycle, 90% OA damper closes and recirculation damper opens. Refer to linkage adjustment instructions in operating and service manual if percentage of outside air needs to be changed.

4. Burner circuit will be enabled and discharge temperature is controlled by PLC.

5. All burner safety controls function as in the winter-paint mode.

In all modes, exhaust fans interlocked with the unit or building relief must be provided by others to ensure proper ventilation.

amu rohner plc recirc hot 2004.doc

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Model: TA-125 NG HLH H.O.T

Man. Part # QtyAbbr. Description

UNIT PARTS LIST

Rep Job # Serial #

Sales Rep

Rohner

1Square D 9007MS01S0200 RA Damper Blade SwitchBS-1

1Belimo NFBUP-S Intake Damper ActuatorDM-1

1Belimo NFB24-MFT OA Damper ActuatorDM-3

1Belimo NFB24-MFT RA Damper ActuatorDM-3A

1Fireye MERT4 Flame Safeguard AmplifierFS-1

1Fireye 61-3060 Flame Safeguard BaseFS-1

1Fireye MEC120 Flame Safeguard ChassisFS-1

1Fireye MEP537 Flame Safeguard Programmer ModuleFS-1

1Mersen US6J3I 3-pole Class J Fuse HolderFU-1

3Mersen HSJ35 Class J High Speed 35a 600vac FuseFU-1

2Mersen ATQR11/2 600 VAC - Class CC Time Delay 1.5 AmpFU-2

1Mersen TRM3 250 VAC - Midget Type: 3 AmpFU-3

1Mersen USCC3I 3-pole Class Cc Fuse HolderFU-4

3Mersen ATMR15 Fus Atmr15 - Class Cc Fast Acting 15a 600vac FuseFU-4

1Baldor EM2515T 20 HP Motor(24A@460V,48A@230V,52A@208V)MT-1

1Cleveland DDP-109-187 Airflow Switch (0.2" & 0.95")P-1

1Dwyer ADPS-04-2-N Clogged Filter SwitchP-4

1Cleveland ANA-126-310 Air Flow Switch (0.2" Set Point)P-5

1Mersen MPDB63133 Power Distribution BlockPB-1

3Mersen MPDBC6263 Power Distribution Block CoverPB-1

4Idec SJ2S-07LW Relay BaseR-

1Idec RJ2S-CL-A120 120 VAC RelayR-1

1Idec RJ2S-CL-A120 120 VAC RelayR-2

1Idec RJ2S-CL-A120 120 VAC RelayR-3

1Idec RJ2S-CL-A120 120 VAC RelayR-4

1ABB OHB65J6 Disconnect HandleSW-1

1ABB OXP6X265 Disconnect ShaftSW-1

1ABB OHZX10 Disconnect Shaft GuideSW-1

1ABB OT63F3 Equipment DisconnectSW-1

1Carling 111-16-73/18 Service SwitchSW-5

1Carling 111-16-73/18 Service SwitchSW-6

1Senasys 2511F003-351 Vestibule Cooling StatT-11

1Eaton TRL04 Time RelayTDR-9

1Future Design FDC-L91-4110 High Temperature LimitTL-1

1Future Design DRA16 Plastic MountTL-1

1Hammond PH250MLI-FK Control TransformerTR-1

1Allanson 2260-P Ignition TransformerTR-2

1Honeywell AT120B1028/B 24 Vac TransformerTR-3

1ACI A/100-3W-D-12"-GD High Temp Limit SensorTS-7

1SC120-W5 Finger Guard For Vestibule Ventilation FansVF-1

1Mechatronics UF12A12-BTH Vestibule Ventilation FanVF-1

1Belimo LMCB24-SR-T Gas Valve ActuatorVM-1

1Lau 05038213C A27-27H Blower Assembly w/ 2-3/16" Bore

2Browning VPB-235-AH Bearing 2-3/16"

2Hammond FG4 Control Trans. Fuse Cover

25VX-&' Drive Belt

1OVH 256B2 Motor Base Motor Base

1SDS 1-5/8 QD Bushing

1SF 1-15/16 QD Bushing

Quote #

16847

Revision

R20200704.0

Date

01/20/21

18349

Tag #Job Name

2/16/2021 1:46:09 PMTitan Air, LLLP. - Kyle Kittelson

Model: TA-125 NG HLH H.O.T

Man. Part # QtyAbbr. Description

UNIT PARTS LIST

Rep Job # Serial #

Sales Rep

Rohner

12/5V550SDS QD Sheave

12/5V1400SF QD Sheave

15102-08-12 72"W X 60"H Standard Intake Damper - 72 X 60

Quote #

16847

Revision

R20200704.0

Date

01/20/21

18349

Tag #Job Name

2/16/2021 1:46:09 PMTitan Air, LLLP. - Kyle Kittelson

Model: TA-125 NG HLH H.O.T

GAS TRAIN/BURNER SPECS

Rep Job # Serial #

Sales Rep

Rohner

Quote #

16847

Revision

R20200704.0

Date

01/20/21

18349

Tag #Job Name

CFM:

Gas Pressure:

Burner Manifold Pressure = 4.6`` w.c. For Specified BTU and Burner

Burner Length in Feet:

Profile:

MB Fixed Opening:

20800 (20800)

14" - 1#

4.0 with 1 Tees

50 in. W x 30.75 in. H

5 in. W x  in. H

Man. Part # QtyAbbr. Description

Temp. Rise F:

@ 2288 CFH.

Burner Type:

MB OA Dmpr:

1Maxitrol RV91-1616 Main Gas Pressure RegulatorGP-1

1OARA 44-1-390-0025 Pilot Gas Pressure RegulatorGP-2

12" Hand Valve Shut-Off Valve (manual)GT-1

12" Hand Valve Shut-Off Valve (manual)GT-3

1Honeywell C6097B1028/U High Gas Pressure SwitchP-3

1Maxitrol BV250T-22 Pilot Shutoff Valve (manual)PG-1

1Honeywell V4046C1047 Pilot Solenoid ValveV-1

1Honeywell V4295A1064 Safety Shut-Off ValveV-2

1Honeywell V4295A1064 Safety Shut-Off ValveV-4

1RTC ABV-1.0NN-VO Modulating Ball ValveV-5

Pipe After V-5 - 2" Sch40 Blk

100 (100)

Midco HMA-2A

60 in. W x 34 in. H

BTU/HR Max:

MB RA Dmpr:

2288000

48 in. W x 42 in. H

Denotes Control Cabinet Terminal Block and Wire Number

Denotes Remote Panel Terminal Block and W ire Number

Denotes Field Wiring By Others

‐‐‐‐

1/25/2021 10:43:16 AMTitan Air, LLLP. - Brandon DeGrasse

RECIRCULATING AIR MAKE-UP UNITS WITH TEMPERATURE CONTROLS, UNIT FUNCTION SWITCHING BY ROHNER PLC

Start-up must be performed by a trained, experienced service person.

This general start-up procedure applies directly to H.O.T. units with mixed air section before burner with temperature controls and unit function switching by others built to accompany a spray booth (by others). Please note any added options for a specific unit which may affect the control sequence or terminal numbering prior to attempting start-up or service work. Read the entire start-up procedure and review all reference material (Unit Specifications, Gas Train/Burner Specifications, Sequence of Operation, Parts Lists, and Electrical Schematic) supplied with each unit.

STEP 1

Turn off incoming electrical power and gas supply to the unit. Electrical power

can be turned off at the unit disconnect. Gas supply shut-off is at the inlet of unit's gas manifold.

At the user control interface, turn the unit off and the discharge temperature

setpoint to the lowest setting. STEP 2

Verify that incoming electrical and gas supply match the name plate requirements

(i.e., voltage/amp capacity, gas pressure and volume capacities, etc). If they do not, stop at this point and contact Titan Air. STEP 3

Open the access doors to blower and control vestibule sections. Check all

electrical connections and hardware (blower drives, bearings, damper linkages, etc.) for tightness and correct field wiring connections. STEP 4

Check that all gas, pilot, vent, and pressure sensing lines are properly connected

and unobstructed. Verify the incoming gas line was "blown out" to flush out debris prior to connecting gas line to unit. Also verify incoming gas line has been purged of air up to unit's gas inlet. STEP 5

At the manifold pressure test port, downstream of the modulating gas valve (V-5),

connect your gas pressure gauge (pressure gauge must read inches of water column to 10" with the capability of reading a negative pressure). STEP 6

Turn on incoming electrical power at unit disconnect. Make sure the blower

access door is securely held open. Turn the blower service switch (SW-5) on. STEP 7

If an optional intake or discharge damper is installed, the blower will not start until

the damper motor's internal "proof open" end switch closes (damper motor and end switch wiring are generally completed in the field after damper is mounted). If an intake or discharge damper is not installed, the blower should start immediately. Check the

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blower for proper rotation direction. If the rotation is reversed, turn both the service switch and the disconnect switch off. For 3 phase motors, reverse any two leads. For single phase motors, see instructions on the motor. STEP 8

With proper blower rotation verified, check and record the RPM of the blower. If

the blower speed needs to be adjusted to change the rated CFM of the unit, the profile plates around the burner will have to be adjusted also. Provide the factory with the AMP draw of the motor and RPM of the blower and a new profile opening will be calculated. STEP 9

Turn the unit off. Close and latch the blower access door.

STEP 10

Start unit with SW-5. Check and record the motor amp draw. If the motor amp

draw exceeds listed Full Load Amps (FLA), stop and call the factory. STEP 11

Check and record the negative pressure reading on your burner manifold

pressure gauge. This measurement is necessary for proper setting of the burner manifold pressure when the unit is forced into high fire mode. At this time, also measure the pressure drop across the airflow switch ports (remove caps from fittings in tubing for air flow switches and connect tubing from differential pressure gauge to fittings). This measurement can be used as a simple indication of proper airflow through the unit. If this second measurement is not between 0.7" w.c. and 0.5" w.c. ΔP, the blower speed may need to be adjusted. If assistance is needed, contact Titan Air. STEP 12

Turn the unit off. Check the pilot gas line for proper and tight connections with no

leaks. For shipping purposes, the pilot lines are disconnected. STEP 13

Turn on the main gas valve and slowly open the manual pilot gas valve. If the unit

is supplied with a low gas pressure switch (P-2), reset to on position. STEP 14

Place the run-check switch (located on flame safeguard programmer module) in

the check position. This will allow the pilot to light without lighting the main burner. If the unit is equipped with an inlet ductstat (T-1), set this stat above the outside air temperature. Start unit with SW-5 and enable the burner with the burner service switch (SW-6).

Note that the burner should not be operated continuously in the check position for

more than 1 minute because the ignition transformer is not rated for continuous duty. STEP 15

The unit should go through its complete burner ignition sequence with only the

pilot ignited. The sequence can be observed by following the indicating LED’s on the flame safeguard. On new installations, resetting of the flame safeguard may be required to purge air from the pilot line. If the unit does not cycle through its burner ignition sequence after a few attempts, refer to the service information in the following section for troubleshooting instructions. STEP 16

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In the center of FS-1 are 2 voltmeter test ports. Set the volt-ohm meter to

approximately 30 VDC scale and insert the meter leads into the test ports (common lead in black port, positive lead in red port). STEP 17

With only the pilot operating, record the DC volt signal. The DCV range is noted

on the amplifier module of the controller (FS-1). There should be a steady DCV signal in the upper range stated on the controller. STEP 18

Once stable pilot is achieved, shut unit down and place run-check switch in the

run position. Force the burner control into a low fire condition. Low fire can be set with the right hand rotation stop on V-5 actuator. Start unit allowing it to operate in low fire. Check and record DC voltage as in the previous step. Check to make sure the flame is contained in the burner casting and extends the full length of the burner with no breaks in the flame. An ideal low fire setting results in a small flame with no breaks and that also produces a stable DC voltage signal in the upper end of the range listed on the flame safeguard amplifier module. If the low fire setting is adjusted, verify that both the DC voltage signal and visual appearance of the flame are satisfactory. STEP 19

Once stable pilot and low fire are achieved, force the burner into a high fire

condition. With your manifold pressure gauge, check the manifold pressure. The reading on your manifold pressure gauge needs to be added to the negative pressure recorded in step 11. The resulting total manifold pressure should be compared to the unit's rated manifold pressure. If the total is higher or lower than the rated pressure, adjustment can be made at the gas pressure regulator (GP-1).

Because of possible variations in the BTU content of gas, it may be necessary to

set the manifold pressure to the rated temperature rise (temperature difference between the incoming air and the unit discharge air).

The high fire flame should be visually observed to verify proper combustion.

Experienced service personnel should be able to assess the appearance of a proper high fire flame. If assistance is needed, contact the factory. STEP 20

With the burner on high fire, turn the high temperature limit (TL-1) to its lowest

setting. The limit should trip out and shut down the burner. Turn TL-1 back to the

factory setting of 185 deg. F (225

F for H.O.T equipment) and reset the control.

STEP 21

With unit operating with the burner enabled, adjust the temperature setpoint and

observe modulation of the burner. If the burner does not modulate, verify the input signal to the modulating gas valve actuator.

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STEP 22

With the unit operating in the winter mode, cycle the burner from SW-6. Verify that

burner fully lights within a few seconds of proved pilot. STEP 23

With the unit operating in the winter mode, close the 2nd manual gas shutoff valve

(GT-3). The burner should shut down in a few seconds (look for flame LED to go out on FS-1) with the unit shutting down in 30 seconds or less. Open GT-3 and reset FS-1 by pressing button protruding through cover. STEP 24

Restart the unit and check the operation of the 2 position, 20% outside air (OA)

damper. The 80% return air (RA) damper should modulate to maintain proper pressure drop across the 20% OA damper. STEP 25

Turn SW-5, SW-6 and the disconnect off. Verify all terminals, electrical

connections and hardware (bearings, sheaves, blower wheels, etc.) are securely tightened. Adjust all controls to desired settings. Remove all gauges, meters, and hand tools from the unit. Replace all covers on controls. Make sure all safety devices are reset. STEP 26

Turn the disconnect on. Start the unit from the remote panel. Verify proper

operation in all modes according to unit's sequence of operation.

The unit should be ready for operation. If any problems arise, refer to the service

information on the following page. To assure long lasting and efficient operation of Titan equipment, a regular service inspection should be set up. Refer to the maintenance section at the back of this manual for detailed maintenance information.

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Titan Air User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual