EVAPORATIVE AND INDIRECT FIRED MAKE
Contents
1. U UU UU UE E EUU LU Uj 8 10 Section VI Unit Shut DOWN 10 Section VII Maintenance Schedule and Lubrication Requirements 10 13 Section VII Replacement Parts UUUUUUUUU 13 Section IX Troubleshooting Guide 14 17 SECTION Il GENERAL INFORMATION A Purpose The purpose of this manual is to present a guide for proper installation maintenance and operation of the Evaporative Make Up Air Unit and supplement but not to replace the services of qualified field service personnel to supervise the initial start up and adjustment of the unit Persons without previous experience with large commercial and industrial HVAC equipment should not attempt the initial adjustment and checkout procedure which is essential before such installation may be considered ready for operation This manual should be made readily available to all operation personnel as an aid in troubleshooting and proper maintenance B Shipping Alton Evaporative Make Up Air units are shipped completely assembled where shipping limitations allow Optional inlet hoods filter and or damper sections or other large accessories are assembled and shipped mounted and wired whenever possible within limitations of shipping and handling Any optional accessories shipped separately are shipped as assembled sections Any wired accessories which have been disassembled for separate shipment require no2. 3 Connect the wires to the appropriate field wiring terminals as indicated on the unit control wiring diagram Il Locating Temperature Controls The room or outdoor thermostats should be mounted where they will not be subjected to direct impact of the heated air or radiant heat from the sun It is also recommended that thermostats especially those with mercury bulb contacts be mounted on a vibration free surface The side of building columns away from heating and air conditioning ducts or interior walls are usually the location best suited for mounting thermostats Controls with outdoor bulbs require that the outdoor sensor be shielded from direct radiation from the sun Unit mounted sensors are factory located and mounted SECTION IV PRE START UP A Pre Start Up The owners representative or equipment operator should be present during start up to receive instructions on care and adjustments of the equipment All Alton equipment has been factory tested adjusted and inspected to meet conditions set at the time the order was placed Only minimal adjustments should be required All information in this service manual is typical All products are semi custom and changes may occur Before operating the unit complete the following checks in sequence for safe and efficient operation WARNING Disconnect electrical power source to prevent injury or death from electrical shock 1 Remove all shipping blocks brackets and bolt
3. 64 inch for every inch of span length For example for a 40 inch span apply a force that will deflect the belt 40 64 or 5 8 of an inch c Compare the force you have applied with the values given in the table below If the force is between the values for normal tension and 1 1 2 times normal tension the belt tension should be satisfactory If the belt tension is not within this range it can be adjusted by loosening the motor mounting bolts and adjusting the position of the motor along its base NOTE A new drive can be tightened to two times the minimum value shown to allow for normal drop in tension during the run in period B Section small Pounds pulley Pounds _ Force for diameter Belt Force for 11 2 times range in Manufacturer Normal Normal Inches amp Type Belt Tension Tension 3 4 Goodyear 4 9 7 4 Goodyear Torque Flex 7 1 10 7 Gates Hi Power 4 4 6 6 4 4 4 6 Goodyear HY T 6 5 9 8 Goodyear Torque Flex 7 7 11 6 Gates Hi Power 4 9 7 4 5 8 8 6 Goodyear 8 2 12 3 Goodyear Torque Flex 9 6 14 4 Gates Hi Power 5 8 8 7 Note For recommendation of other types of belts consult respective manufacturers E Optional Coils and Related Items 1 Evaporator Coils Coil surfaces must be kept clean of dirt and lint in order to operate at rated efficiency Coils should be inspected on a regular basis and cleaned as required CAUTION Solutions used to clean coils must not be corrosive to metals or materials used in th
4. With the temperature controller calling for heat unit operation is automatic 3 Run the unit sequentially through its stages of heating Once proper unit operation is verified perform these final steps a Inspect the interior of the unit Remove any debris which may be present b Disable air handling blower Fire unit and confirm that high limit shuts gas off within approximately 5 minutes Re enable air handling blower Be sure all gas valves and controls are in the operating position if the unit will be operating immediately Secure all exterior panels in place SECTION VI UNIT SHUTDOWN Extended Shutdown Set the blower On Off switch to the OFF position Close the water supply valve Open drain valve and drain all water from sump tank Clean and flush out evaporative media and sump Clean water distribution header Drain fill pipe and leave open DO NOT LEAVE ANY WATER IN THE SYSTEM FREEZING CAN CAUSE MAJOR DAMAGE TO THE UNIT oOn gt gt Oise Remove and clean pump if necessary Check sump tank for leaks and repair if necessary Sump tank is constructed of stainless steel Close the main manual gas valve SMU Units Open the main electrical disconnect switch Emergency Shutdown ONLY Open the main electrical disconnect switch Close the main manual gas valve s SMU Units SECTION VII MAINTENANCE SCHEDULE AND LUBRICATION REQUIREMENTS Periodic maintenance is essential to the efficient o
5. adjustment in input should be made by re orificing ao MANIFOLD PRESSURE METHOD OF CHECKING INPUT a Close the manual gas valve on the unit b Install a 1 8 pipe connection in the tapped hole provided on the valve body and a U tube or slant manometer by means of a rubber hose Fire the unit and observe the pressure Remove the cap from the regulator Turning the screw clockwise will increase the input and turning it counterclockwise will decrease the input ap SECTION V START UP AND OPERATION A UNIT START UP After completing all prestart up checks and procedures the unit may now be operated The following checks and adjustments should be made during the initial start up 1 2 Turn on pump motor disconnect and check for proper operation of the water distribution system After several hours of operation new belts will stretch Belt tension should be checked frequently during the first 24 48 hours of operation Proper belt tension is indicated by a deflection of approximately 3 4 to 1 per foot of span when pressing the belt firmly For quiet operation and long bearing life the belts should be as loose as possible without slippage Slippage may result in belt squeal or insufficient airflow or both A simple test for belt slippage is to check the temperature of the smaller pulley by feel in relation to the temperature of the larger pulley If the smaller pulley is noticeably warmer this is
6. an indication of belt slippage and the belts should be tightened slightly Either excessively low or high tension will adversely affect the life and operation of a V belt If belts are too loose move motor back on its adjustable base by loosening and retightening mounting bolts For more information on belt tensioning see the Maintenance Schedule and Lubrication Requirements section WARNING Disconnect electrical power source when connecting or disconnecting electrical wires for test procedures Do not open service access doors while the unit is operating Failure to exercise caution when completing test procedures or while servicing unit may result in injury or death from electrical shock or contact with rotating parts 3 Measure the motor voltage amperage on all phases to ensure proper operation The readings should fall within the range given on the motor nameplate If voltage is over 10 of nameplate rating or phase voltage unbalance is over 2 notify contractor or power company 4 Turn main disconnect switch on Turn optional blower On Off switch to the On position Damper opens if applicable Supply air blower turns 5 Turn blower On Off switch to the Off position Check supply air blower for proper rotation NOTE To change rotation of the blower simply interchange any two 2 of the line leads of the motor starter for three 3 phase motors 6 Turn blower On Off switch to the On position Check for p
7. electrical shock WARNING Controls must be protected from water Do not allow water to drip on any electrical controls NOTE Before installing any wiring check the unit rating plate for power supply voltage control voltage minimum amperage by supply conductors and maximum fuse size All electrical connections must conform to the current edition of ANSI NFPA No 70 National Electrical Code and applicable local codes in Canada to the Canadian Electrical Code Part 1 CSA Standard C22 1 All wiring must comply with all applicable local state provincial and national electric codes Since shipment of unit may require disassembly after factory check and test reconnection of some electrical devices may be required in the field Connect electrical wires supplied in factory furnished conduit to appropriate terminals All leads are tagged to facilitate field connections See wiring diagram provided with equipment Complete all wiring to any optional accessories as shown on unit bill of material and electrical wiring diagram as required before applying voltage to the unit Entry location for all field installed and control wiring is through the electrical control panel if furnished If optional disconnect is not furnished with unit the field provided disconnect must be of the proper size and voltage Refer to unit nameplate for minimum circuit ampacity and voltage The disconnect must be installed in accordance with Article 430
8. face area on the 2 Remove and replace any fan section evaporative media damaged media 3 Water flow rate too high 3 Adjust water flow rate by slowly closing the balancing valve until carryover stops 4 Average media face velocity too 4 Decrease airflow through evaporative media TROUBLE SHOOTING GUIDE SMU UNITS ONLY SYMPTOM S POSSIBLE CAUSE S CORRECTIVE ACTION S A Gas odor 1 Shut off gas supply 1 Inspect all gas piping and repair immediately 2 Blocked heat exchanger 2 Clean heat exchanger 3 Drafts around heater 3 Eliminate drafts 4 Blocked flue collector 4 Clean flue collector B Delayed ignition 1 Main burner ports clogged near 1 Clean main burner ports pilot 2 Pressure regulator set too low 2 Reset manifold pressure Refer to start up instructions 3 Pilot decreases in size when main 3 Supply piping is inadequately burners come on sized 4 Pilot flame too small 4 Clean pilot orifice C Pilot will not light or will 1 Main gas off 1 Open all manual gas valves not stay lit 2 Pilot adjustment screw turned too 2 Increase size of pilot flame low on combination main gas valve 3 Air in gas line 3 Purge air from gas supply 4 Dirt in pilot orifice 4 Remove pilot orifice Clean with compressed air or solvent Do not ream 5 Extremely high or low gas 5 Refer to start up instructions pressure 6 Pilot valve not opening 6 a Faulty wiri
9. of the current edition of ANSI NFPA No 70 National Electrical Code Check the supply voltage before energizing the unit The maximum voltage variation should not exceed 10 Phase voltage unbalance must not exceed 2 NOTE Should any original wire supplied with the unit have to be replaced it must replaced with wiring material having a temperature rating of at least 105 C F Water Piping CAUTION To prevent water damage to building and equipment piping drain and vent plugs must be installed NOTE Soft water equipment should not be attached to water lines going to the evaporative cooler Soft Water will cause corrosion and decrease the effective life of the cooler NOTE All field installed piping must conform to applicable codes Run a water supply line to each float valve connector on the unit Supply line may be either galvanized pipe or copper tube with adapter A water valve should be installed at a convenient location to allow water to be turned on and off Water inlet to float valve assembly on all models have 3 8 MPT connector as standard Larger primary feed line may be required to maintain adequate water flow Refer to unit submittals for water connection location dimensional details Supply line must be furnished with an indoor shut off valve and bleed connector to prevent freezing and rupture of the line in the winter NOTE Float valve must be adjusted so that water level will coincide wit
10. will continue to spark and pilot gas will continue to flow until the pilot flame is proven LP propane gas units are equipped with 100 lockout The lockout function shuts off the main and pilot gas valves if the pilot gas fails to ignite within 30 seconds In order to initiate a reignition trial the power supply must be interrupted for 30 seconds Gas valves are suitable to a maximum pressure of 0 5 psi 14 inches water column on natural gas If the main gas supply is greater than 14 inches W C a stepdown pressure regulator must be installed ahead of the gas valve For LP propane gas the gas pressure supplied should not exceed 14 inches W C The controls are located inside the compartment on the side of the unit On two stage firing the unit will fire 40 of full fire on the first stage and full fire on the second stage When modulating is used the unit will first fire at 40 of full fire and modulate up to full fire When electronic modulating is used the unit will first fire at 100 of full fire and modulate down to 40 of full fire 2 Lighting the Burners Purge the gas line of air before attempting to light the pilot in the unit Check for gas leaks WARNING Never use an open flame to detect gas leaks Explosive conditions may exist which could result in personal injury or death The unit is furnished with an intermittent pilot ignition system A lighting instruction plate is permanently attached to the un
11. ALM IOM 1 INSTALLATION OPERATION AND MAINTENANCE MANUAL EVAPORATIVE AND INDIRECT FIRED MAKE UP AIR UNITS ATTENTION READ THIS MANUAL AND ALL LABELS ATTACHED TO THE UNIT CAREFULLY BEFORE ATTEMPTING TO INSTALL OPERATE OR SERVICE THESE UNITS CHECK UNIT DATA PLATE FOR TYPE OF GAS WHERE APPLICABLE AND ELECTRICAL SPECIFICATIONS AND MAKE CERTAIN THAT THESE AGREE WITH THOSE AT THE POINT OF INSTALLATION RECORD THE UNIT MODEL AND SERIAL No s IN THE SPACE PROVIDED RETAIN FOR FUTURE REFERENCE Alton Model No Serial No SAVE THIS MANUAL FOR YOUR SAFETY The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous FOR YOUR SAFETY If you smell gas 1 Open windows 2 Don t touch electrical switches 3 Extinguish any open flame 4 Immediately contact your gas supplier WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or death Read the installation operating and maintenance instruction thoroughly before installing or servicing this equipment WARNING Install operate and maintain unit in accordance with the manufacturer s instructions to avoid exposure to fuel substances or substances from incomplete combustion which can cause death or serious illness The state of California has determined that these substances may cause cancer birth defects or oth
12. MENT PARTS Replacement parts may be ordered from Alton All warranty parts will be shipped freight collect from Alton Warranty parts must be returned prepaid within 30 days Credit will be issued if part is complete defective and returned on time When parts are ordered MODEL NUMBER SERIAL NUMBER FACTORY ORDER F O and PART NUMBERS are required Belts filters and fuses are not covered under warranty SECTION IX TROUBLE SHOOTING GUIDE ALL UNITS SYMPTOM S POSSIBLE CAUSE S CORRECTIVE ACTION S A Blower does not operate Low or no voltage a4 Check power source high 2 Fuse s blown 2 Replace fuse s 3 Customer interlock not closed or 3 Close or connect interlock connected 4 Blower On Off switch in Off 4 Switch to On position position 5 Optional damper motor not 5 Check for power at damper motor operating or its end switch not and that end switch has been wired making correctly End switch should be wired N O Normally open 6 Overload protection on motor 6 Push reset button on motor starter starter tripped 7 Belts loose or broken 7 Turn power off and check belts Replace if necessary 8 Motor may be burned or incorrectly 8 Turn power off and check motor wired and wiring Water pump does not 1 Water level in sump is low 1 Adjust float level to maintain proper operate or the volume of level water being recirculated 2 Check o
13. TRANSPORT DRIVE DALLAS TX 75247 on PHONE 214 638 6010 FAX 214 905 0806 www mestek com e Y A A MESTEK COMPANY N
14. additional conduit or wire for field reassembly All wire leads will be tagged for ease of reconnection in the field Shipments are made F O B Dallas Texas by flatbed truck The unit is securely strapped tied and blocked to prevent shipping damage All shipments are checked by an inspector before they are accepted by the carrier Parts that are shipped unmounted are noted on the bill of lading These parts where feasible are packaged and shipped with the units Upon receipt of shipment all units should be checked against the bill of lading to insure all items have been received Items shipped loose may be found packed in the evaporative cooling section the mixing plenum section if furnished or the electrical control box if furnished All equipment and any optional accessories should be checked carefully for physical damage in the presence of the carrier s representative Carefully examine the exterior and interior compartments of the equipment for transportation damage If parts are missing or damage has occurred a claim should be filed immediately with the carrier Notify Alton of any shortage or items shipped in error Prior written permission must be obtained from Alton before any merchandise may be returned All Alton Evaporative Make Up Air units are given a complete operations test and control circuit checkout before shipment Copies of the wiring diagram piping diagram and bill of material are included with each unit
15. andard or optional accessories will be placed inside the fan section of the unit for shipment and must be removed and installed by the mechanical or electrical contractor Remotely located discharge or inlet dampers must be equipped with an end switch and interlocked to insure maximum design opening before starting and running circuits may be energized D Venting All venting installation shall be in accordance with the latest edition of Part 7 Venting of Equipment of the National Fuel Gas Code the latest edition of ANSI 2223 1 or applicable provisions of local building codes WARNING The venting is an integral part of the unit and must not be altered in the field The Natural Vented Rooftop units are equipped with a vent cap which is designed for natural draft venting Air for combustion enters the base of the vent cap through a protective grille and products of combustion are discharged at the upper section of the vent cap The Power Vented Rooftop unit has an induced draft venting system The combustion air inlet and products of combustion discharge grilles are located in the upper section of the Duct Furnace side access panel Never locate these units in an area where the flue products discharge outlet may be directed at any fresh air vents E Electrical Connections WARNING Open all disconnect switches and secure in that position before wiring unit Failure to do so may result in personal injury or death from
16. as required Cleanable filters should be given new application of filter coating after washing to maintain optimum filter performance The frequency of cleaning and replacing air filters applies twelve months of the year where blowers are used for ventilation and heating D Belt Tension and Adjustment Belt tension is adjusted during the initial run in and test periods at the factory However the belts are run as slack as possible to prevent excessive damage to the bearings yet tight enough to prevent slippage It is necessary therefore to tighten all belts during the first few months of operation and to check for proper tension weekly during the first 60 days after which 30 day check intervals are sufficient NOTE Turn off all power to the equipment before checking belt tensions CAUTION Do not attempt to tighten any belt or belts by changing the pitch of an adjustable pulley as this will change the speed of a driven pulley causing the unit to be rendered OUT OF AIR BALANCE Suggested Belt Tension Method 1 Check tension frequently during the first 24 48 hours of run in operation Ideal tension is the lowest tension at which the belt will not slip under peak load conditions Over tensioning shortens belt and bearing life 2 To properly tension a conventional V belt drive use the following procedure a Measure the span length b Atthe center of the span apply a force perpendicular to the span to deflect the belt 1
17. avoid equipment damage or possible personal injury do not connect gas piping to this unit until a supply line pressure leak test has been completed Connecting the unit before completing the pressure leak test may damage the unit gas valve s and result in a fire hazard DANGER Never use an open flame to detect gas leaks Explosive conditions may exist which would result in personal injury or death The gas line should be supported so that no strain is placed on the unit Pipe compounds which are not soluble to liquid petroleum gases should be used on threaded joints The appliance and its individual shutoff valve s must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 PSIG The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve s during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 PSIG Correctly sized piping must be run to the unit Please note that gas line pressure must be as shown on specification plate when unit is operating at full input H Field Wiring and Remote Control Installation 1 Connect the power lines to the line side of the main disconnect switch 2 Mount and wire remote control panel if furnished thermostats temperature sensors and any other field installed controls as indicated on the unit control wiring diagram
18. ction of combination gas valve or complete valve 3 Burner orifice too large 3 Check with local gas supplier for proper orifice size and replace F Flame pops back 1 Burner orifice too large 1 Check with local gas supplier for proper orifice size and replace G Noisy flame 1 Noisy pilot 1 Reduce pilot gas pressure 2 Irregular orifice causing whistle 2 Replace orifice or resonance 3 Excessive gas input 3 a Pressure regulator set too a Reset manifold pressure high b Defective regulator b Replace regulator section of combination gas valve or complete valve c Burner orifice too large c Check with local gas supplier for proper orifice size and replace H Yellow tip flame some 1 Clogged main burner ports 1 Clean main burner ports yellow tipping on propane 2 Misaligned orifices 2 Replace manifold assembly gas is permissible 3 Air shutter linted 3 Check for dust or lint at air mixer opening and around the air shutter 4 Insufficient combustion air 4 Clean combustion air inlet openings in bottom panel 5 Clogged flue collector 5 Clean flue collector J Floating flame 1 Blocked heat exchanger 1 Clean heat exchanger 2 Insufficient combustion air 2 Clean combustion air inlet openings in bottom panel 3 Blocked venting 3 Clean flue 4 Air leak into heat exchanger or 4 Determine cause and repair flue collector accordingly K Burner won t turn off 1 Poor thermostat loca
19. d sealed to prevent water from entering either the unit or building through the duct It is recommended that ductwork have a removable access panel in the duct which is connected to the duct furnace The duct opening shall be accessible when the unit is installed in service and shall be of such size that smoke or reflected light may be observed inside the casing to indicate the presence of leaks in the heating element Duct work should be properly sized so as not to inhibit airflow All ductwork must be properly supported so that no strain is put on the unit Do not alter or bend the discharge duct flanges on the furnace This information should be cross checked with the position of support beams and stand pipes to insure that clearance dimensions coincide with those of the unit The minimum clearance to combustible material must be maintained see Table 1 Table 1 Minimum clearance to combustible material Also consult local codes and regulations Clearances to Combustible Material Evaporative Units Not Applicable Refer to attached furnace manual for specific instructions Indirect Fired Heating Units In addition to the combustible clearances listed above access for service should be allowed around the unit A minimum of 3 feet access clearance is recom mended on all sides Optimum clearance for shaft removal would be equivalent to blower cabinet width C Location of Accessories Where applicable st
20. des may require additional safety controls and or interlocks CAUTION Do not install any heating system in corrosive or flammable atmospheres Premature failure of or severe damage to the unit will result CAUTION Heating system must not be installed in locations where air for combustion would contain chlorinated halogenated or acidic vapors If located in such an environment premature failure of the unit will occur A Handling the Equipment Units Without Base Frame Set unit on lifting platform or run lifting straps around unit Use spreader bars or place 2 x 4 s flat against upper edge of cabinet to prevent damage from lifting cables WARNING Do not attach lifting cables to shipping crate Units With Base Frame Attach lifting cables to the four lifting eyes located on the base of the unit Use spreader bars of sufficient length to maintain cable clearance on each side of unit During transit unloading and setting of the unit bolts and nuts may have become loosened particularly in the pillow block ball bearing assemblies in the fan section It is recommended that all nuts and set screws be tightened Turn fan shaft by hand to make certain that blower does not rub against blower housing and that bearing set screws are tight Open the cover of the electrical control box if furnished located on the unit Inspect all wire terminals and wiring terminations to ensure that all connections are tight B Locating th
21. e manufacture of this equipment If cleaning solutions are applied through means of high pressure spray care must be taken to avoid damaging the coil fins 2 Condensate Drain Periodically flush the condensate pan and drain system with a water hose F Gaskets Gaskets are used on doors inspection covers some filter racks and some outdoor air dampers Inspect gaskets periodically and repair or replace as required G Heater 1 Atleast a yearly inspection is recommended for heating installations and more frequently for process applications in year round operation Your own experience is the best guide in determining frequency of inspection but as a minimum the following procedure should be followed a Shut the system down totally disconnecting or locking out power supply so there can be no accidental start up during inspection b Inspect the burners carefully 2 Inspect the flame rod and ignition electrode for dirt and moisture Wipe off if necessary Examine for any evidence of premature arcing If in doubt check continuity of flame rod to be sure it is not grounding out Replace as required 3 Replace all access panels which have been removed and operate the unit for a test period Check for normal response and function of all controls Check all gas piping for possible leaks using a soap bubble solution 5 Inspect the support means to be sure that everything is firmly anchored in place SECTION VIII REPLACE
22. e Unit Prior to locating the unit make certain that the roof is capable of carrying the additional load of this equipment Authorities having jurisdiction should be consulted before installations are made Approval permits should be checked against the unit received Installations must be made in accordance with local codes In the absence of local codes refer to the latest edition of ANSI Standard Z223 1 N F P A No 54 National Fuel Gas Code All of the ANSI and NFPA Standards referred to in these installations are those that were applicable at the time this manual was printed The ANSI Standards are available from the American Gas Association 1515 Wilson Blvd Arlington Virginia 22209 The NFPA Standards are available from the National Fire Protection Association Batterymarch Park Quincy MA 02269 If installed in Canada the installation must conform with local building codes In the absence of local building codes refer to the current CAN CGA B 149 1 or B149 2 Installation Codes for Gas Burning Appliances and Equipment These outdoor duct furnaces have been designed for and certified to comply with CAN CGA 2 8 Locate the unit exactly level Special attention should be given to the duct electrical and fuel connection points Install duct work with adequate flexible connections to isolate vibration from the duct work All duct work should have taped or caulked seams Ducts exposed to the outdoors must be insulated an
23. er reproductive harm INSTALLER S RESPONSIBILITY Installer Please Note This equipment has been tested and inspected It has been shipped free from defects from our factory However shipment and installation problems such as loose wires leaks or loose fasteners may occur It is the installer s responsibility to inspect and correct any problem that may be found ATTENTION READ CAREFULLY BEFORE ATTEMPTING TO INSTALL OPERATE OR SERVICE THIS EQUIPMENT RETAIN FOR FUTURE REFERENCE POST AND MAINTAIN THESE INSTRUCTIONS IN LEGIBLE CONDITION 4830 TRANSPORT DRIVE DALLAS TX 75247 HSS Alton PHONE 214 638 6010 FAX 214 905 0806 www mestek com R SES A MESTEK COMPANY gt SECTION I FORWARD As is the case with any fine piece of equipment care must be taken to provide attention to the operation and maintenance details of this machine This manual of instructions has been prepared in order for you to become well acquainted with those details In doing so you will be able to give your Alton Evaporative Make Up Air Unit the care and attention which any piece of equipment needs and deserves Table of Contents Section Forward and Table of Contents 2 Section Il General Information 2 Section Ill Installation 3 5 Section IV Pre Start Up EUEEEEEEEEEEUEUUUUU UEU 6 8 Section V Unit Start Up
24. f motor were sitting horizontally on its 4 Dampers Dampers should be inspected every base There may be one or two plugs in each end casing of the motor Add a small amount of a clean good grade ball bearing grease such as Chevron SR1 2 or equal with a low pressure grease gun Run the motor five minutes before removing the grease fittings and replacing the plugs CAUTION An excess of grease will overheat the bearings NOTE On totally enclosed fan cooled TEFC motors the rear end fan housing must be removed to expose the grease plugs spring for securely fastened linkages and smooth operation If dampers are binding or excessively noisy then lubrication may be required Place one drop of 20 wt machine oil on each blade bearing and linkage ball joint Do not over lubricate and wipe any excess from the area Be sure to note that dampers over 49 inches long have intermediate bearings which require lubrication C Air Filters All filter banks should be equipped with a manometer or differential pressure switch to indicate when the filters are dirty Filters should be replaced when the differential pressure across them reaches the manufacturer s recommended final value Dirty filter elements should be replaced with a clean element of the same type and size In addition Alton not only suggests but insists that air filters be checked every 30 days and replaced with new filters throw away type or cleaned washable type
25. h proper water depth as shown by water line indicator located on the side of the water tank CAUTION To prevent improper unit operation make sure the unit is level Run 1 drain line to each 1 MPT drain connection on the unit Provide a 1 gate valve in the drain line located where convenient to permit draining and cleaning of the tank A separate overflow is provided on all units This should be connected to an open drain line or when the unit is outdoors it may be left open to facilitate frequent tank draining CAUTION To prevent unit damage do not plug overflow as this will cause water to overflow into blower compartment CAUTION Failure to properly drain all piping connections not in use during freezing temperatures may result in freeze up damage G Gas Field Piping SMU Units All gas piping must be in accordance with the requirements outlined in the National Fuel Gas Code ANSI Z223 1 and applicable codes It is required that a ground union be installed adjacent to the manifold for easy servicing A drip leg and or filter should be provided upstream of the unit s inlet connection s An additional shut off must be located external of the unit s enclosure where required by local code The location of this valve must comply with all local codes A 1 8 N P T plugged tapping accessible for test gauge connection must be installed immediately upstream of the gas supply connection to the unit WARNING To
26. ilot and main burners are extinguished during each off cycle Each outdoor duct furnace is provided with a gas valve suitable for Class 2 maximum inlet pressure of 0 5 psi 14 inches W C on natural gas Controls for LP gas are available as an option Gravity vented furnaces used in Alton s outdoor make up air units incorporate a unique vent cap which draws combustion air and vents flue products through separate sections of the cap Having both functions in the same plane allows for a balanced venting system under all conditions Units can be located close to a wall or roof peak and can sustain 60 MPH winds from any direction without flame disturbance Optional power vent models have a combustion air inlet and flue outlet louvered ports located in a one piece access panel This design also results in balanced flue operation under all conditions Atmospheric burners are pressed aluminized steel and have stainless steel port protectors Burners are individually removable for ease of cleaning and servicing A pilot burner plate is provided for access to the pilot burner and ignition system without removing the burner drawer Clearance between the furnace and external obstructions must be sufficient for proper servicing of the pull out burner drawer 1 Turn optional blower On Off switch to the On position Turn optional system switch to the Heat position 2 Adjust the temperature control setting to some point above room temperature
27. it for the pilot system supplied with the unit To set the intermittent pilot ignition system in operation proceed as follows a Turn on the main manual valve b Turn on electrical power The unit should now be under the control of the temperature control system c Turn the temperature control system to the high heat reading to see if the pilot and main burners ignite d Turn the temperature control system to the lowest setting to interrupt power to the ignition system Confirm that both the pilot burner and main burner are extinguished e Set the temperature control system at the desired setting for normal operation For complete shutdown turn the main and pilot valves to the OFF position Adjust the temperature control system to the lowest setting Shut off electric power NOTE There may be momentary and spasmodic orange flashes in the flame This is caused by the burning of airborne dust particles and not to be confused with the yellow tipping which is a stable or permanent situation when there is insufficient primary air 3 Pilot Adjustment a With unit firing remove the pilot adjustment cap b Adjust the pilot screw to provide properly sized flame A proper pilot flame is a soft steady flame that envelopes 3 8 to 1 2 of the flame sensor c Replace the pilot adjustment cap 4 Gas Input Adjustment When shipped from the factory all gas fired units are equipped for the average BTU of the gas stamped o
28. n the rating plate CAUTION Since the BTU content of gases varies in many localities the input must be checked after installation of the unit If the unit is overfired the overheating will substantially shorten the life of the heat exchanger Never exceed the input on the rating plate The input may be checked by either the meter method or the pressure of the gas in the manifold A 1 8 pipe tap is available on the body of the gas valve CAUTION Never overfire the duct furnace as this may cause unsatisfactory operation or shorten the life of the heater METER METHOD OF CHECKING INPUT a Obtain the heating value of the gas from the local utility This should be in BTU per cubic foot b The rating plate input should be taken from the unit as stamped on the plate EXAMPLE Assume this is a unit having an input of 250 000 BTU hr And the heating value of the gas to be used in the furnace is 1000 BTU cubic foot 250 000 BTU hr 1000 BTU cu Ft x 60 min hr INPUT 4 17 cu ft per min Before checking the unit input all other gas appliances connected to the same meter must be turned off Fire the unit according to instructions Observe on the meter dial the cubic feet of gas for a period of five minutes This should be 4 17 cu Ft x 5 minutes or 20 8 cu ft Minor adjustments can be made by moving the regulator screw clockwise for increased input or counterclockwise for decreased input Any appreciable
29. ng a Inspect and correct all wiring b Defective ignition b Replace ignition control control c Defective valve c Replace valve 7 No spark 7 a Faulty wiring a Inspect and correct all wiring b Defective pilot b Replace pilot c Defective ignition control c Replace ignition control d Sensor grounded d Inspect and correct ignition system D Main burners will not 1 Main gas off 1 Open all manual gas valves light 2 Lack of power at unit 2 Replace fuse or turn power supply on 3 Thermostat not calling for heat 3 Turn up thermostat 4 Defective limit switch 4 Check limit switch with continuity tester If open replace limit switch 5 Improper thermostat or 5 Check wiring per diagrams transformer wiring at gas valve 6 Defective gas valve 6 Replace gas valve 7 Defective thermostat 7 Check thermostat and replace if defective 8 Defective transformer 8 Be sure 115 volts is supplied to the transformer primary then check for 24 volts at secondary terminals before replacing 9 Loose wiring 9 Check and tighten all wiring connections 10 Defective ignition control 10 Replace TROUBLE SHOOTING GUIDE SMU UNITS ONLY continued SYMPTOM S POSSIBLE CAUSE S CORRECTIVE ACTION S E Flame lifting from burner 1 Pressure regulator set too high _ Reset manifold pressure ports 2 Defective regulator 2 Replace regulator se
30. normal temperature and noise level Excessive leakage of grease at the seals and a high operating temperature suggest too much grease Frequency of Lubrication Frequency of lubrication depends upon operating conditions The bearing operating temperature is the best index for determining a relubrication schedule The following chart gives the continuous operation for various operating temperatures and can be used as a Satisfactory guide for determining when all ball and roller bearings should be relubricated Dampers Alton Sleeve or equal Speed Temperature Cleanliness Interval Recommendation See following note 100 RPM Up to 125 F Clean 6 months 500 RPM Up to 150 F Clean 2 months 1 Blower Motors Some motors require lubrication 1000 RPM Upto 210 F Clean 2 weeks while others do not Those that require lubrication 1500 RPM Over 150 F Clean weekly can be identified by the presence of grease plugs Any Speed Up to 150 F Dirty 1 week to in the motor casing at each end Motors that do 1 month not have grease plugs cannot be greased and are Any Speed Over 150 F Dirty daily to lubricated for the life of the motor bearing 1 week Any Speed Any Temp Very Dirty daily to Lubrication of motors should be done while the 1 week motor is warm and at a standstill Remove and Any Speed Any Temp Extreme daily to clean all grease plugs and insert a grease fitting in Conditions 1 week the upper hole in the motor casing at each end Viewed as i
31. peration and extended service life of this equipment Failure to provide maintenance as recommended may void the equipment warranty A Maintenance Schedule All Units 1 Every Month a Check that blower belts are tight and sheaves are aligned New belts must be checked weekly during first 60 days of run in b Check filters replace or clean as required c Grease main fan bearings refer to frequency of lubrication chart in this section 2 Every Spring a Inspect and clean blower wheel with air pressure if necessary b Lubricate main fan motor as directed by motor manufacturer and inspect blower motor for loose connections Check all electrical connections for tightness Inspect for rust wirebrush sand and repaint as necessary moo Check damper and linkage for free movement h Lightly grease all door latches g Check dampers actuators and linkage adjust and tighten as necessary i Replace cooling media Turbospray units every spring Turbocell units should be done every five years or if passages become blocked j Clean water pump k Adjust bleed off rate 3 Every Fall a Drain units b Lightly grease all door latches SMU Units 1 Every Fall a Check for gas leaks b Inspect and clean pilot burner if necessary c Check burners remove any dirt dust or other foreign matter from the burners using a wire brush and or compressed air Ensure that all parts are unobstructed d Check all limit controls
32. ptional low sump water 2 Replace if defective is not sufficient level shutoff switch 3 Open circuit to water pump 3 Close pump switch or replace fuse 4 Water pump not operating 4 Check pump for internal grounding or heat damage to the pump Replace if necessary 5 Pump inlet screen restricted due 5 Clean screen if necessary to blockage White mineral deposits 1 Low water bleed off rate 1 Open bleed off valve to increase collecting on face of bleed rate Minimum bleed rate evaporative media required is 3 6 of the total water flow being recirculated to evaporative media 2 Low water flow rate over top of the 2 Increase water flow rate over Turbocell media Turbocell media to 1 1 2 to 2 GPM per square foot of media top area This is generally sufficient to prevent dissolved solids in the water from collecting on the face of the evaporative media Uneven water distribution 1 Water distribution header or 1 Remove water distribution header over evaporative media orifices plugged and orifices Clean as necessary surface 2 Evaporative media partially 2 Remove media and clean or blocked replace as necessary Water is being carried 1 Localized media face velocity too 1 Clean or replace supply air inlet over from the evaporative high Inlet air filter section or inlet filters and evaporative media as section onto the floor of face of media is partially blocked required air handling unit or supply 2 Damaged
33. roper blower RPM Check that all motor amp draws do not exceed nameplate ratings 7 Turn blower On Off switch to Off position B COOLING OPERATION The evaporative make up air unit works by drawing outside air through specially designed cooling media Due to the media s unique design a turbulent mix of air and water is created which optimizes heat transfer An air washing effect is also created which removes most dust and dirt from the airstream providing a clean cool environment 1 Turn optional blower On Off switch to the On position Turn optional system switch to the Cool position 2 Adjust water regulator valve Turbospray Units The water regulator valve should be adjusted to allow just enough water to keep the prefilter as wet as possible and fully wet the entire surface of the inside filter The angle of the spray assembly may need to be adjusted so that water spray is pointing toward the prefilter The velocity of the supply airstream will pull the water spray into the cabinet After unit has been shut down check blower cabinet for any signs of water carry over If water is in the blower cabinet the water flow is too high Adjust the water regulator valve until this condition has been corrected Turbocell Units The water regulator valve should be adjusted so that the media is damp from top to bottom If water is flowing down the outside surface of the media the water flow is too high Adjust the water reg
34. s from supply fan base with optional isolation base Rotate blower wheel by hand Blower should turn freely 2 Inspect fan motor and bearings for proper lubrication Refer to Lubrication procedures in the Maintenance section of this manual CAUTION Do not rupture grease seals CAUTION Inadequate lubrication of fan motor or bearings may result in premature bearing or motor failure CAUTION To prevent damage to the bearings and shaft do not strike them with a metallic object in order to position the blower wheel or shaft If necessary to drift the bearing onto the shaft use a brass bar or pipe against the bearing s inner race and strike the bar or pipe 3 Check the blower wheel blower wheel hub clamp and bearing set screws for proper tightness and adjust as necessary 4 To prevent interference of the blower belt with the frame make sure that the edge closest to the motor has proper clearance from the blower frame 5 Inspect electrical connections They should be clean and secure The rooftop make up unit is wired at the factory and is ready to be field connected Actual wiring will differ according to the options used Each rooftop make up air unit is shipped with its own wiring diagram secured to control panel cover Refer to this wiring diagram for all electrical connections to the unit 6 Check that all filter and cooling media is in place and positioned properly CAUTION To prevent damage to the blower mo
35. shipped If correspondence with the factory is necessary please provide the unit model and serial number C Optional Factory Service Periodic service on any piece of mechanical equipment is necessary for efficient operation Alton has a nationwide service support network available to provide quick and dependable servicing of all types of evaporative make up air equipment Alton also offers factory start up service which includes the presence of a service engineer to supervise the initial start up and adjustment of the equipment and provide instructions for the owner s maintenance personnel in proper operations and maintenance Consult factory for quotations on periodic or start up service SECTION Ill INSTALLATION FOR CANADIAN INSTALLATIONS ONLY 1 All installations must conform with local building codes or in the absence of local codes with current CAN CGA B149 Installation Codes For Gas Burning Appliances and Equipment 2 All electrical connections must be made in accor dance with Canadian Electrical Code Part 1 CSA Standard C22 1 This equipment must be installed and wired in accordance with regulations of the National Board of Fire Underwriters National Electrical Code and local governing bodies The following recommendations are not intended to supplant any requirements of federal state or local codes having jurisdiction Authorities having jurisdiction should be consulted before installations are made Local co
36. tion 1 Relocate thermostat away from drafts 2 Defective thermostat 2 Replace thermostat 3 Improper thermostat or 3 Check wiring diagrams transformer 4 Short circuit 4 Check operation at valve Look for short and correct such as staples piercing thermostat wiring 5 Defective or sticking valve 5 Replace gas valve L Rapid burner cycling 1 Loose electrical connections at 1 Tighten all electrical connections gas valve or thermostat 2 Adjust thermostat heat anticipation 2 Excessive thermostat heat for longer cycles anticipation 3 Check for proper air supply 3 Unit cycling on high limit across heat exchanger 4 Poor thermostat location 4 Relocate thermostat TROUBLE SHOOTING GUIDE SMU UNITS ONLY continued SYMPTOM S M Not enough heat 1 POSSIBLE CAUSE S Incorrect input CORRECTIVE ACTION S Refer to unit rating plate for proper manifold pressure 2 Thermostat malfunction 2 Replace thermostat 3 Heater cycling on high limit 3 Check air movement through control heat exchanger Check voltage to power venter motor clean power venter wheel and heat exchanger and oil power venter motor Check filters replace if necessary 4 Check outside dampers if used 4 Adjust dampers accordingly N Too much heat 1 Thermostat malfunction 1 Replace thermostat 2 Heater runs continuously 2 a Improper thermostat or a Check wiring per diagrams
37. to insure proper operation B Lubrication Instructions 2 Item Manufacturer Bearing Type All 3 phase U S Baldor Single row ball fan motors or equal bearings 1 HP to 100 HP ODP TEFC Recommendation See following note All 1 phase Century Bronze sleeve motors Baldor bearings Fractional or equal HP ODP TEFC or TEAO Recommendation See following note Fractional HP Century Bronze sleeve single phase Baldor bearings ODP or or equal TEFC Recommendation See following note 3 Fan shaft Fafnir Self aligning bearings or equal single row ball bearings resilient mounted Recommendation See following note Pillow Block Bearings Pillow block bearings are used on supply blower s Bearings have been prelubricated with a number 2 lithium base grease Relubrication should be done with a similar grease using a low pressure grease gun Wipe all grease fittings clean before adding grease Grease should be added slowly in small amounts at frequent intervals while the shaft is being manually rotated A slight showing of grease at the seals with accompanying normal bearing temperature indicates proper lubrication Normal temperature can range from cool to hot to the touch depending on size speed and surrounding conditions Excessive bearing temperature indicates faulty lubrication An insufficient amount of grease is suggested by a bearing showing no grease at the seals and a higher than
38. tor due to overloading do not operate the unit unless all media is in place 7 Check entire unit for debris Remove all foreign material from the water tank and check overflow for obstructions 8 Close and secure all unit access doors 9 Fill water tank CAUTION The use of untreated or improperly treated water in this unit may cause scaling erosion corrosion algae slime or other equipment damage Consult a qualified water treatment specialist to determine if water treatment is required Alton assumes no responsibility for equipment damage caused by untreated or improperly treated water 10 Check water tank opening and overflow line for obstructions 11 Check piping and valves for leaks Open or close valves to check for proper operation Drain lines should be open 12 Set all thermostats or other remote controls to the desired settings 13 Turn on power to unit by closing the unit disconnect switch Check voltage supplied to disconnect switch The maximum voltage variation should not exceed 10 Phase voltage unbalance must not exceed 2 14 Energize the water pump and allow to run for 10 minutes Drain the water tank Repeat procedure two more times B Operation of Heating System SMU Units Only 1 General All units are equipped withintermittent pilot ignition systems The pilot is lit and extinguished during every cycle of operation There is no burning standing pilot On natural gas units the ignitor
39. transformer wiring at gas valve b Short circuit b Check operation at valve Look for short and correct Such as staples piercing thermostat wiring c Defective or sticking gas valve c Replace gas valve P Power venter motor will 1 Lack of power at unit 1 Replace fuse or turn on power not start 2 Defective power venter relay 2 Replace power venter relay 3 Defective motor 3 Replace motor 4 Thermostat not calling for heat 4 Turn up thermostat 5 Defective limit switch 5 Replace limit switch Q Noisy power venter 1 Power venter wheel loose 1 Tighten or replace 2 Bearings dry 2 Oil bearings on power venter motor 3 Power venter wheel blades dirty 3 Clean power venter wheel blades 4 Power venter wheel rubbing 4 Realign power venter wheel housing R Power venter will not 1 Loose wiring 1 Check and tighten all wiring run connections per diagrams 2 Defective motor overload 2 Replace motor protector or defective motor 3 Defective power venter relay 3 Check for 24V across 1 amp 3 terminals on fan relay If 24V is present jumper terminals numbered 2 and 4 If motor runs relay is defective and must be replaced If 24V is not present check wiring diagrams S Power venter motor will 1 Improperly wired fan relay 1 Check all wiring not stop 2 Defective fan relay 2 Replace fan relay Indicates Power Vent Units Only NOTES NOTES sssssssses A It 4830
40. ulator valve so that media is only damp on the entering air side After unit has been shut down check blower cabinet for any signs of water carry over If water is in the blower cabinet the water flow is too high Adjust the water regulator valve until this condition has been corrected 3 Adjust water bleed off valve The unit is provided with a manually adjustable bleed off valve which will allow for continuous bleed off of water into the overflow connection on the sump The bleed off required is dependent on the quality of water used and the rate of evaporation As climate conditions change the rate of evaporation may increase thereby requiring an increase in the bleed off rate It is recommended that the bleed off rate be set for the condition of maximum water evaporation An indication of insufficient bleed off is a uniform build up of minerals on the entering air face of the cooling media If this condition is observed increase the rate of bleed off until the mineral deposits dissipate Repeated drying of the cooling media will also cause the rapid buildup of insoluble mineral deposits C HEATING OPERATION SMU UNITS ONLY All indirect gas fired duct furnaces used in Alton make up air units are designed for outdoor installation Every duct furnace is A G A certified for safe and efficient performance A solid state ignition control system which ignites the pilot by spark is standard on all outdoor furnaces Both the p
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