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Installation, Operation and Service Manual

1. FILTER SECTION OPTIONAL OPTIONAL END VIEW Table 5 B 650 B 1000 B 2000 and B 3000 Dimensions Model B C D E F G H J M N PI QGTI R B 650 in 44 2 92 3 220 19 0 105 11 1 37 9 32 14 0 T 29 6 327 48 1 35 1 1000 cm 112 3 234 4 55 9 48 3 267 282 963 81 35 6 i 75 2 83 1 122 2 89 2 in 56 0 116 2 31 5 31 5 13 8 12 3 443 60 17 0 188 2 52 6 56 1 69 6 23 3 142 2 295 1 80 0 80 0 35 0 31 2 112 5 15 2 432 477 8 133 6 142 5 176 8 59 2 B 3000 in 68 0 116 2 36 8 36 8 17 0 15 6 563 6 0 17 0 188 2 56 6 60 1 69 6 23 3 cm 172 7 295 1 93 5 93 5 43 2 39 6 143 0 15 2 43 2 477 8 143 8 152 7 176 8 59 2 Model S T U V w Y z AA DD EE FF GG HH KK LL MM NN 650 in 1 6 3 0 10 0 34 56 4 372 34 0 38 8 28 8 28 6 15 11 41 0 0 5 65 25 3 95 25 3 B 1000 cm 4 1 7 6 25 4 8 6 143 2 94 5 863 98 6 732 d 726 3 8 2 8 1041 1 3 16 5 643 241 643 B 2000 B 2000 in 1 5 39 26 5 60 893 44 0 310 497 528 720 33 0 2 0 11 52 0 0 4 N A 35 3 104 35 3 cm 3 8 9 9 673
2. 86 Figure 45 BMS Ready Control MUA Style B 350 87 Figure 46 BMS Ready Control MUA FR Style Units B 650 B 3000 88 Figure 47 BMS Ready Control AM Style Units B 650 B 1000 uu peret 89 Figure 48 Additional Control Wiring for VAV Style 650 and 1000 90 Figure 49 Figure 50 Figure 51 Figure 52 Figure 53 Figure 54 Figure 55 Figure 56 Figure 57 Figure 58 Figure 59 Figure 60 Figure 61 Figure 62 Figure 63 Figure 64 Figure 65 Figure 66 Figure 67 Figure 68 Figure 69 Figure 70 Figure 71 Figure 72 Figure 73 Figure 74 Figure 75 Figure 76 Figure 77 Figure 78 Figure 79 Figure 80 Figure 81 Figure 82 Figure 83 Figure 84 Figure 85 Figure 86 Figure 87 Additional Control Wiring for VAV Style B 2000 3000 91 BMS Ready Control for VAV Style 650 and 1000 92 BMS Ready Control for VAV Style B 2000 3000 93 BMS Ready Control for VAV Style with Inlet Damper B 2000 3000 94 Additional Control Wiring for VAV Style with Inlet Damper B 2000 3000 95 AM Style for 650 and B 1000
3. 96 AM Style for 2000 3000 96 CO2 Sensor Interlock for FR and MUA Style 97 CO2 Sensor Interlock for AM and Style B 650 1000 97 CO2 Sensor Interlock for AM and Style 2000 and 3000 97 CO Sensor Interlock for FR and MUA 98 CO Sensor Interlock for AM and VAV 98 CO Sensor Interlock for AM and VAV with Photohelie au 98 CO Sensor Interlock for AM with Building PresSUte tech e 98 J 1000 1 Pot 75HP or Less 103 V 1000 1 Pot 10 25 103 P7 1 Pot 30HP or 104 J 1000 VFD 75HP or Less with Photohelic 104 V 1000 VFD 10 to 25HP with Photohelic 105 P7 30HP or More with Photohelic 106 Single Exhaust Starter 107 Two Exhaust Starter 107 Air Handler Styles 109 Honeywell Safeguard Jumpers 112 58600 Flame Control B 350 113 RM7890 Flame Control B 650 and B 1000 114 RM7897 Flame Control B 2000 B 3000 115 Sheave Alignm
4. 66 18 2 Inlet Damp t oi temer 67 SECTION 14 Discharge Heads and Splash Plates 69 14 1 One Way and Three Way Discharge Head Installation jose Rie ets 69 14 2 Splash Plate Installation 70 SECTION 15 Duct Considerations 72 15 1 Inlet Duct u uuu uu ls 72 15 2 Return Duct Work 72 15 3 Discharge Duct 72 SECTION 16 Gas Piping 74 16 1 Gas Manifolds esse 74 16 2 Gas Piping and Pressures 74 16 3 Gas Manifold Venting 74 16 4 Gas Piping aeree R 77 16 5 Pressure TeSt 77 16 6 Line Pressure Test Leak Testing 77 SECTION 17 Electrical 78 171 Wiring and Electrical Connections 78 172 Remote Panel eene 78 17 3 Motor Current 78 174 Control Current Draw 78 17 5 Safety 78 17 6 Additional Control Wiring
5. 2 15 Label Placement 3 SECTION 2 Installer Responsibility 6 2 1 Wall T gs int cott et s 6 2 2 Corrosive Chemicals 6 2 3 National Standards and Applicable Codes 7 2 4 Required Equipment see 7 SECTION 3 Critical Considerations 8 3 1 Required Clearances to Combustibles 8 3 2 Purge of Supply Duct 9 3 3 HardW ale uie do poete tee em 9 SECTION 4 National Standards and Applicable Codes 10 4 J G8S Codes uu euren o deerat dcs 10 4 2 Installation Codes eene 10 4 3 Aircraft Flangars uut ecce 10 4 4 Parking Structures and Repair Garages 10 4 5 Electrical unie eneuisaseveeeusue 10 4 6 nee Ree bts 10 47 High Altit de rete Rte 10 SECTION 5 Specifications 11 SECTION 6 Lifting an Air Handler 17 6 1 Lifting an Air Handler 17 SECTION 7 Roof Curb 19 7 1 Roof Curb Assembly and Installation 19 72 Air Handler Mounting to Roof Curb 20 SECTION 8 Upright Stand
6. 73 Table 12 Gas Manifold Size 74 Table 13 Control Voltage Wiring For All Control Systems 78 Table 14 Full Load Current Draw 79 Table 15 Safety Systems 79 Table 16 Minimum and Maximum Fuse Size by Motor Size and Supply 106 Table 17 Configuration Chart 109 Table 18 Factory Preset Schedule on TH8110 Thermostat eret etd Goede 112 Table 19 Site Configuration Jumper Options 112 Table 20 Deflection Force B and BX Belts in Ibs 118 Table 21 Motor Sheave Drive Torque Specifications 119 Table 22 Motor and Blower Bushing Torque 119 Table 23 Burner Mode by Amplifier Type 121 Table 24 Maximum Temperature Rise 121 Table 25 Motor Lubrication Intervals 127 Table 26 Burner Selections 129 Table 27 Control Panel seen 132 Table 28 Power Panel see 133 Table 29 Manifold Components 134 Table 30 BIOWOF ict e t en erepta pega 134 Table 31 Remote Pan
7. For Model B 2000 Attach the bottom panel with five TEK self tapping screws Attach the right panel with five TEK self tapping Screws on each side Top Pane For Model B 3000 Attach the bottom panel with seven TEK self Side Right Panel tapping screws Attach the right panel with seven TEK self tapping Screws on each side 36 of 149 Step 11 3 3 Inlet End 4 eu x Top Panel Top Panel Inside Outside Discharge End To Unit SECTION 11 FILTER SECTION Side Filter Rail Description Part Number Side Filter Rail 13X05031 TEK Screw 13404 For Model B 2000 Attach the side filter rail to the top panel with five TEK self tapping screws Line up filter rail holes with provided holes near the discharge end of the filter section panel For Model B 3000 Attach the side filter rail to the top panel with six TEK self tapping screws Line up with provided holes near the inlet end of the filter section 37 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 11 3 4 Side Filter Rail Inlet End Description Part Number Side Filter Rail 13X05031 gs e B 3000 TEK Screw 13404 Bottom panel For Model B 2000 Attach the side filter rail to the bottom panel with five TEK self tapping screws Line up filter rail holes with provided holes near the discharge end of the filter section Bottom Panel panel For Model B 3000 Attach the side fil
8. Description Models Part Number Pressure Switch Low Airflow All Models 90439802 Pressure Switch High Airflow All Models 90439814 Maxitrol 10140 Temp Control Amp Units with Basic and SDC Remotes 07332 Maxitrol 1044 Temp Control Amp Units with DTC Remotes 07336 Mixing Tube All Models See Page 134 Figure 87 07380 Discharge Air Sensor 1014 Units with Basic and SDC Remotes not shown See Page 134 Figure 87 07350 Discharge Air Sensor 1044 Units with DTC Remotes not shown See Page 134 Figure 87 07410 24 V Transformer 40 VA All Models 90407100 Ignition Transformer All Models 90407219 Belimo LF120 S US B 350 and B 3000 07097 Belimo NF120 S US B 650 and B 3000 07095 Actuator 90 in Lb Floating B 2000 and B 3000 90667110 Actuator 90 in Lb 4 20mA B 2000 and B 3000 90667120 Actuator 90 in Lb 24V B 2000 and B 3000 90667130 Ignition Control Module B 350 07630 Ignition Control Module RM7890 B 650 and B 1000 remove jumper See Page 112 Section 18 3 1 07122 Ignition Control Module RM7897 B 2000 and B 3000 remove jumper See Page 112 Section 18 3 1 07130 Flame Amplifier R7849A B 650 and B 3000 07123 Flame Rod B 350 07590 UV Scanner B 650 and B 3000 07060 Purge Timer 7 seconds B 2000 and B 3000 07133 High Temperature Limit Switch All Models 07063 Igniter All Models 07640 Relay 15Amp All Models 07100 Relay 8Amp All Models 90447110 Relay Socket All Models 90447200 FIGURE 86 Power Panel Layout ELECTRICAL
9. Filter access through side access door 7 Inlet 29 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL 11 2 Filter Section Assembly B 650 and B 1000 Filter Section with Disposable Polyester Filters Filter Section with Permanent Aluminum Mesh Filters Description Part Number 77080 301 W 77081 301 W Quantity Quantity Disposable Polyester Filters 20 x 40 x 1 23629 4 N A Permanent Aluminum Mesh Filters 20 x 20 x 1 20628 N A 8 Insulated Access Cover 77401 002 W 1 1 Header Panel 77402 002 W 1 1 Right Panel 77403 001 W 1 1 Left Panel 77403 002 W 1 1 Channel 77404 002 3 3 Support 77405 002 2 2 End Panel 77406 002 W 1 1 Stiffener 77407 002 W 1 1 Screw 12 x 3 4 Washer HD 13404 38 38 Nut 4 20 Speed Grip 20499 4 4 Bolt 14 20 x 34 HHCS 20504 4 4 Flat Washer 20503 4 4 Fastener Rivnut 3 8 16 91120106 10 10 3 8 Flatwasher 20515 10 10 3 8 16 x 1 Bolt Hex Grade 5 20517 10 10 30 of 149 SECTION 11 FILTER SECTION Step 11 2 1 Side Panel Attach left panel and right panel to the end panel outside mounting flanges Fasten together with 6 TEK screws on each side as shown Insert Screws Description Part Number Left Panel 77403 002 W Right Panel 77403 001 W Side Panel End Panel 77406 002 W TEK Screw 13404 Step 11 2 2 Make sure that the bottom
10. On A Ei o 91010445 EF mn E N A E oa A 5 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 2 INSTALLER RESPONSIBILITY A WARNING Explosion Hazard Equipment must have access to uncontaminated air at all times Failure to follow these instructions can result in death injury or property damage The installer is responsible for the following To install and commission the air handler as well as the gas and electrical supplies in accordance with applicable specifications and codes Bananza recommends the installer contact a local building inspector or Fire Marshal for guidance To use the information given in a layout drawing and in the manual together with the cited codes and regulations to perform the installation To install the heater in accordance with the clearances to combustibles To furnish all needed materials not furnished as standard equipment To plan location of supports To provide access to air handler for servicing To provide the owner with a copy of this Installation Operation and Service Manual To never use heater as support for a ladder or other access equipment and never hang or suspend anything from heater To ensure there is adequate air circulation around the air handler and to supply air for combustion ventilation and distribution in accordance with local codes To a
11. 22 8 1 Upright Stand Installation 22 8 2 Attaching Air Handler to 22 SECTION 9 Legs 9 1 Leg Mounting 9 2 Leg Mounting Horizontal Air Handler B 350 B 3000 eni nieder tes 24 SECTION 10 Indoor Suspension Mounting Horizontal Air Handler eere 26 10 1 Suspension Kit Assembly and Installation 26 SECTION 11 Filter Section 29 11 1 Filter Section B 350 29 112 Filter Section Assembly B 650 and B 1000 30 113 Filter Section Assembly B 2000 and B 3000 34 11 4 Filter Section Support Assembly 41 11 5 Filter Section Installation Horizontal Air Handlers 43 11 6 Filter Section Installation Upright Air Handlers 43 SECTION 12 Inlet Hood 44 12 1 Inlet Hood Assembly B 350 44 12 2 Inlet Hood Assembly B 650 and B 1000 45 12 3 Inlet Hood Assembly B 2000 and B 3000 54 12 4 Inlet Hood Installation 64 SECTION 13 Dampers 65 13 1 Discharge
12. 12 Figure 7 B 650 B 1000 B 2000 and B 3000 Upright Model DIMONSIONS 32 22 c tee nd 13 Figure 8 B 650 B 1000 B 2000 and B 3000 Horizontal Model Dimensions 14 Figure 9 Lifting a Horizontal Air Handler 17 Figure 10 Lifting an Upright Air Handler B 350 B 3000 18 Figure 11 Roof Curb Assembly 20 Figure 12 Curb Mounting 21 Figure 13 Upright Stand Detail B 350 22 Figure 14 Upright Stand Detail B 650 B 3000 22 Figure 15 Stand Shim B 1000 3000 23 Figure 16 Upright Stand Mounting Detail 23 Figure 17 Leg Mounting Holes B 350 B 3000 24 Figure 18 Stud Positioning 25 Figure 19 Leg Bolt Detail u u 25 Figure 20 Indoor Suspension 350 27 Figure 21 Indoor Suspension B 650 and 1000 28 Figure 22 Filter Section Support Assembly 42 Figure 23 Filter Section Installation on Horizontal Air Handler 650 B 3000 43 Figure 24 Inlet Hood Assembly 350 44 Figure 25 Inlet Hood Positioning
13. 64 Figure 26 Motorized Discharge Damper B 350 B 3000 66 Figure 27 Motorized Inlet Damper B 350 B 1000 67 Figure 28 Motorized Inlet Damper B 2000 and B 3000 68 Figure 29 Three Way Discharge Head 350 23000 eere ette HE thi aetna 69 Figure 30 Splash 70 Figure 31 Hole Location B 350 B 3000 71 Figure 32 ANSI FM XL Compliant Manifolds B 350 75 Figure 33 ANSI Compliant Manifold B 650 B 3000 75 Figure 34 FM Compliant Manifold B 650 B 3000 76 Figure 35 XL Compliant Manifold B 650 B 3000 76 Figure 36 Plug Tapping 350 77 Figure 37 Plug Tapping B 650 3000 77 Figure 38 Wiring Diagram Key 80 Figure 39 Basic Remote Wiring Diagram 350 81 Figure 40 Standard Discharge Control Remote SDC Wiring Diagram B 350 sese 82 Figure 41 Deluxe Temperature Control Remote DTC Wiring Diagram B 350 83 Figure 42 Basic Remote Wiring Diagram B 650 B 3000 84 Figure 43 Standard Discharge Control Remote SDC Wiring Diagram B 650 3000 85 Figure 44 Deluxe Temperature Control Remote DTC Wiring Diagram B 650 3000
14. Temperature rise at this CFM is less than the maximum temperature rise Heat output is based on heater operation 100 outside air mode gBA is measured at 10 from unducted discharge Maximum Inlet Gas Pressure ANSI Compliant Manifold 14 in wc 34 9 mbar FM and XL Compliant Manifold 5 psi 344 7 mbar 15 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL Table 9 Estimated Pressure Drop of Accessory Components 16 of 149 Airflow Range Inlet Hood with Filters Filter Section Inlet Hood nih intet Hood with Model Moisture Limiters Bird Screen CFM m3 n in wc mbar in wc mbar in wc mbar in wc mbar B 350 1 000 2 000 1 700 3 400 0 25 0 62 0 25 0 62 0 05 0 12 3 000 4 000 5 100 6 800 0 40 1 0 0 50 1 25 0 05 0 12 B 650 4 000 6 000 6 800 10 200 0 25 0 62 0 25 0 62 0 10 0 25 0 05 0 12 7 000 10 000 11 400 17 000 0 40 1 0 0 50 1 25 0 10 0 25 0 05 0 12 B 1000 7 000 10 000 11 400 17 000 0 25 0 62 0 25 0 62 0 10 0 25 0 05 0 12 11 000 14 000 18 700 23 800 0 40 1 0 0 50 1 25 0 10 0 25 0 05 0 12 B 2000 12 000 16 000 20 400 27 200 0 25 0 62 0 25 0 62 0 10 0 25 0 05 0 12 18 000 25 000 30 600 42 500 0 40 1 0 0 50 1 25 0 10 0 25 0 05 0 12 B 3000 25 000 30 000 42 500 51 000 0 35 0 87 0 75 1 87 0 10 0 25 0 05 0 12 32 500 40 000 55 200 68 000 0 40 1 0 0 85 2 12 0 10 0 25 0 05
15. FIGURE 16 Upright Stand Mounting Detail Air Handler Non Control Enclosure Side oy Air Handler Control Enclosure Side B Model Part Number Height A Weight Ibs Weight kg 30 0 B 350 94000 3 762 75 0 34 0 53 0 B 650 and 91000 2 134 6 160 0 72 6 B 1000 72 0 94000 7 182 9 190 0 86 2 72 0 B 2000 92000 3 182 9 230 0 104 3 72 0 B 3000 93000 3 182 9 300 0 136 1 23 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 9 LEGS A WARNING Crush Hazard Use proper lifting equipment and practices Falling Hazard Use proper safety equipment and prac tices to avoid falling Use proper lifting practices and equip ment Cut Pinch Hazard Wear protective gear during installation operation and service Severe Injury Hazard Equipment and accessories are heavy Edges are sharp Failure to follow these instructions can result in death injury or property damage Part numbers that end with a W indicate that the part can be ordered with either an unpainted galvanized finish or an acrylic modified alkyd enamel finish To order with a galvanized finish do not include the W at the end of the part number to order with a painted finish include the W at the end of the part number 9 1 Leg Mounting Legs can be used when mounting an air handler ona concrete slab or directly on the floor Legs are avai
16. LOW PRES HI PRES SWITCH HI TEMP LIMIT HLS 0 3 8 C o RM7890A SWITCH CLIP JR2 W C 1 4 W C NO 8A C NC 9 9A 9B9C O O O MANUAL RESET iecur CLOGGED FILTER RM7897C CLIP JR2 PRIMARY IGNITION CONTROL FOR B 2000 AND B 3000 NC BURNER LOCKOUT MOTOR THERMOSTAT TH8110R 1008 U THERMOSTAT CONTROL RELAY MOTOR STARTER FAN ON PILOT VALVE IGNITION TRANSFORMER IGNITION CONTROL BURNER ON SSOV O O 20VA SAFETY SHUTOFF VALVE lt RT 24VAC X2 46 z TCA A1044C 4 5 6 7 40 941 48 M9 o ps TEMPERATURE MONITOR TS144C TEMPERATURE SELECTOR T244A GROUND SHIELDED CABLE AT CONTROL PANEL WIRE CONNECTIONS REMOTE TO MAIN PANEL 1 2 3A 4 7 12 24 25 40 41 SHIELD 86 of 149 T1 TRANSFORMER PRIMARY CONNECTION H1 460 USE 1 6 AMP BREAKER H2 230 USE 3 0 AMP BREAKER H3 208 USE 4 0 AMP BREAKER H4 COMMON TEMP CONTROL AMPLIFIER MODULATING REGULATING VALVE MRV FIGURE 45 BMS Ready Control MUA Style B 3 PHASE ONLY puc BREAKER H4 H H3 xi x 120vac n rco DISCONNECT 1 TI BREAKER 3 AMP s M1 4 HITEMP LIMIT TAS 3 O URNER R2 7 Q MANUAL RESET IGNITION CONTROL LOW PRES SWITCH C NO Doc HI PRES SWITCH C NC TES 9 2 a x Ei gt lt amp 8 z 9 amp a z
17. B 2000 B 3000 AM AM Control Wiring 96 of 149 Damper Switch 48 MODULATING REGULATING VALVE REDUCED FLOW SWITCH THIS REPLACES THE MRV WIRING LOCATED ON THE MAIN DIAGRAM DAMPER SWITCH CHANGES WHEN UNIT RECIRCULATING DAMPER IS IN THE FULL RECIRCULATING POSITION ADJUSTMENTS 1 MAKE NORMAL HIGH AND LOW FIRE ADJUSTMENTS WITH SWITCH CLOSED AS OUTLINED IN THE MANUAL 2 THE REDUCED HIGH FIRE SETTING IS PRESET AT THE FACTORY AND MUST NOT BE ADJUSTED S1 S3 Damper Switch 48 MODULATING REGULATING VALVE REDUCED FLOW SWITCH THIS REPLACES THE MRV WIRING LOCATED ON THE MAIN DIAGRAM DAMPER SWITCH CHANGES WHEN UNIT RECIRCULATING DAMPER IS IN THE FULL RECIRCULATING POSITION ADJUSTMENTS 1 MAKE NORMAL HIGH AND LOW FIRE ADJUSTMENTS WITH SWITCH CLOSED AS OUTLINED IN THE MANUAL 2 THE REDUCED HIGH FIRE SETTING IS PRESET AT THE FACTORY AND MUST NOT BE ADJUSTED SECTION 17 ELECTRICAL 17 7 Carbon Dioxide Interlocks All air handlers that recirculate air from the heated space require either a control to limit the temperature rise in proportion to the amount of outdoor air or the use of a room carbon dioxide sensor The carbon dioxide sensor is field provided and set to maintain a CO2 concentration below 5 000 ppm For the additional wiring to accommodate this requirement for the FR and MUA style air handler See Page 97 Figure 56 For the additional wiring to accommodate this requirement f
18. See Page 118 Section 19 4 Electric Components Check for physical damage on any of the electric components and verify all electrical connections are secure Ensure equipment is properly grounded See Page 118 Section 19 3 and Page 132 Figure 86 Temperature Sensors Calibrate space outdoor air and discharge air sensors as required See Page 118 Section 19 2 3 20 5 Burner An annual inspection of the burner and components must be made to ensure proper and safe operation For the most part the burner is self cleaning However if the application is extremely dirty or dusty it may become neces sary to periodically clean the burner Inspect and clean the burner in accor dance with the following recommended procedures 1 To avoid damaging the valves disconnect the burner piping from the manifold at the union and cover the exposed end of the manifold See Page 75 Figure 32 through Page 76 Figure 35 2 Unscrew the UV scanner from the side of the burner and clean the lens with a soft cloth See Page 79 Section 175 4 3 Remove the ignition cable from the igniter on the side of the burner and then remove the spark igniter Clean the igniter contacts with a wire brush Set the gap to 0 078 2 0 mm 4 Inspect each of the stainless steel mixing plates to see that all of the air holes are free of debris Clean with a wire brush as necessary See Page 129 Figure 82 through Page 129 Figure 84 5 The b
19. NOTE Dimension clearance to clear blower mounting bolts 73 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 16 GAS PIPING AWARNING Explosion Hazard Leak test all components of gas piping before operation Gas can leak if piping is not installed properly Do not high pressure test gas piping with air handler connected Failure to follow these instructions can result in death injury or property damage 16 1 Gas Manifolds All gas piping to the air handler must comply with United States Refer to NFPA 54 ANSI 2223 1 latest revision National Fuel Gas Code Canada Refer to CSA B149 1 latest revision Natural Gas and Propane Installation Code The air handlers are available with three gas manifold options American National Standards Institute ANSI compliant manifold See Page 75 Figure 32 for B 350 See Page 75 Figure 33 for B 650 B 3000 Factory Mutual FM compliant manifold See Page 75 Figure 32 for B 350 See Page 76 Figure 34 for B 650 B 3000 e XL compliant manifold See Page 75 Figure 32 for B 350 See Page 76 Figure 35 for B 650 B 3000 16 2 Gas Piping and Pressures The air handler is equipped with a gas manifold suitable for connection to supply pressure of up to e 14 wc maximum 34 9 mbar B 350 B 3000 with ANSI compliant manifold 5 p s i maximum B 350 B 3000 with FM or XL compliant manifold When gas supply exceeds the above list
20. Part Number Side Cover ML 13505099 Outer Support Rail 13505098 TEK Screw 13404 10 24 x 1 2 Bolt 27000 10 24 Nut 26098 53 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL 12 3 Inlet Hood Assembly B 2000 and B 3000 Inlet Hood with Permanent Inlet Hood without filters Inlet Hood with Medel Aluminum Mesh Filters with Birdscreen Moisture Limiter B 2000 13205060 Galvanized 13205058 Galvanized 13205062 Galvanized Description 13205061 Painted 13205059 Painted 13205063 Painted B 3000 13305060 Galvanized 13305058 Galvanized 13305062 Galvanized 13305061 Painted 13305059 Painted 13305063 Painted Mio Quantity Quantity Quantity Double Sided Filter Rails 13X05066 4 4 N A Top Inner Filter Rail 13X05068 1 1 1 Bottom Rail 13X05072 1 1 N A Top Back Panel 1 13X05075 1 1 1 Top Middle Panel 2 13X05076 1 1 1 Top Front Panel 3 13X05077 1 1 N A Left Side Panel 1 13X05080 1 1 1 Right Side Panel 1 13X05081 1 1 1 Left Side Panel 2 13X05082 1 1 1 Right Side Panel 2 13X05083 1 1 1 Left Side Panel 3 13X05084 1 1 1 Right Side Panel 3 13X05085 1 1 1 Upright Mount 13X05090 2 2 2 Horizontal Mount 13X05091 2 B 2000 6 B 3000 2 2 Drip Rail Upper Right 13305092 1 1 1 Drip Rail Upper Left 13305093 1 1 1 Drip Rail Lower Righ
21. Ruptured main or balancing diaphragm No voltage to the amplifier Short in modulator coil circuit Short in T8144 circuit Faulty amplifier Incorrect by pass metering valve adjustment Excessive negative burner pressure Faulty amplifier Short in T244 or TS244 TD244 circuit Incorrect space temperature calibration Improper TS144 location Incorrect discharge air temperature calibrations Foreign material holding valve open Plunger jammed Open circuit in TS144 Inlet pressure too low Incorrect outlet pressure adjustment Faulty amplifier Open circuit in T244 to TS244 TD244 Incorrect space temperature calibration Short in modulator coil circuit Incorrect maximum discharge air temperature setting A1044 Incorrect minimum discharge air temperature setting 1044 Insufficient burner capacity Incorrect space temperature calibration Control circuits external to the Series 44 can cause burner malfunction Always check manual valve to be certain gas is on and check limit controls for normal operation 142 of 149 FIELD TEST 1 Arrow on side of valve should point in direction of gas flow 2 Remove wires connected to amplifier terminals 6 amp 7 and mea sure resistance MR212 60 80 ohms M611 45 55 ohms 3 Inspect plunger should be installed per Maxitrol product infor mation sheet and operate freely in solenoid sleeve 4 Disassemble valve for inspecti
22. Set BURNER switch to ON TO OPERATE AS VENTILATOR 1 Stop Read all safety instructions on this information sheet Turn on electric to the air handler Set FAN switch to ON TO TURN OFF THE AIR HANDLER 1 If equipped set the thermostat to the lowest setting Set BURNER switch to Set FAN switch to OFF IF THE AIR HANDLER WILL NOT OPERATE FOLLOW THESE INSTRUCTIONS TO HELP ENSURE YOUR SAFETY 1 If equipped set the thermostat to the lowest setting 2 Set BURNER switch to OFF 3 Set FAN switch to OFF 4 Turn off electric to the air handler 5 Close the manual gas valve in the air handler supply line 6 Call your registered contractor qualified in the installation and service of gas fired heating equipment Bananza 1100 Seven Mile Road NW Comstock Park MI 49321 Telephone 1 616 726 8800 Fax 1 616 726 8807 Toll Free 800 255 3416 Fire Hazard Keep all flammable objects liquids and vapors the required clearances to combustibles away from equipment Some objects can catch fire or explode when placed close to equipment Failure to follow these instructions can result in death injury or property damage CLEARANCES TO COMBUSTIBLES Clearances to combustibles for Models B 350 B 3000 are 12 30 5 cm on the control enclosure side and 6 15 2 cm on all other surfaces Clearances to combustibles do not denote clearances for accessibility Minimum clearance for access
23. 3 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 3 B 2000 and B 3000 Item Part Number Description 1 91070001 Label Shock Hazard 91070002 Label Severe Injury Hazard 91070003 Label Crush Hazard 91070004 Label Fire Hazard 91070005 Label Falling Hazard 91070006 Label Burn Hazard 19205 Label B Series 91010100 Label Manual Location 19030 Label Recommended Entry 91010427 Label Vent to Outdoors 2 AIR FLOW AIR FLOW LOCATED OVER THE REGULATOR VENTS CO NI Q OC PO 9 BOTTOM CENTE 955 ONSURINCHRAS BY CUNTROE ENCLOSURE 91010431 Label Improper Installation CLOSURE ON SHRINK WRAP 91070015 Label Proposition 65 10 LOCATED OVER THE REGULATOR VENTS LOCATED AT THE BOTTOM CENTER OF THE CONTROL ENCLOSURE 4 of 149 SECTION 1 AiR HANDLER SAFETY FIGURE 4 B Series Interior SPLASH PLATE MOUNTED ON CONTROL ENCLOSURE 13 PLACE INSIDE ITEM 9 13 PLACE INSIDE ITEM 9 9 BLOWER B 350 MOUNT ON ENCL FLOOR UNDER VFD AUX MOTOR STARTER 8 14 B 650 B 3000 Q CONTROL ENCLOSURE DOOR PANEL 5 GROUND LUG ON BURNER RS 4 B 350 CONTROL ENCLOSURE DOOR HIGH TEMP LIMIT SWITCH DISCHARGE SENSOR SAFETY REMOTE BOX REMOTEA REMOTE BOX 12x16 INTERNAL SHUTOF T X jet TERMINA
24. CO Sensor e H Operation Damper Is Forced Into 10096 Outside Air Until CR7 Is Energized By The CO2 Sensor Allowing The Damper To Modulate When The CO2 Sensor Reaches The Set Point The Sensor Contacts Will Open Deenergizing CR7 CO2 Sensor Wiring By Others Models B 2000 and B 3000 Part Number 13205106 Description CO2 Sensor Interlock 17 8 Control Options 17 8 1 Mild Weather Outside Air Stat This option is designed to turn the burner off when the incoming outside air is at or above the temperature setpoint The blower is allowed to run for continued ventilation The mild weather outside air stat is located in the control enclosure It has an adjustable setting between 20 F 29 C and 100 F 38 C OA STAT MOUNTED AT PROFILE PLATE 9A TO TEST SET DIAL TO MAX TEMP UNIT OPERATES SET DIAL TO MIN TEMP UNIT SHUTS DOWN e e BLUE SET AT 85 F 29 C Part Number Models Description Mild Weather Outside Air Stat 80930 All Models 97 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL 17 8 2 Low Temperature Limit with Override Timer FIGURE 60 CO Sensor Interlock for AM and VAV This option is designed to turn the unit off when air is CHO SA discharged below the temperature setpoint for a 62 0 H din in excess of timer setpoint The low PRESSURE perature limit switch is located in the air handler s D
25. Models All Models Part Number 17854 Description Propane Switch Kit SECTION 17 ELECTRICAL 178 8 Auxiliary Relay An auxiliary relay may be added to an air handler for either an interlock or a customer defined purpose Refer to the option sheet supplied with the air handler to indicate whether the relay is wired for an intended purpose or left unwired for a future interface Each relay will be double pole double throw DPDT type Maximum switching capacity on the normally open contact is 8A and for the booth light relay P N 80916 2 15A 12 2 BURNER ON INTERLOCK 4 2 FAN INTERLOCK BOOTH LIGHT ON NOT WIRED Models All Models All Models All Models All Models Part Number 80916 80916 1 80916 2 80916 3 17 8 9 Smoke Detector A smoke detector interlock allows for the air handler to operate based on signal input from the fire alarm FROM 120V 1AQ BREAKER i i 1 Description Aux Relay Fan On Aux Relay Burner On Aux Relay Booth Light On Aux Relay Not Wired AIR HANDLER TERMINALS 1 AND 1A TO BE WIRED TO FIRE ALARM N C CONTACTS BY OTHERS ALL OTHER WIRING TO BE PROVIDED BY OTHERS Models All Models Part Number 25214K Description Smoke Detector 101 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL 17 8 10 Single Point Connection When a variable frequency drive or au
26. 13 5 35 6144 5 118 7 in 4 000 32 3 60 3 28 3 13 8 7 6 82 27 0 1117 311 5 8 0 15 8 1 8 3 1 35 2 30 0 25 0 38 4 7 5 14 17 5 7 4 82 0 153 2 71 9 35 1 19 3 20 8 68 6 297 9 3 8 20 3 40 1 4 6 7 9 89 4 76 2 63 5 97 5 19 0 35 6 44 5 18 7 B 350 11 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 6 B 350 Horizontal Model Dimensions Filter Access X G INLET HOOD FILTER SECTION GC 0H Customer Supplied OPTIONAL OPTIONAL Duct Location See page 73 Table 11 Filter Access L Table 3 B 350 Weights Inlet Splash Filter Roof Discharge Suspension Legs Model Air Handler Stand Hood Plate Section Curb Head Dampers Kit each Skid B 350 Ib 450 75 60 20 100 75 50 40 13 26 50 kg 204 1 34 0 27 2 9 1 45 4 34 22 7 18 1 5 9 11 8 22 7 Table 4 Motor Weights Size HP 2 3 kW 1 5 2 2 Ib 58 69 opp kg 26 3 313 Ib 90 135 kg 40 8 612 12 of 149 SECTION 5 SPECIFICATIONS FIGURE 7 B 650 B 1000 B 2000 and B 3000 Upright Model Dimensions Lifting Lug One Each Corner Customer Supplied Duct Location See Page 73 Table 11
27. Install properly 2 Prove the power source 3 Tighten connections or replace wiring 4 If modulating voltages are obtained Check TS114 circuit for shorts Replace TS114 if necessary 5 If items 2 3 and 4 check out and modulating voltages are still not obtained amplifier may be assumed faulty Replace 6 Replace modulator head if not approximately 45 55 ohms for M611 Valve and 60 80 ohms for MR212 Valve 7 Clean or replace plunger if necessary Install per Maxitrol product information sheet 8 Adjust to proper minimum fire 9 If reading is greater than 1 0 in wc negative pressure check for clogged filters or other inlet air restrictions Consult factory for other solutions 10 Correct wiring if shorts exist 11 If modulating voltages are obtained check TS114 TS10765 for oper circuits Replace TS114 TS10765 12 Correct the wiring 13 Clean seat Clean valve or replace if necessary 14 Clean or if necessary replace plunger 15 Increase inlet pressure if possible 16 See valve adjustments in Section 19 5 17 If flame stabilizes adjust sensitivity control to maintain an even flame 18 If the flame is steady throughout the entire modulating range the TS114 must be moved 19 If smooth operation results isolate effected wiring from source of induced voltage 20 If erratic or unstable DC voltages are obtained throughout the modulating range the amplifier may be assumed faulty Replace If erratic o
28. SECTION 21 Replacement Parts 131 SECTION 22 Troubleshooting 136 22 1 Checks nnie inse dera 137 22 2 Motor and Blower 137 22 9 i cop ertt be ete bor derer 138 22 4 Temperature Controls 139 22 5 A1014 Amplifier Field Checklist 140 22 6 A44 Amplifier Field Service Checklist 142 SECTION 23 BANANZA B Series Start Up Procedures 145 SECTION 24 The BANANZA B Series Warranty 148 2015 Roberts Gordon LLC All rights reserved No part of this work covered by the copyrights herein may be reproduced or copied in any form or by any means graphic electronic or mechanical including Printed in photocopying recording taping or information storage and retrieval systems without the i the U S A written permission of Roberts Gordon LLC TABLE OF FIGURES Figure 1 B 350 si isd cee L EAA el 3 Figure 2 B 650 and 1000 3 Figure 3 B 2000 and 3000 4 Figure 4 B Series Interior a 5 Figure 5 B 350 Upright Model Dimensions 11 Figure 6 B 350 Horizontal Model Dimensions
29. including photocopying recording taping or information storage and retrieval systems without written permission of Roberts Gordon LLC 2015 Roberts Gordon LLC www bananza com P N 91040116 Rev C
30. remote panel will be found inside the air handler Larger accessories i e legs stand filter section inlet hood may either ship with the air handler or separately Check the bill of lading for information If the air handler must be temporarily stored i e job site is not ready for installation of the air handler the air handler should be set on 4 x 4 10 cm x 10 cm pieces of timber on the ground in a protected area Cover the air handler to protect it from the environment Bananza will not be held responsible for any damages that may occur from outdoor storage 1 3 Safety Labels and Their Placement 1 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL Product safety signs or labels should be replaced by product user if they are no longer legible Please contact Bananza or your BANANZA independent distributor to obtain replacement signs or labels See Page 3 Figure 1 through Page 4 Figure 3 1 4 California Proposition 65 In accordance with California Proposition 65 require ments a warning label must be placed in a highly visible location on the outside of the equipment i e near equipment serial plate See label placement drawing on Page 3 Figure 1 through Page 4 Figure 3 for label location Avoid placing labels on areas with extreme heat cold corrosive chemicals or other elements To order additional labels please contact Bananza or your BANANZA independent distributor 2 of 149 SECTION 1
31. the gas setup is completed All taps and instruments must be removed and all caps and plugs must be replaced Please leave all manuals and a copy of this sheet with the air handler Technician s Name Signature Date SECTION 24 THE BANANZA B SERIES WARRANTY BANANZA WILL PAY FOR Within 24 months from date of purchase by buyer or 27 months from date of shipment by Bananza whichever occurs first replacement parts will be provided free of charge for any part of the product which fails due to a manufacturing or material defect Bananza will require the part in question to be returned to the factory Bananza will at its sole discretion repair or replace after determining the nature of the defect and disposition of part in question BANANZA Replacement Parts are warranted for a period of 12 months from date of shipment from Bananza or the remaining BANANZA B Series warranty BANANZA WILL NOT PAY FOR Service trips service calls and labor charges Shipment of replacement parts Claims where the total price of the goods have not been paid Damage due to Improper installation operation or maintenance Misuse abuse neglect or modification of the BANANZA B Series in any way Use of the BANANZA B Series for other than its intended purpose Incorrect gas or electrical supply accident fire floods acts of God war terrorism or other casualty Improper service use of replacement parts
32. the provided shims one bottom and two sides to reduce the size of the gap between the air handler and the filter section Re install the hardware that was removed through the filter section and the shims to mate the air handler to the filter section Hardware must be torqued to recommended specifications on Page 9 Table 1 Caulk provided by others the sides roof and bottom seams between the filter section and air handler Apply 3 zip tape provided by others over the roof seam Install the filters in proper orientation See Page 130 Section 20 6 and attach the filter access door Secure filter access door in the closed position 11 5 2 Filter Section Installation B 650 B 3000 For installation directly onto the inlet of the air handler foam tape provided by others must be applied to the air handler sides and bottom To place the filter section the top flange of the filter section will slide up under the top panel drip edge of the air handler Refer to Page 43 Figure 23 All hardware in this top panel drip edge will need to be removed prior to placing the filter section on the air handler Attach the sides of the filter section to the factory installed riv nuts on the inlet of the air handler with the supplied hardware Re install the hardware from the top panel of the air handler through the top panel and top flange of the filter section Additional TEK screws may be used along the bottom flange of the filter section to
33. 000 22 100 B 1000 10 10 10 10 15 67 69 CF 1 404 1 123 7 175 1 25 82 14 000 23 800 1000 10 10 15 15 15 69 CF CF 1 512 1 210 7 175 1 25 32 12 000 20 400 B 2000 75 75 75 75 75 66 70 73 1 296 1 037 9 22 5 1 5 38 14 000 23 800 B 2000 10 10 10 10 10 69 70 73 1 512 1 210 9 22 5 1 5 38 16 000 27200 B 2000 10 10 10 10 10 70 72 76 1 728 1 382 9 22 5 1 5 38 18 000 30 600 B 2000 15 15 15 15 15 70 74 77 1 944 1 555 9 22 5 1 5 38 20 000 34 000 B 2000 15 15 15 15 15 70 74 77 2 160 1 728 9 22 5 1 5 38 22 000 37400 B 2000 20 20 20 20 20 71 74 77 2 376 1 901 9 22 5 1 5 38 25 000 42 500 B 2000 20 20 20 20 20 72 75 77 2 700 2 160 9 22 5 1 5 38 25 000 42 500 B 3000 15 15 15 15 15 70 72 74 2 700 2 160 11 275 2 0 51 27 500 46 700 B 3000 15 15 15 15 15 71 73 75 2 970 2 376 11 275 2 0 51 30 000 51 000 B 3000 20 20 20 25 25 73 75 76 3 240 2 592 11 275 2 0 51 32 500 55 200 B 3000 20 20 20 20 25 75 76 77 3 510 2 808 11 275 2 0 51 35 000 59 500 B 3000 20 25 25 25 25 77 77 79 3 780 3 024 11 275 2 0 51 37 500 63 700 3000 25 25 30 30 30 78 79 79 4 050 3 240 11 27 5 2 0 51 40 000 68 000 B 3000 30 30 30 80 4 320 3 456 11 27 5 2 0 51
34. 02 50 D4 01 1 REDUCED FLOW SWITCH E1 01 VOLTS E2 01 AMP H1 03 10 H1 05 11 Part Number Description Models VAV VAV Control Wiring B 2000 and B 3000 91 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 50 BMS Ready Control for VAV Style B 650 and B 1000 VFD TERMINALS VARIABLE AIR VOLUME CONTROLLED BY THE DDC P N VAV DDC UP TO 25HP BOHP AND UP 52 53 50 59 DECEL 52 o ACCEL DECEL ACCEL 53 CONTACTS WIRED BY OTHERS TO FUSABLE DISCONNECT PHOTOHELIC PNEUMATIC DIAGRAM PROFILE PLATE PHOTOHELIC 1 LOCATED INSIDE CONTROL ENCLOSURE PRESSURE CONTROLS DIFFERENTIAL PRESSURE ACROSS BURNER PRESET AT 0 75 LOW AND 0 90 HIGH NOTE MOTOR STARTER OVERLOAD AND M1 AUXILIARY CONTACT IS REPLACED MODU WITH RM1 RELAY LATING DAMPER MOTOR PROFILE PLATE BURNER VED PROGRAM PARAMTERS 25HP OR LESS C1 01 20 ACCEL TIME SEC MODULATING C1 02 20 DECEL TIME SEC REGULATING d2 02 5096 MINIMUM HZ 50 30HZ VALVE e H1 03 10 H1 04 11 H1 05 0F H1 07 0F V1000 ONLY L2 01 1 L5 01 5 VED PROGRAM PARAMTERS 30HP OR MORE B1 02 1 1 01 25 C1 02 25 D2 02 50 D4 01 1 E1 01 VOLTS E2 01 AMP H1 03 10 H1 05 11 REDUCED FLOW SWITCH Part Number Description Models VAV DDC VAV DDC Control Wiring B 650 and B 1000 92 of 149 SECTION 17 ELECTRICAL FIGURE 51 BMS Ready Control for VAV Style B 2000 B 3000 VA
35. 15 2 226 8 111 8 78 7 126 2 134 1 182 9 83 8 5 1 2 8 132 1 1 0 89 5 26 4 89 5 B 3000 in 1 5 39 30 5 60 86 9 44 0 310 641 568 72 0 33 0 2 0 14 664 0 4 N A 40 8 13 6 40 8 3 8 9 9 775 15 2 220 7 111 8 78 7 162 8 144 3 182 9 83 8 5 1 2 8 1687 1 0 103 5 34 5 103 5 cc Stand Model M Height in 145 3 53 0 B 650 cm 369 1 134 6 1000 in 164 3 72 0 4173 182 9 13 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 8 B 650 B 1000 B 2000 and B 3000 Horizontal Model Dimensions m Ho T 4 O 1 HH Filter Access GC w Z B Customer Supplied INLET HOOD FILTER SECTION Duct Location OPTIONAL OPTIONAL See Page 78 Table 11 Lifting Lug One Each Corner Filter Access 3 1 Q er Support Brace Table 6 B 650 B 1000 B 2000 and B 3000 Weights Splash Filter Inlet Hood Roof Legs Suspension Model Air Handler Stand Plate Section Filtered Moisture Limiter Curb Head each K
36. 20 x 1 2 Bolt Hex Head Cap Screw 20483 8 8 8 1 4 20 Nut Flange 20630 8 8 8 1 4 Flat Washer 20503 8 8 8 41 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL 11 4 1 Filter Section Support Assembly Installation B 650 B 3000 It is best to assemble the support base and support arms to the filter section prior to attaching the filter section to the air handler but can also be assembled to a previously installed filter section Refer to Page 42 Figure 22 FIGURE 22 Filter Section Support Assembly Support Base Support Leg Su Leg Left Side Es Right Side 2 Cross Brace Ja Support Extension y Extension Arm Left Side icm FILTER SECTION 6668800 o o 1 CONTRACTOR INSTALLER MUST MAKE APPROPRIATE ALLOWANCES FOR DUCT CONNECTIONS 2 SUPPORT LEG IS REQUIRED WHEN A FILTER SECTION AND INLET HOOD ARE ORDERED 3 SUPPORT LEG IS PROVIDED FOR USE WITH STANDARD 19 50 cm ROOF CURB SUPPORT LEG FOR USE WITH STANDARD 46 116 8 cm LEGS PROVIDED BY OTHERS Led 54 Model Part Number Weight Ibs kg B 650 and B 1000 77412 001 16 73 B 2000 77412 002 18 8 2 B 3000 77412 003 pop 20 9 1 Step 1 Place the support base P N 7740800X up to the bottom of the filter section towards the
37. 30 4 42 6 28 1 39 3 14 0 19 7 10 6 14 8 40 3 56 4 15 11 2 42 4 59 4 39 3 55 0 19 6 275 16 8 23 5 20 14 9 51 4 72 0 49 3 69 0 24 6 34 5 19 8 277 25 18 6 66 4 93 0 61 3 85 8 30 6 42 9 24 5 34 3 30 22 4 78 4 109 8 73 3 102 6 36 6 51 3 29 6 41 4 106 of 149 SECTION 17 ELECTRICAL FIGURE 69 Single Exhaust Starter SINGLE EXHAUST STARTER P N 061XX 3C M2 OL gt 9 4 2 EXHAUST 1 FIGURE 70 Two Exhaust Starter TWO EXHAUST STARTERS 1 DROPS OUT IN CURE P N 061XX EXHAUST 1 EXHAUST 2 TR SEQUENCE 1 TR2 2 TR3 3 TR1 SET OVERRIDE TIME TO 60 SECONDS 107 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 18 SEQUENCE OF OPERATION A DANGER Electrical Shock Hazard Disconnect electric before service More than one disconnect switch may be required to disconnect electric from equipment Equipment must be properly grounded Failure to follow these instructions can result in death or electrical shock AWARNING Carbon Monoxide Hazard Do not recirculate air from the heated space over burner Air supply to burner must be from outside Failure to follow these instructions can result in death or injury 18 1 Air Handler Configuration Based on the air handler application the air handler may be configured in any of the four styles described in
38. 8800 Fax 1 616 726 8807 Toll Free 800 255 3416 www bananza com Bananza s liability and your exclusive remedy under this warranty or any implied warranty including the implied warranties of merchantability and fitness for a particular purpose is limited to providing replacement parts during the term of this warranty Some jurisdictions do not allow limitations on how long an implied warranty lasts so this limitation may not apply to you There are no rights warranties or conditions expressed or implied statutory or otherwise other than those contained in this warranty Bananza shall in no event be responsible for incidental or consequential damages or incur liability for damages in excess of the amount paid by you for the BANANZA B Series Some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages so this limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from jurisdiction to jurisdiction Bananza shall not be responsible for failure to perform under the terms of this warranty if caused by circumstances out of its control including but not limited to war fire flood strike government or court orders acts of God terrorism unavailability of supplies parts or power No person is authorized to assume for Bananza any other warranty obligation or liability LIMITATIONS ON AUTHORITY OF REPRESEN
39. 90 17 7 Carbon Dioxide Interlocks 97 17 8 Control Options a 97 17 9 Optional Exhaust Motor Starters Variable Frequency Drives eese 103 17 10 Disconnect Fuse Sizing 106 SECTION 18 Sequence of Operation 108 18 1 Air Handler Configuration 108 18 2 HVAC Remote Panels and Panel Options 110 18 3 Basic Air Handler Sequence of Operation 112 SECTION 19 Start up 116 19 1 Installation of Recirculating Air Handler 117 19 2 Mechanical 117 19 9 Electrical tet e e 118 19 4 etel icc deae dite Med cens 118 19 5 Gas Piping and Initial Pressure Settings 119 19 6 Safety Shut Off Valve 121 19 7 Temperature Control System Calibration 121 SECTION 20 Maintenancoe 124 20 1 General ene eic eet 125 20 2 Unit Exterior n 125 20 3 Blower Section a 125 20 4 Manifold and Controls 128 200 B rnet aad ie ite nine 128 20 6 Optional 130
40. AiR HANDLER SAFETY Part Number Description 1 91070001 Label Shock Hazard 91070002 Label Severe Injury Hazard 7 91070003 Label Crush Hazard 91070004 Label Fire Hazard 91070005 Label Falling Hazard 91070006 Label Burn Hazard 19205 Label B Series 91010100 Label Manual Location 19030 Label Recommended Entry 8 ON SHRINK WRAP BY CONTROL ENCLOSURE 91010427 Label Vent to Outdoors 91010431 Label Improper Installation ON SHRINK WRAP 91070015 Label Proposition 65 1 5 Label Placement FIGURE 1 B 350 CO On A N CONTROL ENCLOSURE FIGURE 2 B 650 and B 1000 Part Number Description 91070001 Label Shock Hazard 91070002 Label Severe Injury Hazard 91070003 Label Crush Hazard 91070004 Label Fire Hazard 91070005 Label Falling Hazard 91070006 Label Burn Hazard 19205 Label B Series 91010100 Label Manual Location 19030 Label Recommended Entry 91010427 Label Vent to Outdoors 91010431 Label Improper Installation 91070015 Label Proposition 65 10 LOCATED OVER THE REGULATOR VENTS LOCATEDATTHE g BOTTOM CENTER li OFTHECONTROL ENCLOSURE f 3 ON SHRINK WRAP 9 21 2 N o a gt o N 28 ON SHRINK WRAP BY CONTROL ENCLOSURE E 10 LOCATED OVER THE REGULATOR VENTS LOCATED AT THE BOTTOM CENTER OFTHECONTROL ENCLOSURE 9
41. Galvanized 13205020 Galvanized Number 13205023 Painted 13205021 Painted Quantity Quantity Access Door 13205025 1 1 Right Panel 13205026 1 1 Left Panel 13205028 1 1 Top Bottom Panel 13205029 2 2 Filter Rail 13205030 5 5 Side Filter Rail 13205031 2 2 Screw 12 x 34 Washer HD 13404 64 64 Nut 4 20 Speed Grip 20499 3 3 Hinge Butt 3 x 3 Zinc 20500 2 2 1 4 Flat Washer 20503 3 3 Bolt 14 20 x 34 HHCS 20504 3 3 Bolt Retainer Pushnut 1 4 20505 3 3 3 8 Flatwasher 20515 14 14 3 8 16 x 1 Bolt Hex Grade 5 20517 14 14 10 24 KEPS Nut 20698 12 12 Permanent Aluminum Mesh Filter 20 x 25 x 1 20629 12 N A Disposable Polyester Filter 20 x 50 x 1 23628 N A 6 Bolt 10 24 x 34 HHCS 21699 6 6 10 24 x HMS Bolt 27000 6 6 Fastener Rivnut 3 8 16 91120106 14 14 Spacer Hinge Filter 13205032 8 8 Gasket Door Filter 13205035 11 11 B 3000 Filter Section Permanent Aluminum Mesh Filters Disposable Polyester Filters Description Part 13305022 Galvanized 13305020 Galvanized Number 13305023 Painted 13305021 Painted Quantity Quantity Access Door 13305025 1 1 Right Panel 13305026 1 1 Left Panel 13305028 1 1 Top Bottom Panel 13305029 2 2 Filter Rail 13305030 7 7 Side Filter Rail 13305031 2 2 Screw 12 x 34 Washer HD 13404 86 86 Nut 4 20 Speed Grip 20499 3 3 Hinge Butt 3 x 3 Zinc 20500 2 2 Flat Washer 20503 3 3 Bolt 14 20 x 34 HHCS 20504 3 3 Bolt Retainer Pushnut 1 4 20505 3 3 3 8 Flatwasher 20515 14 14 3 8 16 x 1
42. O LINE VOLTS IN LOAD SIDE OUT FIGURE 64 V 1000 1 Pot 10 25HP WIRES CONNECTED TO CONTROL PANEL 2 3C 35 SHIELDED X1 X2 X3 WITH REMOTE POT ONLY WIRES GOING INTO VFD MUST BE SHIELDED AND ONE END GROUNDED OPTIONAL WIRING REQUIRED FOR REMOTE POT 1 x2 x3 53 TIMER DELAY ON BREAK PRESET TO rL 4 T MINUTE RUN RELAY CURE RELAY 1 Pod LINE VOLTS IN LOAD SIDE OUT CURE RELAY 103 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 65 P7 1 Pot 30HP or More WIRES CONNECTED TO CONTROL PANEL 2 3C 35 SHIELDED X1 X2 X3 WITH REMOTE POT ONLY TIMER DELAY ON BREAK WIRES GOING INTO VFD MUST BE SHIELDED AND ONE END GROUNDED PRESET TO 1 MINUTE 6 H 123 eri RUN RELAY CURE RELAY g CURE RELAY LINE VOLTS IN LOAD SIDE OUT FIGURE 66 J 1000 VFD 7 5HP or Less with Photohelic LOCATED ON VFD PANEL INSIDE CONTROL ENCLOSURE 52 53 50 EXHAUST MOTOR S SUPPLIED DISCONNECT AND FUSING TIMER INCREASE OVERRIDE SET TO 60 SEC PHOTOHELIC LOCATED INSIDE SEPARATE REMOTE ENCLOSURE PHOTOHELIC LOW CONTROLS BOOTH PRESSURE PRESET AT 0 1 LOW AND 0 3 HIGH 104 of 149 SECTION 17 ELECTRICAL FIGURE 67 V 1000 VFD 10 to 25HP with Photohelic LOCATED ON VFD PANEL INSIDE CONTROL ENCLOSURE 52 53 50 EXHAUST MOTOR S TO CUSTOMER SUPPLIED DISCONNECT AND
43. Static Temperature Rise Pressure Manifold Size CFM m n Pressure in wc Pressure in wc Btu h x 1000 in wc mbar in NPT mm 0 0 2510 5010 75 1 00 0 0 50 1 00 NG LPG 1 000 1 700 B 350 2 2 2 2 2 62 66 70 97 76 7 175 0 75 19 2 000 3 400 B 350 2 2 2 2 2 60 66 70 194 151 7 175 0 75 19 3 000 5 100 B 350 3 3 3 3 3 60 65 70 292 227 7 175 0 75 19 4 000 6 800 B 350 3 3 3 3 3 62 65 70 389 302 7 175 0 75 19 4 000 6 800 B 650 3 3 3 3 3 59 65 69 432 346 7 175 1 0 25 5 000 8 500 B 650 3 3 3 3 3 58 63 68 540 432 7 175 1 0 25 6 000 10 200 B 650 5 5 5 5 5 58 62 67 648 518 7 175 1 0 25 7 000 11 400 B 650 5 5 5 5 5 59 62 66 756 605 7 175 1 0 25 8 000 13 600 B 650 5 5 5 5 5 60 63 66 800 691 7 175 1 0 25 9 000 15 300 B 650 75 75 75 75 75 61 64 67 800 778 7 175 1 0 25 10 000 17000 B 650 75 75 75 75 75 62 65 68 800 800 7 175 1 0 25 7 000 11 900 1000 5 5 5 5 5 59 62 66 756 605 7 175 1 25 32 8 000 13 600 1000 5 5 5 5 5 60 63 66 864 691 7 175 1 25 82 9 000 15 300 1000 75 75 75 75 75 61 64 67 972 778 7 175 1 25 82 10 000 17000 B 1000 75 75 75 75 75 62 65 68 1 080 864 7 175 1 25 82 11 000 18 700 B 1000 10 10 10 10 10 64 66 68 1 188 950 7 175 1 25 82 12 000 20 400 B 1000 10 10 10 10 10 66 68 69 1 296 1 037 7 175 1 25 82 13
44. TERMINALS CONTROL CIRCUIT BREAKER BRANCH CIRCUIT CONTACTOR o Olo 7 ocpoooo leooooloo BREAKER AUXILIARY CONTACT 269 S OVERLOAD CONTROL TRANSFORMER 132 of 149 SECTION 21 REPLACEMENT PARTS Table 28 Power Panel Voltage Description 350 28 3000 2 5 7 5 10 15 20 25 30HP Disconnect 08036 08040 08038 08041 Contactor 90600200 90600205 90600210 90600215 90600220 Aux Contact N A 90447000 Overload 90446010 90446025 90446035 90446040 90446045 90446050 90446055 208 3 60 Branch Circuit Breaker 91300500 Control Circuit Breaker 9030049
45. accordance to NFPA 70E latest revision when working with electrical components Thin sheet metal parts have sharp edges To prevent injury the use of work gloves is recommended Before installation check that the local distribution conditions nature of gas and pressure and adjustment of the appliance are compatible The equipment must be applied and operated under the general concepts of reasonable use and installed using the best building practices This piece of equipment is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision or instruction concerning use of the equipment by a person responsible for their safety Children should be supervised to ensure that they do not play with the equipment For additional copies of the Installation Operation and Service Manual please contact Bananza Gas fired equipment is not designed for use in atmospheres containing flammable vapors or dust or atmospheres containing chlorinated or halogenated hydrocarbons Recirculated room air may be hazardous if containing flammable solids liquids SECTION 1 AiR HANDLER SAFETY and gases explosive materials and or substances which may become toxic when exposed to heat i e refrigerants aerosols etc 1 1 Description of Operation This air handler is a direct gas fired fresh air piece of equipment It
46. amplifier and modulator valve Too low an Override Temperature setting Burner capacity may be insufficient FIELD TEST 1 Arrow on side of Valve should point in direction of gas flow 2 Check for 24VAC at amplifier terminals 7 amp 8 3 Inspect for loose or broken wires between amplifier terminals 1 amp 2 and TD114 terminals 1 amp 2 and TD114 terminals 1 amp 3 4 Connect test resistor as described in Preliminary Circuit Analysis in Max itrol product information sheet Follow procedure outlined 5 Check items 2 3 and 4 6 Measure resistance across modulator terminals with connecting wires detached 7 Inspect Plunger should be installed per diagrams in Maxitrol information sheet and operate freely in solenoid sleeve 8 See valve adjustments in Section 19 5 9 Measure manifold pressure as outlined in Section 19 4 10 Inspect for shorts at or between Amplifier terminals 1 amp 2 or TD114 termi nals 1 amp 3 11 Check TS114 TS10765 for open internal circuit Connect test resistor as described in Preliminary Circuit Analysis in Maxitrol product information sheet Follow procedure outlined 12 Inspect 13 Remove button plate and inspect valve and seat 14 Inspect Plunger should be smooth clean and operate freely in solenoid sleeve 15 Read pressure at inlet to modulating valve using a manometer with unit operating at full fire Pressure should be equal to the sum of outlet pressure setting
47. blower housing inside the air handler 17 5 2 Pressure Switches The low airflow velocity pressure switch monitors the airflow differential pressure across the burner When the airflow across the burner reaches the proper velocity volume for combustion the switch closes When the switch closes it permits the flame safeguard relay to begin ignition This switch is factory set at 0 32 in wc 0 8 mbar The high velocity pressure switch will open if the airflow across the burner reaches its maximum allowable limit This switch is factory set at 1 40 in wc 3 5 mbar The pressure switch is a safety device which cannot be field adjusted or tampered with 17 5 3 Gas Pressure Switches Gas pressure switches are standard on certain models FM compliant gas trains above 2 500 MBH and XL compliant gas trains and are also available as an option on the others The function of the gas pressure switches is to protect against insufficient lack of gas pressure and excessive pressure in the system On the low gas pressure switch side this switch opens its internal switch which shuts the burner down and prevents its operation due to insufficient gas pressure On the high gas pressure switch side its internal switch will open shutting down the burner due to excessive gas pressure passing through the gas train The settings of the gas pressure switches are field adjustable The one monitoring the incoming gas pressure is the low gas pres
48. combustible materials corrosive chemicals or halogenated hydrocarbons anywhere in the premises Halogenated Hydrocarbons are a family of chemical compounds characterized by the presence of halogen elements fluorine chlorine bromine etc These compounds are frequently used in refrigerants cleaning agents solvents etc If these compounds enter the air supply of the burner the life span of the air handler components will be greatly reduced The loca tion of the outside air supply must be carefully chosen to supply outside air free of these compounds to the burners whenever the presence of these compounds is suspect Warranty will be invalid if the air handler is exposed to halogenated hydrocar bons 2 3 National Standards and Applicable Codes All equipment must be installed in accordance with the latest revision of the applicable standards and national codes This refers also to the electric gas and venting installation Note Additional standards for installation in public garages aircraft hangars etc may be applicable 2 4 Required Equipment When lifting of the equipment is required the installing contractor is responsible for supplying or arranging for the appropriate lifting equipment so that the air handler and accessories may be placed in a safe manner The qualified installer or service technician is responsible for having the appropriate equipment for the safe installation and start up of a direct fired air
49. connection of ductwork In cases where flanges are not provided flat surfaces on the exterior skin of the air handler are provided to facilitate connection of ductwork 15 1 Inlet Duct Work Inlet duct work height and width must be no smaller than the air handler inlet height and width and supply only fresh air to the air handler See Page 77 Section 5 for inlet dimensions 15 2 Return Duct Work Inlet duct work height and width must be no smaller than the air handler inlet height and width and supply only fresh air to the air handler See Page 77 Section 5 for inlet dimensions 15 3 Discharge Duct Work Refer to Page 73 Table 10 for minimum discharge duct sizes by model Refer to Page 73 Table 17 for discharge duct size required for connecting to heater BD or RD these dimensions provide clearance for duct flange to blower mounting bolts SECTION 15 DucT CONSIDERATIONS Table 10 Minimum Recommended Duct Size Model Height Width E in 14 15 6 B00 cm 35 6 39 7 B 650 and in 24 24 B 1000 cm 61 0 61 0 3 32 32 2000 81 3 81 3 38 38 852000 cm 96 5 96 5 Table 11 Discharge Duct Size Recommendations to Connect to Heater for BD RD Model Height Width in 14 175 Bon cm 35 6 44 5 B 650and in 25 3 25 3 B 1000 cm 63 5 63 5 40 35 3 572000 101 6 89 5 in 47 40 8 3000 119 4 103 5
50. failsafe interlock set the fan switch to off and then on again The air handler will return to the normal sequence of operations AIR FLOW SWITCH CONTROL RELAY EXHAUST FAN AIR FLOW SWITCH TIMING RELAY SET AT 5 MIN 8 CR3 gA REPLACES LOW PRESSURE SWITCH ON MAIN WIRING DIAGRAM TIMING RELAY SET AT 5 MIN AFS 3 FIELD LOCATE ON EXHAUST FAN SWITCH PROVIDIED BY OTHERS LOW TEMP LIMIT LOCATED AT DISCHARGE SIDE OF BLOWER TO TEST SET DIAL TO MIN TEMP UNIT OPERATES SET DIAL TO MAX TEMP UNIT SHUTS DOWN NOTE LOW PRES SWITCH BETWEEN WIRES 8 AND 8A LOW PRES SWITCH BETWEEN WIRES 1 AND 20 REPLACES CR3 RELAY NORMALLY OPEN CONTACTS REPLACE LOW PRESSURE SWITCH ON MAIN WIRING DIAGRAM BETWEEN WIRES 8 AND 8A XXXXXXXXXXX FIELD WIRED BY OTHERS CLOGGED FILTER WIRING FOR SDC 80010 AND DTC 80000 REMOTE PANELS Part Number Description Models 01004 MUA Exhaust Failsafe Inlock All Models 99 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL 17 8 4 Motorized Inlet Damper The motorized inlet damper covers the outside air inlet of the air handler When the air handler blower is turned on the damper motor is energized and opens the damper The damper motor has an auxiliary switch that prevents the blower from starting until that damper has opened sufficiently to allow the required air volume to pass through the air handler Upper Damper For All Models Lower Damper For VAV a
51. feature is added The FR style air handler uses a fixed damper and also does not require additional control wiring unless an optional feature is added The VAV style air handler controls a floating damper and a variable frequency drive VFD and requires additional control wiring For additional VAV style wiring for models B 650 and B 1000 See Page 90 Figure 48 and Page 92 Figure 50 For additional VAV style wiring for models B 2000 and B 3000 See Page 91 Figure 49 and Page 93 Figure 51 through Page 95 Figure 53 The AM style air handler controls a floating damper and requires additional control wiring For additional AM style wiring for models B 650 and B 1000 See Page 96 Figure 54 For additional AM style wiring for models B 2000 and B 3000 See Page 96 Figure 55 FIGURE 48 Additional Control Wiring for VAV Style B 650 and B 1000 VARIABLE AIR VOLUME CONTROLLED BY THE DDC P N VAV DDC VFD TERMINALS L 1 DECEL 52 9 ACCEL DECEL CONTACTS WIRED BY OTHERS ACCEL 53 FUSABLE DISCONNECT PHOTOHELIC 1 LOCATED INSIDE CONTROL ENCLOSURE CONTROLS DIFFERENTIAL PRESSURE ACROSS BURNER PRESET AT 0 75 LOW AND 0 90 HIGH NOTE MOTOR STARTER OVERLOAD AND M1 LOW AUXILIARY CONTACT IS REPLACED MODU WITH RM1 RELAY LATING DAMPER MOTOR o e Damper Switch MODULATING REGULATING VALVE REDUCED FLOW SWITCH Part Number VAV Models B 650 and B 1000 Description VAV Co
52. finish or an acrylic modified alkyd enamel finish To order with a galvanized finish do not include a W at the end of the part number to order with a painted finish include a W at the end of the part number NOTE Check to be sure that all required components are present If any are missing contact your BANANZA independent distributor 12 1 Inlet Hood Assembly B 350 FIGURE 24 Inlet Hood Assembly B 350 Description Part Number B 350 Inlet Hood 77030 301 W Top Panel 73031 002 W Filter Cap 73032 002 W Left Panel 73033 001 W Right Panel 73033 002 W Permanent Filters 20 x 25 x2 10 24 x 3 4 Hex Head Cap Screw Bolt 10 24 Keps Nut 20698 Filters load from topside TEK Screw 13404 s a Filter Channel 73035 002 Bottom Guide 73036 002 Filter Cap Bottom Panel 73034 002 W 22628 21699 Filter Rail Left Panel Bottom Panel Note Inlet hood is also available with screen mesh no filters P N 13405059 44 of 149 12 2 Inlet Hood Assembly B 650 and B 1000 SECTION 12 INLET HoOD Part Inlet Hood with Permanent Aluminum Mesh Filters Inlet Hood Without Filters With Birdscreen Inlet Hood with Moisture Limiter Description Number 13505060 Galvanized 13505058 Galvanized 13505062 Galvanized 13505061 Painted 13505059 Painted 13505063 P
53. flanges are facing out Attach supports to top inside of the left and right panels making sure that the channel portion is facing down into the filter Insert Screws section nsert Screws Description Part Number Supports 77405 002 TEK Screw 13404 31 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 11 2 3 Insert Screws Attach channels to end plate Make sure top channel is facing down and bottom channels are facing up NOTE Channels open to the inside of the filter box Description Part Number Channels 77404 002 TEK screw 13404 Channels Step 11 2 4 Attach header in between the lower portion of the left and right side panels Attach stiffener in between top portion of left and right side panels Attach loose end of upper filter channel to stiffener attach loose end of lower filter channels to header piece On the inlet of the filter section rivnuts P N 91120106 are factory installed With additional 3 8 hardware P N 20515 and P N 20517 the filter section can be installed on the inlet of the unit See Page 43 Section 11 5 for additional insert information on filter section installation H eader Panel NOTE For easier installation the filer section may be mounted to the Description Part Number air handler at this point prior to the Panel N addition of filters and access door 15404 Refer to Page 43 Fig
54. handler Tools required to commission the equipment include but are not limited to the following Various screwdriver types and sizes Various adjustable wrenches Torque wrenches Pipe wrenches sized appropriately for the gas train components Drill motor and various drills U tube manometer or gas pressure gauge Volt meter Clamp style ammeter Belt tension gauge Caulk non silicone SECTION2 INSTALLER RESPONSIBILITY 7 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 3 CRITICAL CONSIDERATIONS AWARNING Fire Hazard Keep all flammable objects liquids and vapors the minimum required clearances to combustibles away from equipment Some objects will catch fire or explode when placed close to equipment Failure to follow these instructions can result in death injury or property damage AWARNING Explosion Hazard Fresh air supply duct and burner housing must be purged with fresh air four times before every ignition Explosive vapors will ignite if not evacuated before ignition attempt Failure to follow these instructions can result in death injury or property damage 8 of 149 3 1 Required Clearances to Combustibles Clearances are the required distances that combustible objects must be away from the air handler to prevent fire hazards Combustibles are materials that may catch on fire and include common items such as wood paper rubber fabric etc Maint
55. help facilitate optimum performance and safety Bananza recommends that a qualified contractor conduct at a minimum annual inspections of your BANANZA equipment and perform service where necessary using only replacement parts sold and supplied by Bananza Check installation site to ensure all codes and engineering specifications are correct This section of the manual is intended to be used as an instructional guide to the commissioning of the direct fired air handler Fill out the start up sheet located at the back of the manual as each step of the procedure is performed This procedure must be completed by the commissioning contractor and returned to Bananza If the document is not returned the manufacturing date will be used as the warranty start date All components have been checked at initial factory startup During transit components may have loosened shifted check all wiring before initial startup 19 1 Installation of Recirculating Air Handler Every direct fired air handler which recirculates room air i e AM and FR styles must utilize either a control system which limits temperature rise in proportion to the amount of outdoor air or a room carbon dioxide sensor installed per the manufacturer s recommendations The normally closed contacts of this sensor must be wired in as per the interlock diagram maintaining the room concentration of below 5 000 ppm Select the CO interlock diagram based on air han
56. inlet end and line up the pre drilled holes Use TEK self tapping screws P N 13404 in the middle of the support base P N 7740800X to secure the support base in place Step 2 Line up the pre drilled holes at the ends of the support base the filter section and the support legs P N 7740900X and attach the legs to the bottom of the filter section through the support base with TEK self tapping screws P N 13404 Install TEK self tapping screws P N 13404 at each of the remaining hole locations in the support base Step 3 Mount the filter section to the air handler as described on Page 43 Section 11 5 Step 4 Line up the support extension P N 77410001 with the left support leg P N 77409001 and select the appropriate height alignment Attach the support extension and left support legs and support brace P N 774110X at the lowest overlap position with one 14 20 bolt P N 20483 and flange nut P N 220630 on the front surface Install a second 14 20 bolt P N 20483 and flange nut P N 220630 directly above the first securing all three parts together Repeat step 4 on the right side of the support assembly 42 of 149 11 5 Filter Section Installation Horizontal Air Handlers 11 5 1 Filter Section Installation B 350 For installation directly onto the inlet of the air handler remove the hardware on the inlet surface of the air handler that would prevent the filter section from being mated to the inlet of the air handler Use
57. is 48 122 cm on all models Minimum clearance for accessibility applies to the control enclosure blower access panel and filter access panel when equipped Installation Code and Annual Inspections All installation and service of BANANZA equipment must be performed by a contractor qualified in the installation and service of equipment sold and supplied by Bananza and conform to all requirements set forth in the BANANZA manuals and all applicable governmental authorities pertaining to the installation service operation and labeling of the equipment To help facilitate optimum performance and safety Bananza recommends that a qualified contractor conduct at a minimum annual inspections of your BANANZA equipment and perform service where necessary using only replacement parts sold and supplied by Bananza Air handlers are approved for installation up to 2000 610 m For installations at elevations above 2000 610 m consult factory Further Information Applications engineering and detailed guidance on systems design installation and equipment performance is available through BANANZA representatives Please contact us for any further information you may require including the Installation Operation and Service Manual These products are not for residential use All rights reserved No part of this work covered by the copyrights herein may be reproduced or copied in any form or by any means graphic electronic or mechanical
58. is designed for indoor or outdoor installation with fresh outdoor air delivered to the burner Air handlers are designed to operate in temperatures as low as 30 F 34 C The air handler is factory tested to fire with natural gas or LPG check the air handler s rating plate for information on the appropriate gas The burner flame will modulate to maintain the selected discharge air temperature or room air temperature depending on the selected controls See Page 110 Section 18 2 For maximum temperature rise See Page 121 Table 24 The air handler may be provided with several different controls and options to meet various application requirements Be sure to read this entire manual before installation and start up 1 2 Inspection and Setup The air handler is shipped fully assembled The air handler was inspected and operated prior to shipment Immediately upon receipt of the air handler check the fuel and electrical characteristics of the air handler and verify that they match the fuel and electrical supply available Verify that the specifications on the air handler rating plate match the order Check the air handler for any damage that may have occurred during shipment If any damage is found file a claim with the transporting agency Do not refuse shipment Check the installation location to ensure proper clearances to combustibles See Page 8 Section 3 1 Any small options which do not come attached to the air handler i e
59. must be applied to the top edge of the stand The bolts on the air handler that correspond to the attaching location of the mounting stand must be removed and saved for re installation to secure the air handler to the stand Lift the air handler on to the mounting stand See Page 17 Section 6 1 for safe lifting practices Once the air handler is placed on the stand secure it with the attaching hardware that was removed prior to lifting it in to place per recommended torque settings See Page 9 Table 1 See Page 22 Figure 13 B 350 and Page 22 Figure 14 B 650 B 3000 After placing the air handler on the mounting stand seems 22 of 149 between the mounting stand and the air handler must be properly caulked caulk provided by others NOTE If using a filter section with an upright air handler and stand the filter section must be set into the stand before the air handler is mounted on the stand The 1 2 12 7 cm thick double sided urethane foam tape should be applied between the stand and the filter section See Page 43 Section 116 FIGURE 13 Upright Stand Detail B 350 Attaching Locations A Ta 777Z 777 7 77Z77 Z 7 777777Z77 Z7 7777777 Upright Stand Foam Tape FIGURE 14 Upright Stand Detail B 650 B 3000 Attaching Location a Upright Stand Foam Tape SECTION 8 UPRIGHT STAND FIGURE 15 Stand Shim B 1000 B 3000 NOTE Quantity 8 required per stand
60. one disconnect switch may be Equipment may start automatically required to disconnect electric from equipment Do not operate with door open Equipment must be properly grounded Installation operation and service must be done by a trained technician only Failure to follow these instructions can result in death electrical shock or injury A WARNING Explosion Hazard Carbon Monoxide Falling Hazard Burn Hazard Leak test all compo Hazard Use proper safety Allow equipment to nents of equipment 00 not recirculate air equipment and cool before service gas piping before _ from the heated practices to avoid operation space over burner falling Internal components of equipment may Gas can leak if Air supply to burner not use part still be hot after piping is not must be from outside equipment as operation installed properly support Do not high pressure test gas piping with equipment connected Failure to follow these instructions can result in death injury or property damage 116 of 149 Installation Code and Annual Inspections All installation and service of BANANZA equipment must be performed by a contractor qualified in the installation and service of equipment sold and supplied by Bananza and conform to all requirements set forth in the BANANZA manuals and all applicable governmental authorities pertaining to the installation service labeling and operation of the equipment To
61. or accessories not specified by Bananza Failure to install or maintain the BANANZA B Series as directed in the Installation Operation and Service Manual e Relocation of the BANANZA B Series after initial installation Use of the BANANZA B Series in a corrosive atmosphere containing contaminants Use of the BANANZA B Series in the vicinity of a combustible or explosive material Any defect in the BANANZA B Series arising from a drawing design or specification supplied by or on behalf of the consumer Damage incurred during shipment Claim must be filed with carrier WARRANTY IS VOID IF The BANANZA B Series is not installed by an contractor qualified in the installation and service of gas fired heating equipment You cannot prove original purchase date and required annual maintenance history The data plate and or serial number are removed defaced modified or altered in any way The ownership of the BANANZA B Series is moved or transferred This warranty is non transferable Bananza is not permitted to inspect the damaged equipment and or component parts SECTION 24 THE BANANZA B SERIES WARRANTY READ YOUR INSTALLATION OPERATION AND SERVICE MANUAL If you have questions about your equipment contact your installing professional Should you need Replacement Parts or have additional questions call or write Bananza 1100 Seven Mile Road NW Comstock Park MI 49321 Telephone 1 616 726
62. plate is available Remove obstruction Clean burner orifices holes Adjust low fire as per the relevant Maxitrol temperature control instruc tions No main flame Minimum gas supply pressure Burner openings obstructed Improper burner lower fire adjustment on modulating valve 22 4 Temperature Controls If temperature control problems occur and are not remidied in the troubleshooting procedure refer to the trouble shooting table for the unit specific temperature control amplifier For units with the Maxitrol series 14 temperature control amplifier refer to the Field Service Check List for Series A1014 Amplifiers Series 14 Amplifiers are supplied on units equipped with Basic and SDC style remote panels For units with the Maxitrol series 44 temperature control amplifier refer to the Field Service Check List for Series A 1044 Amplifiers Series 44 Amplifiers are supplied on units equipped with DTC remote panels If problems persist after performing the troubleshooting procedure and the temperature control amplifier troubleshooting procedure contract the factory 139 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL 22 5A1014 Amplifier Field Checklist SYMPTOM POSSIBLE CAUSE No Gas Flow Continuous Low Fire electronics problem Qn Continuous Low Fire electronics ok Incorrect Minimum Fire Erratic or Pulsating Flame Continuous High Fire electronics p
63. splash plate Torque hardware after leveling FIGURE 30 Splash Plate Air Handler Models B 350 B 3000 1 2 5 cm Ductliner Provided Nuts and Washers Provided by Others Weight Ibs kg 77354 301 W B 350 20 0 9 1 Part Number Model B 650 77053 301 W 5 4090 40 0 18 1 B 2000 77253 301 W B 3000 70 of 149 FIGURE 31 Hole Location B 350 B 3000 Model B 350 B B 2000 B 3000 19 5 41 5 51 3 51 25 105 4 130 2 130 2 572 105 4 130 2 130 2 SECTION 14 DISCHARGE HEADS AND SPLASH PLATES 71 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 15 DUCT CONSIDERATIONS A WARNING Cut Pinch Hazard Wear protective gear during installation operation and service Falling Hazard Use proper safety equipment and prac tices to avoid falling Edges are sharp Failure to follow these instructions can result in death injury or property damage The air handler has been designed to operate at the specific air volume and external static pressure that was ordered air handlers set up to accept an external static pressure ESP of 1 in wc 2 5 mbar This static pressure is generated by any additional components that are added to the heater i e inlet hood filter sec
64. step 54 of 149 SECTION 12 INLET HoOD Step 12 3 1 Without Air Handler Top Panel SIDE VIEW With SIDE VIEW Filter Section Filter Section _ E Ims Inlet Hood Inlet Hood Horizontal Mount Horizontal Mount Horizontal Mount d External Support TOP VIEW TOP VIEW Without Filter Section With Filter Section With Filter Section Without Filter Section Horizontal Mount Air Handler re Air Handler JE Air Handler Air Handler 1 Upright Mount Filter Box 7 Upright Mount 1 For an air handler without a filter section On the inlet of the air handler install horizontal and upright mounts The mounts will be installed via angles open towards the outside of the air handler For an air handler with a filter section First attach the filter section to the air handler Then bolt the inlet hood horizontal and upright mounts to the inlet of the filter section with the angles opening towards the inside of the filter section Upright mounts P N 13X05090 are attached with seven 3 8 16 bolts P N 20517 and flat washers P N 20515 each the receiving riv nut P N 91120106 will be factory installed on the air handler or filter section Horizontal mounts P N 13505091 are attached using nine TEK self tapping screws P N 13404 Prior to installing the mounts seal the gap between the ma
65. tices to avoid falling Severe Injury Hazard Use proper lifting practices and equip ment Cut Pinch Hazard Wear protective gear during installation operation and service Equipment and accessories are heavy Edges are sharp Failure to follow these instructions can result in death injury or property damage Part numbers that end with a W indicate that the part can be ordered with either an unpainted galvanized finish or an acrylic modified alkyd enamel finish To order with a galvanized finish do not include the W at the end of the part number to order with a painted finish include the W at the end of the part number 14 1 One Way and Three Way Discharge Head Installation All discharge heads are shipped assembled The discharge head is designed for mounting to the face of the air handler covering the discharge opening or to an interior wall All discharge heads must be field supported by others The discharge head has four outward turned flanges If the discharge head is to be installed to the face of the air handler install hardware provided by others on all four sides of the discharge head topview To install the discharge head on an interior wall drill holes every 8 20 5 in the flanges on all four sides of the discharge heads to accommodate lag bolts supplied by others Sheet metal supplied by others may be required See Page 69 Figure 29 for the three way discharge head a
66. using a manometer with heater operating at full fire Pressure should be at least equal to the sum of outlet pressure setting and pressure drop of the valve See Max itrol Capacity Chart Bulletin plus 1 0 in wc 20 Read outlet pressure using manometer and compare with recommendation of equipment manufacturer 21 Follow procedure outlined in PRELIMINARY CIRCUIT ANALY SIS Sections amp 11 in Maxitrol product information sheet 22 Measure resistance per item 12 23 Follow procedures outlined in PRELIMINARY CIRCUIT ANALYSIS Section IV in Maxitrol product information sheet 24 Measure resistance per item 2 25 Check to see if heater is delivering air at maximum discharge air setting 26 Check to see if heater is delivering air at maximum discharge air setting 27 Check to see if heater is operating at high fire 28 Place thermometer next to T244 or T8244 Compare space temperature reading with T244 or TD244 dial setting SECTION 22 TROUBLESHOOTING REMEDY 1 Install properly 2 If proper resistance values are not observed replace modulator head or repair wiring 3 Clean or replace plunger if necessary and install per Maxitrol product infor mation sheet 4 Replace diaphragm if ruptured 5 Provide 24VAC to amplifier Refer to item 24 6 If proper resistance values are not observed replace modulator head or repair wiring 7 If readings are incorrect replace the TS144 or repair wiring 8 I
67. with Building Pressure Part Number Description Models 13205106 CO Sensor B 2000 and B 3000 62 oc S246 WIRED BY OTHERS e BUILDING MODULATING 1 PRESSURE DAMPER MOTOR SWITCH Part Number Description Models 13205103 CO Interlock All Models 60 L RELAY CR7 CONNECTIONS ARE LOCATED BETWEEN THE DAMPER MOTOR AND THE BUILDING PRESSURE SWITCH 1 CO2SENSOR e 5 Part Number Description Models 13205106 CO Sensor B 2000 and B 3000 98 of 149 17 8 3 MUA Exhaust Failsafe Interlock This option incorporates the low temperature limit with override timer and an exhaust fan airflow switch monitor The exhaust fan airflow switch is field provided and field wired as per the option sheet supplied with the unit When the air handler is turned on there is a 5 minute establishing period for the low temperature limit switch and the exhaust fan interlock If the air handlers discharge temperature falls to the predetermined low temperature limit LOW PRESSURE SWITCH 0 3 wc 20 21 AFS 3 LOW TEMP LIMIT TAS 3 Q SECTION 17 ELECTRICAL setpoint after the 5 minute establishing period the air handler fan will be turned off If there is a failure of the exhaust fan to activate the field supplied airflow switch after the 5 minute establishing period the air handler fan will be turned off To reset the MUA exhaust
68. 0 250 VA Ctrl Transformer 90407200 350VA Ctrl Transformer 90407205 Timer 90445000 Voltage Description B350 8 3009 2HP 3HP 5HP 7 5HP 10HP 15HP 20HP 25HP 30HP Disconnect 08036 08040 08038 08041 Contactor 90600200 90600205 90600210 90600215 90600220 Aux Contact N A 90447000 Overload 90446005 90446015 90446020 90446025 90446030 90446035 90446045 90446050 230 3 60 Branch Circuit Breaker 91300510 Control Circuit Breaker 90300490 250 VA Ctrl Transformer 90407200 350VA Ctrl Transformer 90407205 Timer 90445000 Voltage Description P B3000 2HP 3HP 5HP 7 5HP 10HP 15HP 20HP 25HP 30HP Disconnect 08039 08037 Contactor 90600200 90600205 90600210 Aux Contact N A 90447000 Overload 90446005 90446005 90446015 90446020 90446025 90446030 90446035 460 3 60 Branch Circuit Breaker 91300520 Control Circuit Breaker 91300490 250 VA Ctrl Transformer 90407200 350VA Ctrl Transformer 90472050 Timer 90445000 Voltage Description 350 Bone 2HP 3HP 5HP 7 5HP 10HP 15HP 20HP 25HP 30HP Disconnect 08039 08037 Contactor 90600200 90600205 90600210 Aux Contact N A 90447000 Overload 90446000 90446005 90446015 90446020 90446025 90446030 90446035 575 3 60 Branch Circuit Breaker 91300530 Control Circuit Breaker 91300490 250 VA Ctrl Transformer 9047210 350VA Ctrl Transformer 90407215 Timer 90445000 Voltage Description B 390 9000 2HP 3HP 5HP 7 5 10HP Disconnect 08036 08040 08038 Contactor 90600200 90600205 90600210 Aux Contact N A 904
69. 0 12 Airflow Range Discharge Heads Splash Plate InleDischarge Model mn Damper in wc mbar in wc mbar in wc mbar B 350 1 000 2 000 1 700 3 400 0 10 0 25 0 05 0 12 0 10 0 25 3 000 4 000 5 100 6 800 0 10 0 25 0 05 0 12 0 10 0 25 B 650 4 000 6 000 6 800 10 200 0 10 0 25 0 05 0 12 0 10 0 25 7 000 10 000 11 400 17 000 0 10 0 25 0 05 0 12 0 10 0 25 B 1000 7 000 10 000 11 400 17 000 0 10 0 25 0 05 0 12 0 10 0 25 11 000 14 000 18 700 23 800 0 10 0 25 0 05 0 12 0 10 0 25 B 2000 12 000 16 000 20 400 27 200 0 10 0 25 0 05 0 12 0 10 0 25 18 000 25 000 30 600 42 500 0 10 0 25 0 05 0 12 0 10 0 25 B 3000 25 000 30 000 42 500 51 000 0 10 0 25 0 05 0 12 0 10 0 25 32 500 40 000 55 200 68 000 0 10 0 25 0 05 0 12 0 10 0 25 Crush Hazard Use proper lifting equipment and practices Failure to follow these instructions can result in death injury or property damage The air handler must be installed in compliance with all applicable codes The qualified installer or service technician must use best building practices when installing the air handler and any optional equipment This piece of equipment requires at least 4 CFM 6 8 m h of outside air per 1 000 Btu h 0 293 kW Any air handler that recirculates air from the heated space must use the return air opening to prevent any return air from passing over the burner Before installation check that the local distribution condition nature of gas and gas pressure and the current
70. 026L NOTE Colors refer to blower frame 134 of 149 Table 31 Remote Panel Table 32 V Belt SECTION 21 REPLACEMENT PARTS Description Remote Panel Part Number Description Part Number Rocker Switch Center Off B78 Belt 04312 DPDT SDC e 22099 B81 Belt 04315 Rocker Switch DPST All 22039 B101 Belt 04318 Remote Temperature Selector DTC 22664 B105 Belt 04320 Thermostat with Timer DTC 90425111 B110 Belt 04323 Amber Status Light All 18663 B130 Belt 04328 Temperature Selector Basic Remote amp SDC 07345 B118 Belt 04349 Thermostat SDC 83200052 BX128 Belt 04352 20VA Transformer DTC 90436900 B130 Belt 04353 Terminal Block All 91300121 BX140 Belt 04355 BX74 Belt 04362 BX78 Belt 04363 BX76 Belt 04364 B74 Belt 04365 BX123 Belt 04510 135 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 22 TROUBLESHOOTING A DANGER Electrical Shock Hazard Severe Injury Hazard Disconnect electric before service Do not enter equipment while in operation More than one disconnect switch may be Equipment may start automatically required to disconnect electric from equipment Do not operate with door open Equipment must be properly grounded Installation operation and service must be done by a trained technician only Failure to follow these instructions can result in death electrical shock or injury A WARNING Ex
71. 2 For Model B 2000 Insert 4 pieces of 12 30 5 cm x 96 243 8 cm moisture limiter media from the right side with the long dimension running top to bottom For Model B 3000 Insert 5 pieces of 12 30 5 cm x 96 243 8 cm moisture limiter media from the right side with the long dimension running top to bottom SECTION 12 INLET HoOD Inner Support Rail Description Part Number Inner Support Rail TEK Screw 13205097 13305097 13404 10 24 x 1 2 Bolt 27000 10 24 Nut 26098 Moisture Limiter Media Description Moisture Limiter Media Part Number 90740002 63 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 12 3 13 Outer Support Rail Moisture Limiter Side Cover Place the moisture limiter frame side cover to the flange at the escription Part Number top overlaps the top of the frame Attach to the inlet hood drip rail Side Cover 18205079 13305079 using eight TEK screws Attach to the bottom pan assembly and Outer Support Rail 13205098 13305098 top with two 10 24 x 1 2 bolts and 10 24 nuts each Attach TEK Screw 13404 front stiffeners to the left and right side of the moisture limiter frame using four TEK screws for each support 12 4 Inlet Hood Installation The inlet hood may be installed either onto the inlet of the air handler or to an outside wall 12 4 1 Inle
72. 47000 Overload 90446015 90446020 90446030 90449035 90446040 230 1 60 Branch Circuit Breaker 91300510 Control Circuit Breaker 91300490 250 VA Ctrl Transformer 90407200 350VA Ctrl Transformer 90407205 Timer 90445000 133 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL Table 29 Manifold Components Model B 350 B 650 B 1000 B 2000 B 3000 Manifold Size NPT 75 1 0 1 25 1 5 2 0 ANSI ANSI ANSI ANSI Safety Shut Off Valve E 90076020 90076021 90076022 90076023 SSOV FM XL IRI FM XL IRI FM XL IRI FM XL IRI B 90076010 90076011 90076012 90076013 SSOV Adapter 07196 07197 07198 07199 Modulating Valve 07440 Regulator 07185 07485 3 07490 3 07500 3 07500 3 Pilot Regulator 07552 07552 07552 07552 07552 Pilot Solenoid 07523 07522 07522 07522 07522 Manual Gas Valve Main 62019 62021 62034 62035 62023 Manual Gas Valve Pilot 62016 62016 62016 62016 62016 FIGURE 87 Blower Layout BEARINGS BLOWER WHEEL HIGH TEMPERATURE DISCHARGE TEMPERATURE MIXING TUBE LIMIT SWITCH SENSOR Table 30 Blower Model B 350 B 650 B 1000 B 2000 B 3000 Blow r Delhi Green G9 G12 918 925 930 Lau Gray 9 9 12 12 18 18 25 25 30 30 Assembly Part Number 62924 62923 62920 62037 62420 05545 05546 Bearing 05544 05545T 05546T 05545L 05546L 05594 05596 Shaft 05593 05594T 05596T 05594L 05596L 06025 06026 Wheel 06020 06025T 06026T 06025L 06
73. 4V GND 24V SPARK SENSE TCA A1044C X2 24VAC X1 PILOT VALVE SAFETY SHUTOFF VALVE BURNER ON RELAY 24VAC BURNER ON LIGHT TEMP CONTROL WIRE CONNECTIONS REMOTE TO MAIN PANEL TEMPERATURE 1 2 3A 4 7 12 24 25 MONITOR 40 41 SHIELD TS144C TEMPERATURE SELECTOR GROUND SHIELDED CABLE AT CONTROL PANEL T244A AMPLIFIER T1 TRANSFORMER PRIMARY CONNECTION H1 460 USE 1 6 AMP BREAKER H2 230 USE 3 0 AMP BREAKER H3 208 USE 4 0 AMP BREAKER H4 COMMON MODULATING REGULATING VALVE MRV 83 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 42 Basic Remote Wiring Diagram B 650 B 3000 3 PHASE ONLY BLOWER MOTOR FUSABLE DISCONNECT RETT BREAKER FUSES BY OTHERS H4 BREAKER H1 H2 H3 250VA xi 2 120 VAC MOTOR STARTER Lures MN 0 3 W C 14 W C HLS N A N A 9B o 9 E OR ie P PILOT VALVE L M2 T2 MANUAL DX li IGNITION TRANSFORMER IGNITION CONTROL UV BURNER ON SCANNER RM7890A CLIP JR2 o A o SAFETY SHUTOFF VALVE UV SCANNER TEMP CONTROL AMPLIFIER TCA A1014 PRIMARY RM7897C IGNITION CLIP JR2 CONTROL FOR B 2000 AND B 3000 TEMPERATURE REGULATING SELECTOR VALVE MRV TD114 TEMPERATURE MONITOR TS114 GROUND SHIELDED CABLE AT CONTROL PANEL WIRE CONNECTIONS T1 TRANSFORMER REMOTE TO MAIN PANEL PRIMARY CONNECTION 1 2 3A 4 7 12 H1 460 USE 1 6 AMP
74. 6 of 149 Description Part Number Bottom Rail 13205072 13305072 13205095 13305100 TEK Screws 13404 Step 12 3 4 Attach the middle sidewall panels left panel right panel with four 5 16 18 x 1 bolt 5 16 flat washer 5 16 flange nut each Attach outermost sidewall panels left panel right panel to each side of the inlet hood using three 5 16 18 x 1 bolt 5 16 flat washer 5 16 flange nut Step 12 3 5 Top Front Panel 3 Attach top front panel to the sidewall panels using four TEK SECTION 12 INLET HoOD Description Part Number Left Side Panel 2 13205082 13305082 Right Side Panel 2 13205083 18305083 Left Side Panel 3 Right Side Panel 3 13205084 13305084 13205085 18305085 5 16 18 x 1 Bolt 20507 5 16 Flat Washer 95211600 5 16 Nut Flange 20509 Description Part Number self tapping screws on each side NOTE Ensure that the side tabs of the top panel are to the Top Front Panel 3 13205077 13305077 13205096 13305096 outside of the side panels TEK Screw 13404 57 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 12 3 6 Top Front Panel Roof SIDE VIEW s 8 Top Inner Filter Rail For Model B 2000 Attach top inner filter rail to the inside of the top front panel using five TEK self tapping screws For Model B 3000 A
75. 9 20 2 Unit Exterior Cabinet Exterior After installation touch up scratches Periodic painting should be done there after as required The caulk around weather enclosures and over field joints should be inspected annually Re apply caulk as needed to maintain integrity Warning labels and logo labels should be legible and accurate Please con tact Bananza or BANANZ independent distributor if you need replacement warning labels or logo labels See Page 3 Figure 1 through Page 5 Figure 4 Unit Location handler Verify that no flammable objects liquids or vapors are present near the air Do not hang anything from or place anything on the air handler Keep the area under and around the air handler free of all objects See Page 8 Section 3 for Clearances to Combustibles 20 3 Blower Section Blower Wheel Inspect blower wheel and clean as necessary A small build up of dust can cause a significant decrease in blower performance Check for excessive vibration repair as required Critical labels are located on or near the blower housing Contact Bananza or BANANZA independent distributor if you need replacement labels See Page 5 Figure 4 125 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL Drive Belts and Sheaves Check for belt ride in the groove In multiple groove drives belt ride should be uniform Check groove wear area for wear Side wall of groove should be straight not
76. AL Step 11 3 7 Filter Section On right panel apply provided gasket material to the filter access Panel opening Attach filter access door with two hinges Attach the hinges to the door using three 10 24 x 1 2 bolts and 10 24 nuts Attach the hinge to the filter section right panel using three 10 24 x 3 4 bolts and 10 24 nuts Use four hinge spacers between the hinge and the right panel to keep the hinge aligned Press the 14 20 grip nuts into each of the three square cut outs in the filter section right panel on the opposite side of the filter access opening from the hinges Place a washer on a 4 20 bolt and insert it into one of the three bolt holes on the door panel Place a push nut on to the bolt from the inside of the door panel to keep the bolt from being separated from the door panel when it is open Repeat for the other two bolt holes Secure the door in the closed position by threading the three bolts in the door panel to the grip nuts on the filter section Gasket right panel Door Panel On the inlet of the filter section rivnuts P N 91120106 are factory p p adu installed With additional 3 8 hardware P N 20515 and Door Panel 7 P N 20517 the filter section can be installed on the inlet of the unit See Page 48 Section 11 5 for additional information on filter section installation Grip Nut a Right Panel Hinges 26 Bolt Push Nut Washer Filter Box Panel Description Pa
77. AMPER MOTOR 61 o SWITCH control enclosure The low temperature limit switch 2 has an adjustable setting between 20 F 29 C 5 and 100 38 C The timer by passes the low ES E temperature limit switch for the first 5 minutes to allow the burner to establish a flame when the air handler is turned on If the air handler s discharge temperature falls to the predetermined low temperature limit setpoint after the 5 minute CR5 HLS establishing period the air handler s blower will be HW turned off To reset the low temperature limit switch RN set the fan switch to off and then on again The air RESET handler will return to the normal sequence of operations WIRED BY OTHERS LOW LIMIT SWITCH LOW LIMIT TIMER RED YELLOW SET AT 5 MIN Part Number Description Models 13205104 CO Interlock All Models 3A 3B 3A LT SET AT 50 F 10 C FIGURE 61 CO Sensor Interlock for AM and VAV LOCATED AT DISCHARGE SIDE OF BLOWER with Photohelic TO TEST SET DIAL TO MIN TEMP UNIT OPERATES SET DIAL TO MAX TEMP UNIT SHUTS DOWN Part Number Description Models Low Temperature Limit with Override Timer CR7 0824 0 62a MODULATING DAMPER MOTOR 1 PHOTOHELIC 01003 All Models CO2 SENSOR 63 FIGURE 59 CO Sensor Interlock for FR and MUA LIMIT y GRE MS pes pena FIGURE 62 CO S i RESET ensor Interlock for AM
78. ANUAL RESET HI TEMP LIMIT WINTER TIME DELAY 30S LOW PRES SWITCH C NO IGNITION CONTROL FLAME ROD FR CHECK BYNC FILTERS O 825 C NC 9 9A 9B 9C gt e O O HI PRES SWITCH 77 x E a 77 gt N a 2 a N a z gt amp s amp TEMP CONTROL AMPLIFIER TCA A1014 TEMP CONTROL AMPLIFIER TEMPERATURE SELECTOR TD114 MODULATING REGULATING VALVE MRV TEMPERATURE MONITOR TS114 GROUND SHIELDED CABLE AT CONTROL PANEL WIRE CONNECTIONS T1 TRANSFORMER REMOTE TO MAIN PANEL PRIMARY CONNECTION 1 2 3A 4 7 12 24 25 H1 460 USE 1 6 AMP BREAKER 40 41 SHIELD H2 230 USE 3 0 AMP BREAKER 208 USE 4 0 AMP BREAKER H4 COMMON 82 of 149 MOTOR STARTER BURNER LOCKOUT LIGHT PILOT VALVE SAFETY SHUTOFF VALVE BURNER ON RELAY 24VAC BURNER ON LIGHT SECTION 17 ELECTRICAL FIGURE 41 Deluxe Temperature Control Remote DTC Wiring Diagram B 350 3 PHASE ONLY BLOWER 1 FUSABLE DISCONNECT J 7 BREAKER 7 BREAKER 3AMP A X1 2 120vac T1 250VA 3A 3B Q 59 5 WINTER IGNITION CONTROL LOW PRES SWITCH THERMOSTAT TH8110R 1008 U THERMOSTAT CONTROL RELAY 8 gt MOTOR STARTER TIME DELAY 30S FLAME ROD FR C NO NC CHECK FILTERS HI PRES SWITCH C NC 9 MV MV PV PV GND 2
79. ATION OPERATION AND SERVICE MANUAL SECTION 4 NATIONAL STANDARDS AND APPLICABLE CODES 4 1 Gas Codes 4 4 Parking Structures and Repair Garages The type of gas appearing on the nameplate must be the type of gas used Installation must comply with national and local codes and requirements of the local gas company United States Refer to NFPA 54 ANSI Z223 1 latest revision National Fuel Gas Code Canada Refer to CSA B149 1 latest revision Natural Gas and Propane Installation Code Installation in garages must be in accordance with the following codes United States Refer to Standard for Parking Structures NFPA 88A latest revision or the Code for Motor Fuel Dispensing Facilities and Repair Garages NFPA 30A latest revision Canada Refer to Natural Gas and Propane Installation Code Standard CSA B149 1 latest revision 4 2 Installation Codes 4 5 Electrical Installations must be made in accordance with the Standard for the Installation of Air Conditioning and Ventilating Systems NFPA 90A latest revision for the installation of air conditioning and ventilating systems 4 3 Aircraft Hangars Installation in aircraft hangars must be in accordance with the following codes United States Refer to Standard on Aircraft Hangars NFPA 409 latest revision Canada Refer to Natural Gas and Propane Installation Code Standard CSA B149 1 latest revision E
80. AV style Refer to the burner mode setting chart on Page 121 Table 23 for specific amplifier and action required to place it into high fire Measure the recirculation temperature rise and compare it to Page 121 Table 24 The resistor on the reduced flow switch mounted inside the control enclosure may need adjustment until recirculation temperature rise is obtained e Return unit to normal operating conditions 120 of 149 Reconnect any wires that were removed for adjustment Maximum discharge temperature is 160 F 71 C for models approved to Z83 4 and Z83 18 see ETL Standard For models approved Z83 25 see ETL Standard the maximum discharge temperature is 200 F 93 C Low fire adjustment NOTE High fire gas pressure must be set BEFORE adjusting low fire There are three critical items to consider before adjusting low fire A Low fire adjustment does not regulate gas pressure B If the low fire adjustment screw is set to maximum high fire regulation problems will occur C The burner control system must be forced into low fire per the Burner Mode by Amplifier Type table See Page 121 Table 23 Low fire is set at the MR212 valve using the adjustment screw under the low fire adjustment cap screw loosen locking screw before adjustment See Page 122 Figure 79 or on the M611 valve using the brass adjusting screw on the front side See Page 123 Figure 80 The burner must be forced int
81. BREAKER H2 230 USE 3 0 AMP BREAKER 40 41 SHIELD H3 208 USE 4 0 AMP BREAKER H4 COMMON 84 of 149 SECTION 17 ELECTRICAL FIGURE 43 Standard Discharge Control Remote SDC Wiring Diagram B 650 B 3000 3 PHASE ONLY BLOWER MOTOR FUSABLE DISCONNECT FUSES BY OTHERS H4 BREAKER H1 H2 H3 T1 3 AMP 250VA x1 x2 120vac M1 OL M HEN MOTOR STARTER FAN ON CYCLE STAT SUMMER o WINTER RM7890A LOW PRES HI PRES CLIP JR2 HI TEMP SWITCH SWITCH LIMIT 0 3 W C 1 4 W C HLS C NO 8A C NCQ o g a o 0 2 2 2 PILOT VALVE MANUAL m IGNITION RESET 2 TRANSFORMER IGNITION CONTROL BURNER ON e SAFETY SHUTOFF VALVE SCANNER TEMP CONTROL X1 24VAC X2 AMPLIFIER TCA A1014 PRIMARY 789 IGNITION CLIP JR2 CONTROL FOR B 2000 AND B 3000 TEMPERATURE SELECTOR MODULATING TD114 REGULATING VALVE MRV TEMPERATURE MONITOR GROUND SHIELDED CABLE AT CONTROL PANEL TS114 WIRE CONNECTIONS T1 TRANSFORMER REMOTE TO MAIN PANEL PRIMARY CONNECTION H1 460 USE 1 6 AMP BREAKER 1 poc 29 H2 230 USE 3 0 BREAKER HS H3 208 USE 4 0 AMP BREAKER H4 COMMON 85 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 44 Deluxe Temperature Control Remote DTC Wiring Diagram B 650 B 3000 BLOWER FUSABLE DISCONNECT FUSES BY OTHERS BREAKER 3 AMP x1 120vac o WINTER
82. Bolt Hex Grade 5 20517 14 14 10 24 KEPS Nut 20698 12 12 Permanent Aluminum Mesh Filter 20 x 20 x 1 20628 16 N A Permanent Aluminum Mesh Filter 20 x 25 x 1 20629 8 N A Disposable Polyester Filter 20 x 60 x 1 23631 N A 8 Bolt 10 24 x 34 HHCS 21699 6 6 10 24 x HMS Bolt 27000 6 6 Fastener Rivnut 3 8 16 91120106 14 14 Spacer Hinge Filter 13205032 8 8 Gasket Door Filter 13205035 12 12 34 of 149 SECTION 11 FILTER SECTION Note In the instructions an X in a part number indicates a digit that changes based on model Replace the X with a 2 for model B 2000 replace the X with a 3 for model B 3000 For further clarification reference the individual table of components for each assembly at the begining of the instructions Step 11 3 1 Side Left _ b Top Panel For Model B 2000 On a flat clean and dry surface attach the top panel and side panel of the filter section using five TEK Top Panel self tapping screws a Uh For Model B 3000 On a flat clean and dry surface attach the top panel and side panel of the filter section using seven TEK self tapping screws Description Part Number Top Panel 13X05029 Side Left Panel 13X05028 TEK Screw 13404 35 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 11 3 2 c Bottom Panel Side Right Panel Description Part Number Bottom Panel 13X05029 Side Right Panel 13X05026 TEK Screw 13404
83. Control Closed Safe Start Check Flame Proving Preignition Interlock PII FIGURE 75 RM7897 Flame Control B 2000 B 3000 MASTER SWITCH LED Display Burner Operating Controls and Interlocks Flame Signal SECTION 18 SEQUENCE OF OPERATION LIMITS RUNNING INTERLOCK INC AIRFLOW SWITCH 108 EC INTERUPTED T IGNITION N VALVE E PILO E MAI IGNITION o Initiate Initial Powerup only Power Standby js S Power O Pilot O Flame O Main O Alarm Pilot Flame Establishing Period 10 Sec Power e Pilot Flame O Main O Alarm Main Flame Establishing Period Run Power O Pilot Flame e Main O Alarm Power Pilot Flame Main O Alarm Postpurge Standby Burner Blower Motor ignition Interrupt Pilot Main Valve Limits and Burner Controller Closed to 9 Running Interlock to Preignition Interlock Closed toy Safe Start Check Flame Proving 115 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 19 START UP PROCEDURES A DANGER Electrical Shock Hazard Severe Injury Hazard Disconnect electric before service Do not enter equipment while in operation More than
84. Description Part Number Top Inner Filter Rail 13505068 TEK Screw 13404 Description Part Number Top Front Panel 13505076 13505096 TEK Screw 13404 REVERSE INLET VIEW lop Front Panel Top Inner Filter Rail Bottom Rail Attach the top inner filter rail to the inside of the front top panel using four TEK self tapping screws Ensure that the rail is installed with the ends tight against the flanges of the sidewall panels and the angle opening toward the inside of the inlet hood 48 of 149 SECTION 12 INLET HoOD Step 12 2 6 Top Back Panel J Bend V Attach top back panel with four TEK self tapping screws on each side with five TEK self tapping screws to the top attaching flange and with five 5 16 18 x 1 hex head cap screws 5 16 washers and 5 16 flange nuts at o 15505075 the J bend joint Ensure that the side tabs of the roof panel 1 Hex Head Cap 20507 are to the outside of the side panels and that the J bend 15716 Washer 9521600 interlocks with the front roof panel 5 16 Flange Nut 20509 Description Part Number For inlet hoods with permanent aluminum mesh filters continue to step 12 2 8 For inlet hoods with birdscreen no filters continue to step 12 2 7 For inlet hoods with moisture limiter continue to step 12 2 9 Step 12 2 7 SIDE VIEW Description Part Number Horizontal mountforb
85. EAKER BREAK TRANSFORMER 750VA L1 9 Q GFI RECEPTACLE DIN RAIL MOUNT 15 AMP MOUNTED IN CONTROL ENCL Pari Number Description Modes 9130070X All Models 17 8 12 Soft Start SOFT STARTER MOTOR SOFT STARTER SETTINGS viz 2 5 SEC T U NC 10 SEC Al A2 ST RUN COM 7 46 NOTE SOFT STARTER IS WIRED BETWEEN THE OVERLOAD AND THE MOTOR un 60 96 Models All Models Part Number 90600XXX Description Soft Start 17 8 13 Room Override Stat For use with Basic Il HVAC remote or Standard Discharge Control remote This option provides additional thermostat capability based on room temperature The thermostat senses room temperature and resets the discharge air to a higher temperature whenever the temperature falls below settings indicated on the temperature selection dial located on remote panel Override temperature can be set 0 F to 40 F above the temperature selection dial on the remote panel SECTION 17 ELECTRICAL 17 9 Optional Exhaust Motor Starters Variable Frequency Drives FIGURE 63 J 1000 1 Pot 7 5 or Less WIRES CONNECTED TO CONTROL PANEL 2 3C 35 SHIELDED X1 X2 X3 WITH REMOTE POT ONLY OPTIONAL WIRING REQUIRED FOR REMOTE POT WIRES GOING INTO VFD MUST BE SHIELDED AND ONE END GROUNDED ot RUN RELAY CURE RELAY O O
86. FOR YOUR SAFETY If you smell gas Open windows DO NOT try to light any appliance DO NOT use electrical switches DO NOT use any telephone in e yur bling BANANZA B Series Extinguish any open flame Leave the building Immediately call your local gas supplier after leaving the building Direct Gas Fired Industrial Follow the gas supplier s Air Handler supplier call the Fire Department A WARNING Installation Operation amp Service Manual B 350 Keep all flammable objects liquids and B 650 vapors the minimum required clear B 1000 ances to combustibles away from equipment B 2000 Some objects will catch fire or explode B 3000 when placed close to equipment Fire Hazard Failure to follow these instructions can result in death injury or property damage WARNING Installer Please take the time to read and understand Improper installation adjustment alteration service th ior t installati or maintenance can result in death injury or IONS RIOT i any sia a ont property damage Read the Installation Operation Installer must give a copy of this manual to the owner and Service Manual thoroughly before installing or Owner servicing this equipment 3 Keep this manual in a safe place in order to provide Installation must be done by a contractor qualified your service technician with necessary information in the installatio
87. FUSING TIMER INCREASE OVERRIDE SET TO 60 SEC PHOTOHELIC LOCATED INSIDE SEPARATE REMOTE ENCLOSURE PHOTOHELIC HIGH LOW CONTROLS BOOTH PRESSURE PRESET AT 0 1 LOW AND 0 3 HIGH 105 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 68 P7 30HP or More with Photohelic LOCATED ON VFD PANEL INSIDE CONTROL ENCLOSURE 52 53 50 EXHAUST MOTOR S TO CUSTOMER SUPPLIED DISCONNECT AND FUSING TIMER INCREASE OVERRIDE SET TO 60 SEC PHOTOHELIC LOCATED INSIDE SEPARATE REMOTE ENCLOSURE PHOTOHELIC OW CONTROLS BOOTH PRESSURE PRESET AT 0 1 LOW AND 0 3 HIGH 17 10 Disconnect Fuse Sizing The fuse classification must be determined by the service disconnect rating plate and all applicable codes Fuse sizing is determined by the motor size control current and supply voltage Fuses that are being replaced must be replaced with the same type size and class of fuse that was supplied with the air handler For additional information or to confirm original fuse specifications consult the factory Table 16 Minimum and Maximum Fuse Size by Motor Size and Supply Voltage Electrical Characteristics Motor Size HP kW 208 3 60 230 3 60 460 3 60 575 3 60 230 1 60 2 1 5 7 3 10 2 6 9 9 6 3 4 4 8 2 6 3 6 13 3 18 6 3 2 2 10 1 14 2 9 3 13 0 4 6 6 5 3 7 5 2 17 3 24 2 5 3 7 15 4 21 6 15 1 21 1 7 5 10 6 6 1 8 5 24 3 34 0 7 5 5 6 23 1 32 4 21 3 29 8 10 6 14 9 8 3 11 6 32 3 45 2 10 7 5
88. Failure to follow these instructions can result in death injury or property damage Suspension Kits are available for models B 350 B 1000 Kits are shipped unassembled and must be assembled prior to installation Suspension Kits for models B 2000 B 3000 are not available NOTE Before installation verify all required components are present If any are missing contact your BANANZA independent distributor 10 1 Suspension Kit Assembly and Installation After the air handler is in place the installer must fasten the air handler to the suspension frame Once the suspension frame is secure the air handler may be mounted See Page 17 Section 6 for safe lifting practices 26 of 149 On model B 350 remove the 1 4 bolts from four corners of base on length of air handler Slide suspension angle assembly onto both ends of the air handler aligning holes in angle tab with bottom holes Once completed reinstall hardware See Page 27 Figure 20 On model B 650 and B 1000 drilling holes down through the floor of the air handler and into the suspension frame At least three 12 sheet metal screws supplied by others equally spaced on each angle side must be used to attach the air handler to the suspension frame See Page 28 Figure 27 FIGURE 20 Indoor Suspension B 350 Suspension 5 8 for 1 2 Angle Clip Threaded Rod Single 1 2 Hex Nut on Top Side of Angle to secure unit in position Suspension Double 1 2 Hex Nuts
89. H RM1 RELAY HIGH LOW PROFILE PLATE BURNER 48 VED PROGRAM PARAMTERS 25HP OR LESS 1 01 20 ACCEL TIME SEC C1 02 20 DECEL TIME SEC 42 02 5096 MINIMUM HZ 50 30HZ H1 03 10 H1 04 11 1 05 0 H1 07 0F V1000 ONLY L2 01 1 L5 01 5 MODULATING REGULATING VALVE REDUCED FLOW SWITCH VED PROGRAM PARAMTERS 30HP OR MORE B1 02 1 C1 01 25 C1 02 25 D2 02 50 D4 01 1 E1 01 VOLTS E2 01 AMP H1 03 10 H1 05 11 Part Number Description Models VAV VAV Control Wiring B 2000 B 3000 95 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 54 AM Style for B 650 and B 1000 MODULATING DAMPER MOTOR ADJUSTING OUTSIDE RETURN AIR RATIO BUILDING PRESSURE PHOTOHELIC PNEUMATIC DIAGRAM OPERATION BULDING PRESSURE INCREASES DAMPER GRADUALLY OPENS RETURN AIR SUPPLY UNTIL DESIRED BULDING PRESSURE HAS BEEN OBTAINED BUILDING PRESSURE DECREASE CONTROLS REVERSE PRESET TO 0 1 LOW AND 0 25 HIGH part Number Bescipion Models AM Control Wiring B 650 and B 1000 FIGURE 55 AM Style for B 2000 B 3000 HIGH LOW MODULATING L2 DAMPER MOTOR ADJUSTING OUTSIDE RETURN AIR RATIO BUILDING PRESSURE PHOTOHELIC PNEUMATIC DIAGRAM OPERATION BULDING PRESSURE INCREASES DAMPER GRADUALLY OPENS RETURN AIR SUPPLY UNTIL DESIRED BULDING PRESSURE HAS BEEN OBTAINED BUILDING PRESSURE DECREASE CONTROLS REVERSE PRESET TO 0 1 LOW AND 0 25 HIGH Part Number Models Description
90. KER H4 COMMON 88 of 149 RM7897C CLIP JR2 _ BREAKER 4 ER H1 H2 H3 T1 250VA x1 x2 120vac R2 BURNER HI PRES SWITCH 1 4 W C C NC UV SCANNER PRIMARY IGNITION CONTROL RM7890A CLIP JR2 TEMP CONTROL AMPLIFIER _ 3 ALL POSITIONS OFF MODULATING REGULATING VALVE MRV 4 20MA Input Signal OR 0 10VDC Signal SET DIP SWITCH BEFORE CONNECTING POWER WIRE CONNECTIONS DDC CONTROL TO CONTROL PANEL 1 1 40 41 42 43 44 45 46 47 BLOWER MOTOR STARTER PILOT VALVE IGNITION TRANSFORMER BURNER LOCKOUT LIGHT FLAME FAILURE IGNITION CONTROL SAFETY SHUTOFF VALVE RELAY R1 AND R2 VOLTAGE IS SPECIFIED BY CONTRACTOR CAN BE 120VAC 24VAC OR 24VDC 42 43 COIL CONN BY OTHERS 44 COIL CONN BY OTHERS 46 R3 47 BURNER LOCKOUT CONTACT CONN BY OTHERS FIGURE 47 BMS Ready Control AM Style Units B 650 B 1000 FUSABLE DISCONNECT FUSES BY OTHERS BREAKER 3 AMP x1 XE BREAKER H4 H1 H2 H3 T1 250VA 2 120vac R1 R2 BURNER LOW PRES HI TEMP SWITCH LIMIT 0 3 W C HLS C NO HI PRES SWITCH 14 W C 8A MANUAL PRIMARY IGNITION CONTROL FOR B 2000 B 3000 RM7897C CLIP JR2 THREE POSITION DIP SWITCH ON SC11 B 4 20mA 0 10 VDC ALL POSITIONS o _ 3 ALL POSITIONS OFF o e o ON OF SECTION 17 ELECTRICAL BLOWER MOTOR MOTOR STARTER MODULATING DAMPE
91. L RAIL VALVE 10R2 Z REMOTE BOX REMOTE BOX 10X10 INTERNAL LEFT SIDE TERMINAL RAIL REMOTE BOX MOTOR 11 6 RIGHT SIDE 16 I REMOTE BOX RIGHT SIDE 10 10 Wakas B 650 B 3000 SPLASH PLATE MOUNTED NOTE LABEL 3 4 AND 10 MUST BE ORIENTATED ON CONTROL ENCLOSURE BOTTOM PANEL SO THAT IT CAN BE READ FROM TOP LEFT B 350 CONTROL ENCLOSURE FLOOR UNDER TO BOTTOM RIGHT WHEN THE AIR HANDLER VED AUX MOTOR STARTER AND OR IS INSTALLED AT THE JOB SITE f LABEL 15 IS USED ANY TIME THERE IS A GFI OUTLET THAT IS POWERED BY OTHERS TO BE POSITIONED NEXT TO LABEL 8 AND OR 14 Part Number Description 19024 Label Propane Gas 19025 Label Natural Gas 19162 Label Rotation 19161 Label High Temperature Limit 19100 Label Ground 91070009 Label Electric Shock Hazard Mini 91010444 Label B Series Rating Plate 91010443 Label B Series Exhaust Fan Motor Control 90911300 9 x 13 Clear Pouch Label B Series Wire Connection Control Panel Remote Panel 91010446 Label ETL Certification Without Recirculation Z83 4 91010447 Label ETL Certification With Recirculation Z83 18 80XXX Wiring Diagram Varies by Order 91040128 Label Auxiliary Motor Starter 91010448 Label Shock Hazard GFI 91010451 Label Panel Shop Approval
92. More than one disconnect switch may be required to disconnect electric from equipment Equipment must be properly grounded Failure to follow these instructions can result in death or electrical shock Each air handler is equipped with a wiring diagram which will vary depending on the type of remote panel supplied See Page 80 Figure 38 through Page 86 Figure 44 Depending on the air handler configuration and optional equipment ordered an option sheet may also be included This option sheet overwrites the wiring diagram between the electrical terminals indicated Air handlers can also be supplied as building management system BMS reagy In this case a remote panel is not supplied See wiring diagrams on Page 87 Figure 45 through Page 89 Figure 47 Note Spark testing or shorting of the control wires by any means will render the transformers inoperative Each unit is equipped with a fused rotary disconnect The rotary disconnects are for copper wire only 17 1 Wiring and Electrical Connections All electrical wiring and connections including electrical grounding must comply with United States Refer to National Electrical Code NFPA 70 latest revision Wiring must conform to the most current National Electrical Code local ordinances and any special diagrams furnished Canada Refer to Canadian Electrical Code CSA C22 1 Part 1 latest revision Check rating plate on air handler for supply voltage and curren
93. OSURE CONTROLS DIFFERENTIAL PRESSURE ACROSS BURNER PRESET AT 0 75 LOW AND 0 90 HIGH NOTE MOTOR STARTER OVERLOAD AND M1 LOW AUXILIARY CONTACT IS REPLACED WITH RM1 RELAY MODU LATING DAMPER PROFILE PLATE BURNER S1 53 Damper Switch VFD PROGRAM PARAMTERS 25HP OR LESS 48 MODULATING REGULATING VALVE REDUCED FLOW SWITCH Part Number Description Models VAV DDC VAV DDC Control Wiring B 2000 B 3000 94 of 149 1 01 20 ACCEL TIME SEC 1 02 20 DECEL TIME SEC d2 02 50 MINIMUM HZ 50 30HZ H1 03 10 H1 04 11 1 05 0 H1 07 0F V1000 ONLY L2 01 1 L5 01 5 VED PROGRAM PARAMTERS OR MORE B1 02 1 C1 01 25 C1 02 25 D2 02 50 D4 01 1 E1 01 VOLTS E2 01 AMP H1 03 10 H1 05 11 SECTION 17 ELECTRICAL FIGURE 53 Additional Control Wiring for VAV Style with Inlet Damper B 2000 B 3000 VARIABLE AIR VOLUME WITH INLET DAMPER CJA BIC sc PINVAV PHOTOHELIC 2 LOCATED INSIDE CONTROL ENCLOSURE 52 53 50 PHOTOHELIC 2 HIGH LOW DECEL ACCEL AIRHANDLER MOTOR TO FUSABLE DISCONNECT CONTROLS BUILDING PRESSURE PRESET AT 0 05 LOW AND 0 1 HIGH PHOTOHELIC PNEUMATIC DIAGRAM BUILDING PROFILE PLATE PRESSURE PRESSURE PHOTOHELIC 1 LOCATED INSIDE CONTROL ENCLOSURE CONTROLS DIFFERENTIAL PRESSURE ACROSS BURNER PRESET AT 0 75 LOW AND 0 90 HIGH NOTE MOTOR STARTER OVERLOAD AND M1 62 AUXILIARY CONTACT IS REPLACED WIT
94. OT be used In this case the hardware on the lip of the air handler roof panel should be removed the mount slid under the lip and hardware re installed Foam tape to be used on remaining three sides To install inlet hood on an exterior wall drill holes every 8 20 3 cm in the flanges of the inlet hood and mount with lag bolts provided by others 46 of 149 Step 12 2 2 C Left Panel Attach left panel and right to each side flange of the air handler filter section using five TEK self tapping screws Ensure that the flanges on the panels break inward Step 12 2 3 Bottom Rail SECTION 12 INLET HoOD Description Left Panel Part Number 13505080 Right Panel 13505081 TEK Screw 13404 Description Part Number Bottom Rail 13505072 13505095 TEK Screw 13404 Attach the bottom panel to the bottom attaching flange with five TEK self tapping screws and to each side panel with two TEK self tapping screws Ensure that the side tabs of the bottom panel are to the inside of the side panels 47 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 12 2 4 Top Front Panel Attach top front panel to the sidewall panels using four TEK self tapping screws on each side Ensure that the side tabs of the top panel are to the outside of the side panels Step 12 2 5 SIDE VIEW Top Front Panel Ne ps Top Inner Filter Rail
95. R MOTOR ADJUSTING OUTSIDE RETURN AIR RATIO 61 SIGNAL 60 USE V WHEN 0 10VDC amp SIGNAL SIGNAL IS REQUIRED 2 USE 1 WHEN 4 20MA SIGNAL IS REQUIRED MODULATING DAMPER MOTOR M9184D1021 WITH Q7230A INTERFACE UV SCANNER PRIMARY IGNITION CONTROL RM7890A CLIP JR2 TEMP CONTROL AMPLIFIER 5 11 MODULATING REGULATING VALVE MRV 4 20MA Input Signal OR 0 10VDC Signal SET DIP SWITCH BEFORE CONNECTING POWER T1 TRANSFORMER PRIMARY CONNECTION H1 460 USE 1 6 AMP BREAKER H2 230 USE 3 0 AMP BREAKER H3 208 USE 4 0 AMP BREAKER H4 COMMON WIRE CONNECTIONS DDC CONTROL TO CONTROL PANEL 1 1A 40 41 42 43 44 45 46 47 60 61 2 B PILOT VALVE IGNITION TRANSFORMER BURNER LOCKOUT LIGHT FLAME FAILURE IGNITION CONTROL SAFETY SHUTOFF RELAY R1 AND R2 VOLTAGE IS SPECIFIED BY CONTRACTOR CAN BE 120VAC 24VAC OR 24VDC 42 43 RD COIL CONN BY OTHERS COIL CONN BY OTHERS 46 R3 47 BURNER LOCKOUT CONTACT CONN BY OTHERS 89 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL 17 6 Additional Control Wiring Depending on the style of the air handler MUA FR AM or VAV there may be additional control wiring that will be factory installed when the air handler is ordered Any additional control wiring that is added to the air handler will be on the supplemental option sheet On the MUA style there are no additional controls unless an optional
96. RIABLE AIR VOLUME CONTROLLED BY THE DDC P N VAV DDC 52 53 50 DECEL 52 e ACCEL DECEL ACCEL 53 e CONTACTS WIRED BY OTHERS TO FUSABLE DISCONNECT PHOTOHELIC PNEUMATIC DIAGRAM PROFILE PLATE PRESSURE PHOTOHELIC 1 LOCATED INSIDE CONTROL ENCLOSURE CONTROLS DIFFERENTIAL PRESSURE ACROSS BURNER PRESET AT 0 75 LOW AND 0 90 HIGH NOTE MOTOR STARTER OVERLOAD AND M1 62 AUXILIARY CONTACT IS REPLACED MODU WITH RM1 RELAY LATING DAMPER MOTOR HIGH LOW PROFILE PLATE BURNER VFD PROGRAM PARAMTERS 25HP OR LESS C1 01 20 ACCEL TIME SEC C1 02 20 DECEL TIME SEC T d2 02 5096 MINIMUM HZ 50 30HZ MODULATING H1 03 10 H1 04 11 H1 05 0F H1 07 0F V1000 ONLY REGULATING POE aa VALVE 2 01 1 15 01 5 Damper Switch VED PROGRAM PARAMTERS 30HP OR MORE B1 02 1 1 01 25 C1 02 25 D2 02 50 D4 01 1 REDUCED FLOW SWITCH E1 01 VOLTS E2 01 AMP H1 03 10 H1 05 11 Part Number Description Models VAV DDC VAV DDC Control Wiring B 2000 B 3000 93 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 52 BMS Ready Control for VAV Style with Inlet Damper B 2000 B 3000 VE VARIABLE AIR VOLUME CONTROLLED BY THE DDC WITH INLET DAMPER P N VAV DDC 52 53 50 DECEL 52 ACCEL DECEL CONTACTS WIRED BY OTHERS ACCEL 53 TO FUSABLE DISCONNECT PHOTOHELIC PNEUMATIC DIAGRAM PROFILE PLATE PRESSURE PHOTOHELIC 1 LOCATED INSIDE CONTROL ENCL
97. SERIES INSTALLATION OPERATION AND SERVICE MANUAL 5 Adjust air handler high fire gas pressure Determine the high fire gas pressure by adding the manifold pressure for maximum input from the rating plate and the burner negative pressure from the measurement made in the burner pressure section of this procedure Record this value for use in adjustment step For example Differential pressure 1 0 in wc Maximum manifold pressure from rating plate 2 0 in wc High fire gas pressure 2 0 1 0 in wc High fire gas pressure 1 0 in wc Force the burner into high fire Refer to the burner mode setting chart on Page 121 Table 23 for the specific amplifier and action Set the pressure at the burner side of the modulating valve to the calculated value from the begining of this step by removing high fire adjustment cap and rotating the regulator adjustment screw A clockwise rotation increases manifold pressure Temperature rise should not exceed maximum as listed on Page 121 Table 24 For Model B 350 the high fire gas pressure is set by adjusting the regulator upstream of the M611 valve See Page 123 Figure 81 Reconnect any wires that were used for adjustment 6 Adjust recirculating mode or reduced air vol ume high fire gas pressure This adjustment is required for and only applies to AM and VAV style units Force the unit into high fire and maximum recirculation for AM style or minimum air volume for V
98. TATIVES No representative of Bananza other than an Executive Officer has authority to change or extend these provisions Changes or extensions shall be binding only if confirmed in writing by Bananza s duly authorized Executive Officer 147 of 149 SECTION 24 THE BANANZA B SERIES WARRANTY OWNER WARRANTY REGISTRATION CARD Mail or Fax to Bananza 1100 Seven Mile Road N W Comstock Park 49321 Phone 1 616 726 8800 Fax 1 616 726 8807 Toll Free 800 255 3416 e www bananza com About the Owner Name Address City State Zip Code Phone Fax E mail About the Installer Name Address City State Zip Code Phone Fax E mail Purchased From if different than installer Name Address City State Zip Code Phone Fax E mail About your Heater Model Serial Fuel Installation Date Type of Installation check one 0 Automotive o Manufacturing 0 Warehouse 0 Recreational 0 Aircraft o Public Building 0 Office o Retail 0 Agricultural 0 Other Installation Code and Annual Inspections All installation and service of BANANZA equipment must be performed by a contractor qualified in the installation and service of equipment sold and supplied by Bananza and conform to all requirements set forth in the BANANZA manuals and all applicable governmental authorities pertaining to the installation service operation and labeling of the equipment To help facilit
99. agout the electrical disconnect and gas valve that supplies the unit in accordance with OSHA regulations and allow ample time for the air handler to cool After maintenance is performed or air handler is serviced the air handler shall be re commissioned to the start up procedure as outlined on Page 116 Section 19 20 1 General SECTION 20 MAINTENANCE Installation Code and Annual Inspections All installation and service of BANANZA equipment must be performed by a contractor qualified in the installation and service of equipment sold and supplied by Bananza and conform to all requirements set forth in the BANANZA manuals and all applicable governmental authorities pertaining to the installation service and operation and labeling of the equipment To help facilitate optimum performance and safety Bananza recommends that a qualified contractor conduct at a minimum annual inspections of your BANANZA equipment and perform service where necessary using only replacement parts sold and supplied by Bananza First 8 Hours of Operation Check belts and adjust as required See Page 118 Section 19 2 2 Though belts were properly adjusted at the factory they will stretch after the first few hours of operation First 100 Hours of Operation Re check belt tension and adjust if necessary Annual Fall Start Up Follow entire start up procedure at this time and check control settings and operation See Page 116 Section 1
100. ain clearances to combustibles at all times for safety Check the clearances on each air handler being installed to make sure the product is suitable for your application and the clearances are maintained Clearances to combustibles for models B 350 B 3000 are 12 30 5 cm on the control enclosure side and 6 15 2 cm on all other surfaces Read and follow the safety guidelines below Locate the air handler so that the air intakes are not too close to any exhaust fan outlets gasoline storage propane tanks or other contaminants that could potentially cause dangerous situations Keep gasoline or other combustible materials including flammable objects liquids dust or vapors away from this air handler or any other piece of equipment Maintain clearances from heat sensitive material equipment and workstations Clearances to combustibles do not denote clearances for accessibility Minimum clearance for access is 48 122 cm Minimum clearance for accessibility applies to the control enclosure blower access panel and filter access panel when equipped The stated clearances to combustibles represent a surface temperature of 90 F B0 C above room temperature 90 F 50 C plus ambient temperature Building materials with a low heat tolerance i e plastics vinyl siding canvas tri ply etc may be subject to degradation at lower temperatures It is the installer s owner s responsibility to assure that adjacent materials a
101. ainted Quantity Quantity Quantity Filter Rail Assembly 13505066 2 2 N A Top Inner Rail 13505068 1 1 1 Bottom Rail Assembly 13505072 1 1 N A Top Back Panel 13505075 1 1 1 Top Front Panel 13505076 1 1 N A Left Panel 13505080 1 1 1 Right Panel 13505081 1 1 1 Upright Mount 13505090 2 2 2 Horizontal Mount 13505091 2 2 2 Drip Rail 13505092 2 2 2 TEK Screw 13404 82 105 92 5 16 18 x 1 Bolt HHCS Grade 5 20507 5 5 5 5 16 Flat Washer 95211600 5 5 5 5 16 Nut Flange 20509 5 5 5 Permanent Filter 20 x 20 x 1 20628 6 N A N A 10 24 KEPS Nut 20698 8 8 N A A1 Snap Fastener 20900 6 N A N A 10 24 x 1 2 HMS Bolt 27000 8 8 N A Fastener Rivnut3 8 16 912000 1 1 38Flatwsher 2085 1 1 3 8 16 x 1 Bolt Hex Grade 5 20517 10 10 10 Foam Tape 92700017 14ft 14ft 14ft Horizontal Mount for Birdscreen 13505087 N A 2 N A Screen 38 75 x 59 90740051 N A 1 N A Fender Washer 1 4 x 1 95211550 N A 12 N A Bottom Rail Assembly 13505095 NA 14 Top Front Panel ML 13505096 N A N A 1 Inner Support Rail ML 13505097 N A N A 1 Outer Support Rail ML 13505098 N A N A 1 Side Cover ML 13505099 N A N A 2 Moisture Limiter Media 12 x 60 x 5 5 90740001 N A N A 3 45 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 12 2 1 Without Air Handler Top Panel SIDE VIEW With SIDE VIEW Filter Section Filter Section _ Inlet Hood E Inlet Hood H
102. allow motor to run for 10 minutes before replacing relief hardware NOTE In general it is not recommended to mix greases of different brands The mixing of different types of thickeners may destroy the composition and physical properties of the grease In the event that a different grease is required by the end user the following steps can be taken Using the instruc tions for lubrication open grease outlet and purge the system as much as possible of the old or unwanted grease Repeat this same operation after 1 week of service Consult Bananza or the motor manufacturer for further rec ommendations on grease compatibility 127 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL 20 4 Manifold and Controls Manifold Periodically check gas control assembly and internal and external piping for leaks Relief vent lines to outdoors on gas controls should be checked to ensure against blockage caused by insects or any other substance Clean as required All gas piping to the air handler must comply with the National Fuel Gas Code NFPA54 latest edition and all local codes Verify gas soundness of each SSOV Safety Shut Off Valve This test must be repeated after the first 100 hours of operation See Page 75 Figure 32 through Page 76 Figure 35 Air Flow Switch An annual check of the tubes attached to the air flow switch should be made to ensure against blockage caused by insects or any other substance Clean as required
103. alve The manual main gas shutoff valve is shipped loose for field installation A union must also be installed supplied by others between the supplied manual gas valve main and the first tee pipe Be sure that the fuel supply pipe connected at this point is large enough to ensure the proper gas flow and line pressure at the inlet of the air handler The piping must comply with United States Refer to NFPA 54 ANSI Z223 1 latest revision National Fuel Gas Code Canada Refer to CSA B149 1 latest revision Natural Gas and Propane Installation Code Gas supply piping must conform to best building practices and local codes During installation of the gas piping be sure that no piping restricts accessibility to the air handler or its removable access doors Lockable manual shut off valve must be added by the installer in compliance with Occupational Safety and Health Administration OSHA regulations 16 5 Pressure Test Ports There are 1 8 3 2 mm and 1 4 6 4 mm pressure test ports located on the manifold The test ports are available to measure the manifold inlet gas pressure and the burner gas pressure during burner setup 16 5 1 Manifold Inlet Gas Pressure The pressure port for measuring manifold inlet pressure is located on the inlet side of the first safety shutoff valve Refer to the unit rating plate for the acceptable inlet gas pressure 16 5 2 Burner Gas Pressure A pressure tap is used to measure negative ai
104. ate optimum performance and safety Bananza recommends that a qualified contractor conduct at a minimum annual inspections of your BANANZA equipment and perform service where necessary using only replacement parts sold and supplied by Bananza Further Information Applications engineering and detailed guidance on systems design installation and equipment performance is available through BANANZA representatives Please contact us for any further information you may require including the Installation Operation and Service Manual These products are not approved for residential use 2015 Roberts Gordon LLC All rights reserved No part of this work covered by the copyrights herein my be reproduced or copied in any form or by any means graphic electronic or mechanical including photcopying recording taping or information storage and retrieval systems without written permission of Roberts Gordon LLC Printed in the U S A 149 of 149 Attach this information to the wall near the BANANZA remote panel or equipment controls Read the Installation Operation and Service Manual thoroughly before installation operation or service OPERATING INSTRUCTIONS Stop Read all safety instructions on this information sheet Open the manual gas valve in the air handler supply line Turn on electric to the air handler Set temperature selector and if equipped thermostat to desired setting Set FAN switch to ON
105. cted by the air handler or another heat source as it may interfere with the operation of the air handler 18 2 1 Basic II HVAC Remote o FAN BURNER ON ON OFF OFF a 1 This control is typically used for air handlers providing make up air The burner flame modulates to maintain a constant discharge air temperature as selected on the temperature selection dial FAN ON BURNER ON Mode The air handler blower and burner operates continuously discharging air at the setpoint on the discharge temperature selection dial The burner flame modulates to maintain a constant discharge air temperature as selected on the temperature selection dial FAN ON BURNER OFF Mode Only the blower operates continuously to provide unheated air The burner remains off regardless of temperature on the temperature selection dial FAN ON indicator Indicates that the unit is supplying power to the blower motor via the M1 motor starter BURNER ON indicator Indicates that the unit has supplied power to open the main gas safety shut off valve 110 of 149 18 2 2 Standard Discharge Control SDC Remote OPERATING INSTRUCTIONS TOOPERATE AS HEATER MAIN AND PILOT GAS VALVE SMTOH ON 3 SET FAN SWITCH TO TAN ON OR TAN 4 SET BURNER SWITCH TO WINTER 5 SELECT ROOM TEMPERATURE SHUT OFF T FAN SMTON TO OFT AND BURNER ICH TO SUMMER BURNER OF FF OGGED E TER This control is typically use
106. cteristics Motor Size HP KW 2 1 5 3 2 2 5 4 0 7 5 5 5 10 7 5 15 11 20 15 25 18 5 30 22 5 230 1 60 12 0 16 0 23 0 31 0 39 0 208 3 60 5 9 8 7 14 0 21 7 29 0 41 0 50 0 65 0 77 0 230 3 60 5 6 8 0 13 8 20 0 26 8 38 0 48 0 60 0 72 0 460 3 60 2 8 4 0 6 9 10 0 13 4 19 0 24 0 30 0 36 0 575 3 60 2 2 3 1 5 5 77 10 0 16 2 19 2 24 5 29 6 Table 15 Safety Systems Safety Controls Location Voltage Manual Reset High Temp Limit All Models Blower Discharge 120 Pressure Switches All Models Air Handler Control Enclosure 120 Flame Control B 650 B 1000 B 2000 B 3000 Air Handler Control Enclosure 120 Flame Control B 350 Air Handler Control Enclosure 24 Discharge Temperature Monitor All Models Blower Discharge 24 AM Resistor AM VAV Style Air Handler Control Enclosure 24 17 5 1 Manual Reset High Temperature Limit Switch If for any reason the temperature of the air at the discharge of the blower reaches the limit set point of 160 F 71 1 C the high temperature limit switch will open the circuit to the burner system and discontinue all burner functions Events that could result in excessive discharge air temperatures include if the burner modulation amplifier is defective i e temperature sensor goes open circuit or if a surge in gas pressure reaches the burner Restarting of the burner can only be accomplished after the limit has cooled down and the reset button on the switch has been depressed This switch is located on the
107. d must be field supplied 17 5 6 Positive Low Fire Start This feature forces the burner to start in low fire rather than high fire during the air handler s start up sequence of operations The burner maintains its low fire setting for 10 seconds as per timer setpoint before it begins to modulate SECTION 17 ELECTRICAL FIGURE 39 Basic Remote Wiring Diagram B 350 3 PHASE ONLY BLOWER MOTOR md FUSABLE DISCONNECT BREAKER 1 3 AMP x1 120vac MOTOR STARTER HI TEMP LIMIT TAS 3 MANUAL RESET IGNITION CONTROL LOW PRES SWITCH C NO We HI PRES SWITCH C NC 9 9A O O 2 PILOT VALVE SAFETY SHUTOFF VALVE BURNER ON RELAY 24VAC BURNER ON LIGHT 120VAC T3 TEMP CONTROL 22 AMPLIFIER e TCA A1014 X1 24VAC X2 TEMP CONTROL AMPLIFIER TEMPERATURE SELECTOR TD114 MODULATING TEMPERATURE Hattie MONITOR GROUND SHIELDED CABLE AT CONTROL PANEL 75114 WIRE CONNECTIONS T1 TRANSFORMER REMOTE TO MAIN PANEL PRIMARY CONNECTION 1 2 3A 4 7 12 H1 460 USE 1 6 AMP BREAKER H2 230 USE 3 0 AMP BREAKER eee H3 208 USE 4 0 AMP BREAKER H4 COMMON 81 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 40 Standard Discharge Control Remote SDC Wiring Diagram B 350 3 PHASE ONLY BLOWER _ BREAKER 9 1 FUSABLE DISCONNECT H1 H2 BREAKER 3AMP abiit Eo X1 X2 120vac 1 M
108. d equip during installation practices tices to avoid falling ment operation and service Equipment and accessories are Edges are sharp heavy Failure to follow these instructions can result in death injury or property damage The B 350 filter section is shipped assembled The B 650 B 3000 filter sections are shipped unassembled and must be assembled prior to installation Part numbers that end with a W indicate that the part can be ordered with either an unpainted galvanized finish or an acrylic modified alkyd enamel finish To order with a galvanized finish do not include the W at the end of the part number to order with a painted finish include the W at the end of the part number If the filter section support is necessary it may be installed prior to attaching the filter section to the air handler See Page 41 Section 11 4 NOTE Check to be sure that all required components are present If any are missing contact your BANANZA independent distributor 11 1 Filter Section B 350 ight Part Number Description A B C Weights Ibs kg Filter section with 77082 301 W permanent alumi 28 3 270 32 3 num mesh filters Filter section with 77083 301 W disposable polyes cm 71 9 68 6 82 1 ter filters Filter Size Quantity Part Number in 20x25x2 2 2262 cm 50 8 x 63 5 x 5 1 628 lt in 20x50x1 1 2362 cm 50 8 x 127 x 2 5 5628
109. d for air handlers providing space heating The burner flame modulates to maintain a constant discharge air temperature as selected on the temperature selection dial While in auto mode a space temperature thermostat controls the operation of the air handler to maintain the desired space temperature AUTO WINTER Mode The air handler blower and burner cycle on and off to maintain space temperature as selected on the room thermostat When the air handler is operating air is being discharged at the setpoint on the discharge temperature selection dial The burner flame modulates to maintain a constant discharge air temperature as selected on the temperature selection dial The discharge air temperature setting must be higher than the thermostat setting ON WINTER Mode The air handler blower and burner operate continuously to provide heated air When the air handler is operating air is being discharged at the setpoint on the discharge temperature selection dial The burner flame modulates to maintain a constant discharge air temperature as selected on the temperature selection dial The unit disregards the thermostat setpoint while in this mode ON SUMMER Mode Only the blower operates continuously to provide unheated air The burner remains off regardless of temperatures on the temperature selection dial and thermostat FAN ON indicator Indicates that the air handler is supplying power to the blower motor via the M1 mot
110. dished out Bottom of groove should show no signs of belt contact Sheave alignment set screw torque and belt tension should be checked after 8 24 and 100 hours of initial start up Visually inspect belts and sheaves for excessive wear If belts have a slick glazed look the belts are slipping Check drive capacity and belt tension Never replace only one belt in a used set as used belts will elongate Replace the entire set if replacement is necessary See Page 117 Section 19 2 1 and Page 118 Section 19 2 2 Blower Bearing Lubrication Blowers with spider bracket bearings are pre lubricated and do not require any re lubrication during their entire service life Blowers that use pillow block bearings should be re lubricated per the chart below The recommended lubricant is Shell Alvania 2 or S3 grease To re lubricate the blower pillow block bearings be sure that the grease fittings on the bearing housing or air handler cabinet wall in the case of extended grease lines are clean Apply the recommended grease to the fitting with a low pressure grease gun and add slowly while the shaft is spun by hand Do not over grease Over greasing will reduce the service life of the bearings Consult the blower manufacturer for grease capacity recommendations as capacities vary by model See Page 134 Table 30 for blower manufacturer based on blower frame Lubrication Schedule Use a No 2 Lithium complex base grease or equivalent Hours Run S
111. dler configuration and model See Page 97 Figure 56 through Page 97 Figure 58 With the AM and VAV package a temperature rise limiting resistor comes prewired See Page 90 Figure 48 through Page 96 Figure 55 When the air handler goes into full recirculation the resistor is activated lowering the maximum temperature rise to comply with government standards For the FR package the gas valve is preset to the proper temperature rise See Page 121 Table 24 SECTION 19 START UP PROCEDURES 19 2 Mechanical This piece of equipment requires at least 4 CFM 6 8m3 h of outside air 1 000 Btu h 0 293 kW Before installation check that the local distribution condition nature of gas and pressure and the current state of adjustment of the equipment are compatible If filters are not installed via inlet hood or filter section an air strainer must be installed on the inlet of the air handler with openings less than or equal to 5 8 16 mm in diameter Air inlets must be installed with the lowest edge 19 500 mm above any surface This applies to roof curbs upright stands and suspended air handlers 19 2 1 Sheave Alignment Sheaves are factory aligned On all air handlers check sheave alignment as follows 1 Attach a string to the vertical surface next to the blower shaft bearing See Page 117 Figure 76 2 Wrap the string around the blower sheave and across both sheave surfaces as shown 3 Adjust until all fo
112. e Max Wire 120 18 150 45 m 120 16 250 75 m 120 14 350 106 m NOTE Wiring for temperature controls must be run in shielded cable as indicated on the wiring diagram 172 2 Low Voltage Control Wiring Low voltage 24 V AC DC control wiring in excess of 100 30 5 m in length should be in its own separate conduit run to prevent interference 173 Motor Current Draw For current requirements of the motor refer to Page 79 Table 14 For specific current requirements see rating plate located on the blower motor Current draw may be adjusted downward by reducing blower rotations per minute RPM or by increasing external static pressure 174 Control Current Draw The maximum current draw for an air handler s controls and accessories is 3A 175 Safety Systems Safety systems are required for proper performance of the air handler The air handler shall not be permitted to operate with any safety system disabled If a fault is found in any of the safety systems then the system shall be repaired only by a contractor qualified in the installation and service of gas fired Table 14 Full Load Current Draw SECTION 17 ELECTRICAL heating equipment using only components that are sold and supplied by Bananza Refer to Page 79 Table 15 for a brief description of each safety device its location and its switching voltage Electrical Chara
113. e first 100 hours of operation 19 7 Temperature Control System Calibration The temperature control system components are factory calibrated to a base resistance so that component replacement will not upset the system calibration If the temperature control system should require field calibration refer to the provided temperature control amplifier product information sheet Table 24 Maximum Temperature Rise Series MP2 Natural Gas LPG Model oF oF 5 350 90 50 70 38 9 Non Recirculating 100 55 80 44 5 Booval 1000 Recirculating 49 272 42 234 Non Recirculating 100 55 80 44 5 B 2 B 999 3000 Recirculating 73 5 40 8 63 35 Also applies to VAV style at minimum airflow SECTION 19 START UP PROCEDURES 121 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 79 MR 212 Valve B 650 B 3000 TOP VIEW cover removed Low Fire Adjustment loosen locking screw before adjustment High Fire Adjustment Cap Modulator Wire 48 and 49 or 49A SIDE VIEW NOTE For high fire adjustment turn clockwise to increase manifold pressure turn counter clockwise to decrease manifold pressure Outlet Pressure Inlet Pressure Tap Burner Pressure 122 of 149 SECTION 19 START UP PROCEDURES FIGURE 80 M611 Valve B 350 NOTE Modulating only Gas Inlet Low Fire Adjus
114. ed maximum 74 of 149 gas pressures an additional high pressure gas regulator will be required to assure that the correct gas pressure is supplied to the regulator Pressure should be measured between the high pressure gas regulator and safety shut off valve Minimum gas pressure as indicated on data plate must be measured with the burner operating in high fire Table 12 Gas Manifold Size Model B 350 B 650 B 1000 B 2000 B 3000 Gas NPT 1 1 1 2 Connection 16 3 Gas Manifold Venting Vent valves fitted on XL compliant manifolds must be piped to the atmosphere outside the structure and in accordance with applicable codes This is the responsibility of the installer 16 3 1 Main Gas Regulator Venting The main regulator used on 174 and larger manifolds must be piped to the atmosphere outside the structure This is the responsibility of the installer 16 3 2 Vent Line Installation The following may be used as a guideline for installation but all applicable codes and regulations must be followed Natural gas and LPG are toxic and flammable substances They must be released where they will not cause personal injury or property damage The end of the vent line must be located where it is safe to release gas Pipe the vent line outside the structure Use as short a vertical run of pipe as possible Do not run pipe from a high point to a lower point to avoid obstacles Use a minimum numbe
115. eedures in Maxitrol product information sheet 24 If proper resistances are not observed replace modulator head or repair wiring 25 If desired temperature is not reached increase maximum discharge air temperature setting 26 If desired space temperature is not reached decrease minimum discharge air temperature setting 27 If desired space temperature is not reached with heater at high fire it may be undersized Consult manufacturer 28 If temperature reading is incorrect check items 25 26 amp 27 then recalibrate if necessary 143 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL 144 of 149 SECTION 23 BANANZA B SERIES START UP PROCEDURES SECTION 23 BANANZA B SERIES START UP PROCEDURES Service Company Date of Installation Model Serial Installed at Name Name Address Address Phone Phone Fax Fax Notice Please return a completed copy to Bananza If this document is not returned the manufacturing date will be used as the warranty start date A WARNING Explosion Hazard Carbon Monoxide Leak test all compo Hazara nents of equipment 00 not recirculate air gas piping before from the heated operation space over burner Gas can leak if Air supply to burner piping is not must be from outside installed properly Do not high pressure test gas piping with equipment connected Falling Hazard Burn Hazard Use proper safety Allow equipment to eq
116. el esee 135 Table 32 V Belt 2 ie ete detect 135 There are references in this manual to various trademarks All trademarks mentioned herein whether registered or not are the property of their respective owners Bananza is not sponsored by or affiliated with any of the trademark or registered trademark owners and makes no representations about them their owners their products or services SECTION 1 AIR HANDLER SAFETY Your Safety is Important to Us This symbol is used throughout the manual to notify you of possible fire electrical or burn hazards Please pay special attention when reading and following the warnings in these sections Installation service and at a minimum annual inspection of air handlers must be done by a contractor qualified in the installation and service of gas fired heating equipment Read this manual carefully before installation operation or service of this equipment This air handler is designed for heating non residential indoor spaces Do not install in residential spaces These instructions the layout drawing local codes and ordinances and applicable standards that apply to gas piping electrical wiring ventilation etc must be thoroughly understood before proceeding with the installation Protective gear is to be worn during installation operation and service in accordance to the Occupational Safety and Health Administration OSHA Gear must be in
117. ent 117 Belt Tension onore 118 Honeywell Flame Module 119 MR 212 Valve B 650 3000 122 M611 Valve B 350 eere 123 Regulator 350 123 6 15 3 cm Straight Cast 129 12 30 5 cm Straight Cast 129 12 30 5 cm Tee Cast Iron 129 Control Panel Layouts 131 Power Panel 132 Blower Layout eene 134 LIST OF TABLES Table 1 Recommended Torque Settings 9 Table 2 B 350 Dimensions 11 Table 3 B 350 Weights 12 Table 4 Motor Weights 12 Table 5 B 650 B 1000 B 2000 and B 3000 Dimensions 13 Table 6 B 650 B 1000 B 2000 and B 3000 Weights 14 Table 7 Motor Weights 14 Table 8 B Series Selection Guide 15 Table 9 Estimated Pressure Drop of Accessory Components ohne e RU p 16 Table 10 Minimum Recommended Duct Size 73 Table 11 Discharge Duct Size Recommendations to Connect to Heater for BD RD
118. ep 12 3 13 61 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 12 3 12 Filter SS Load filters into the inlet hood checking to see that each filter is in the proper orientation by verifying that the arrow on the side of the filter points in the direction of air flow All of the arrows should be Description Size pointing towards the air handler when installed in the i 20x25x1 proper orientation Once filters are installed close snap Permanent Aluminum 50 8 x 63 5 x 2 5 fasteners installed previously See Page 60 Step 12 3 9 Mesh Filter i 20x 20x 1 to hold filters in place 50 8 x 50 8 x 2 5 For inlet hoods with permanent aluminum mesh filters the instructions end here Step 12 3 13 Moisture Limiter Side Cover Attach side cover of moisture limiter frame to the left side of the inlet hood drip rail using eight TEK screws Attach to the bottom pan assembly with two 10 24 x 12 bolts TEK Screw 13404 and 10 24 nuts Description Part Number Left Side Cover ML 13205078 13305078 62 of 149 Step 12 3 14 Moisture Limiter Side Cover Place the moisture limiter inner support rail under the top flange of the moisture limiter frame side cover and to the top of the inlet hood Attach to the top of the inlet hood using nine 1110 24 x 1 2 bolts and 10 24 nuts Attach to the side cover of the frame using two 10 24 x Ye bolts and 10 24 nuts Step 12 3 1
119. f power source and modulator coil check out items 5 amp 6 but proper modu lating voltages cannot be obtained then amplifier may be assumed at fault Install replacement amplifier 9 Adjust to proper low fire 10 If greater than 1 0 in wc negative pressure check equipment for clogged filters amp other inlet air restrictions For other solutions consult factory 11 If amplifier is proven at fault install replacement amplifier 12 If reading is incorrect replace the T244 TS244 TD244 or repair wiring 13 If proper action is obtained first check item 12 Recalibrate if necessary See section 19 7 14 Move TS144 to location where average temperature can be sensed 15 If proper temperatures are not observed refer to temperature calibration procedures in Maxitrol product information sheet 16 Clean replace valve and or seat if necessary 17 Clean or if necessary replace plunger 18 If readings are incorrect replace the T8144 or repair wiring 19 Increase inlet pressure if possible or change to larger valve Consult factory about possibility of using special spring to reduce pressure drop on selected installations 20 See valve adjustments in section 19 5 21 If amplifier is proven at fault install replacement amplifier 22 If reading is incorrect replace the T244 TS244 TD244 or repair wiring 23 If proper action is obtained first check item 22 Recalibrate if necessary Refer to Temperature Calibration Proc
120. gt amp gt TEMP CONTROL AMPLIFIER SC11 B THREE POSITION DIP SWITCH ON SC11 B 4 20mA ALL POSITIONS ON 0 10 VDC 3 Au Posmovs OFF Lo 2 Lo ON OFF 4 20MA Input Signal OR 0 10VDC Signal SET DIP SWITCH BEFORE CONNECTING POWER T1 TRANSFORMER PRIMARY CONNECTION H1 460 USE 1 6 AMP BREAKER H2 230 USE 3 0 AMP BREAKER H3 208 USE 4 0 AMP BREAKER H4 COMMON SECTION 17 ELECTRICAL 350 BLOWER MOTOR 350VA MOTOR STARTER BURNER LOCKOUT RELAY TIME DELAY 30S PILOT VALVE SAFETY SHUTOFF VALVE BURNER ON RELAY 24VAC 13 X1 RELAY R1 AND R2 VOLTAGE IS SPECIFIED BY CONTRACTOR CAN BE 120VAC 24VAC OR 24VDC MODULATING REGULATING VALVE MRV BURNER LOCKOUT CONTACT CONN BY OTHERS WIRE CONNECTIONS WIRES GROUNDED AT CONTROL PANEL REMOTE TO MAIN PANEL 42 43 44 45 46 47 40 41 SHIELD 87 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 46 BMS Ready Control MUA FR Style Units B 650 B 3000 FUSABLE DISCONNECT FUSES BY OTHERS BREAKER 3 AMP HI TEMP LIMIT HLS LOW PRES SWITCH 0 3 W C C NO 8A MANUAL PRIMARY IGNITION CONTROL FOR B 2000 B 3000 L THREE POSITION DIP SWITCH ON SC11 B 4 20mA ALL POSITIONS ov flo l2 o Ji ON 0 10 VDC T1 TRANSFORMER PRIMARY CONNECTION H1 460 USE 1 6 AMP BREAKER H2 230 USE 3 0 AMP BREAKER H3 208 USE 4 0 AMP BREA
121. h a light molybdenum oil in aerosol can Dampers furnished with stainless steel side seals should also have the seals lubricated generously Dampers should then be manually operated several times until linkages and blades operate freely Reconnect linkages and check dampers for proper operation See Page 65 Section 13 Filters 130 of 149 Filters should be checked for dirt restriction on a monthly basis or as required Replace filters with filters of equal specification when they appear dirty NOTE When using Bananza supplied disposable polyester filters they must be inserted with the white media side facing the inlet of filter section When using Bananza supplied permanent aluminum mesh or disposable filters they must be inserted with the arrow on the filter pointing in the direction of airflow toward the air handler See inlet hood or filter section for filters See Page 29 Section 11 and See Page 44 Section 12 SECTION 21 REPLACEMENT PARTS SECTION 21 REPLACEMENT PARTS ADANGER A WARNING Electrical Shock Hazard Explosion Hazard Fire Hazard Carbon Monoxide Hazard Use only genuine BANANZA replacement parts per this installation operation and service manual Failure to follow these instructions can result in death electric shock injury or property damage A WARNING AWARNING Severe Injury Hazard Cut Pinch Hazard Use proper lifting practices and equipment Wear protective gear during installation ope
122. ices to avoid falling Severe Injury Hazard Cut Pinch Hazard Use proper lifting Wear protective gear practices and equip during installation ment operation and service Equipment and accessories are Edges are sharp heavy Failure to follow these instructions can result in death injury or property damage A stand can be used when an upright air handler is to be installed on a concrete slab or on the floor The stand for model B 350 is 30 76 2 cm tall stands for models B 650 and B 1000 are available at 53 134 6 cm or 72 182 9 cm tall stands for models B 2000 and B 3000 are 72 182 9 cm tall The stand must first be fastened to the concrete slab or floor before the air handler is mounted 8 1 Upright Stand Installation To attach the stand to a concrete slab it must be secured with the use of studs embedded in the concrete Four 5 8 studs minimum must be installed in the slab one for each corner of the stand The stand has four 11 16 17 4 mm holes drilled through the stand pads See Page 23 Figure 16 Fasten the stand to the slab with four 5 8 hex nuts and lock washers provided by others 8 2 Attaching Air Handler to Stand Once the stand is secured to a concrete slab the air handler may be placed on the stand Prior to lifting the air handler apply the foam tape and remove the attaching hardware as described below The 72 12 7 mm thick double sided urethane foam tape provided by others
123. ifting lugs on the inlet end using a spreader bar across the long axis Lift the air handler off the skid and place it on a flat clean dry surface Step 2 Remove the lifting lugs on the inlet end of the air handler and re install hardware Step 3 Use all four lifting lugs on the discharge end of the air handler to enable the air handler to be lifted into the upright position Step 4 Lift the air handler into upright position Step 5 Next refer to the applicable portions of Page 22 Section 8 for specific mounting instructions FIGURE 10 Lifting an Upright Air Handler B 350 B 3000 18 of 149 Remove These Lifting Lugs SECTION 7 RooF CURB SECTION 7 ROOF CURB A WARNING Crush Hazard Falling Hazard Severe Injury Hazard Cut Pinch Hazard Use proper lifting Use proper safety Use proper lifting Wear protective gear equipment and equipment and practices and equip during installation practices tices to avoid falling ment operation and service Equipment and accessories are Edges are sharp heavy Failure to follow these instructions can result in death injury or property damage The roof curbs only support the burner and blower sections of the air handler Roof curbs are shipped unassembled and require field assembly NOTE Before installation verify that you have the correct roof curb and that all required components are present If any are missing contact your BANANZA independen
124. il Ensure that the drip rails are positioned above the filter clips where applicable using the provided holes in the sidewall panels Apply caulk to the drip rails before attaching to the side panels NOTE Double sided filter rails or snap fasteners are not required for inlet hood with moisture limiter For inlet hoods with permanent aluminum mesh filters continue to step 12 2 11 For inlet hoods with birdscreen no filters the instructions end here For inlet hoods with moisture limiter continue to step 12 2 12 Step 12 2 11 a TS Description Size Part Number in 20x20x1 Permanent Aluminum Mesh Filter 150 8x508x25 20628 Load filters into the inlet hood checking to see that each filter is in the proper orientation by verifying that the arrow on the side of the filter points in the direction of air flow All of the arrows should be pointing towards the air handler when installed in the proper orientation Once filters are installed close filter clips installed previously See Page 50 Step 12 2 8 to hold filters in place For inlet hoods with permanent alumimum mesh filters the instructions end here 51 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 12 2 12 Moisture Limiter Side Cover Description Part Number Attach side cover of moisture limiter frame to the left side Side Cover ML 13505099 TEK Screw 13404 of the inlet hood rain gutter using eight TEK screw
125. ing any two incoming power legs For blowers powered by a single phase motor refer to the motor rating plate for reversing instructions 22 2 Motor and Blower PROBLEM POSSIBLE CAUSE SOLUTION Motor does not operate Main disconnect switch is OFF Turn disconnect to ON Blown fuse s in disconnect Replace fuse s Blown fuse s breaker tripped in control transformer Replace fuse s reset breaker with disconnect off Fan switch on Power on terminals 3 3A Check wiring between remote panel and air handler Replace switch Cool down timer TD4 if equipped does not reset Power on 3A Replace TD4 timer Optional Damper does not open Check that damper is not obstructed Check that linkage is tight and secure Verify that 120 V at terminal 3B Replace damper actuator Time delay relay defect Power on terminal 3D after set time delay Replace time delay relay TR1 Motor starter contactor does not operate Power on terminal 3D and 2 Replace starter Tripped motor overload Power out to MUA motor when motor starter is energized Reset Check for proper FLA setting Replace overload If applicable Tighten screws on heater packs or overload Optional Low limit switch set to high Re adjust low limit switch setting Blower does not operate Belts broken or loose Replace tighten belts Loose motor or blower sheaves pulleys Reinstall and properly
126. irdscreen 13505087 Screen 90740051 TEK Screw 13404 Install horizontal mounting brackets for birdscreen on to face of inlet hood Mount birdscreen with brackets and secure with self tapping screws and washers 49 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 12 2 8 Double Sided Filter Rail Description Part Number Double Sided Filter Rails 13505066 10 24 x 1 2 Bolt 27000 10 24 Nut 20698 Snap Fastener 20900 Double Sided Filter Rail TEK Screw 13404 Attach the double sided filter rails horizontally to the face of the inlet hood using two 10 24 x 1 2 bolts and 10 24 nuts on each side When attaching the filter rails insert the bolt from the inside of the filter rail to allow for maximum clearance for the filters Attach the snap fastener with one TEK self tapping screw each First remove the washer as the washer will restrict the snap fastener making it difficult to open NOTE Inlet hood with birdscreen does not require filters or snap fasteners Step 12 2 9 Caulk the seams between the inlet hood and the air handler filter section and on the open sides of the J bend that lock the roof panels together 50 of 149 SECTION 12 INLET HoOD Step 12 2 10 Drip Rail Description Part Number Drip Rail 13505092 TEK Screws 13404 Attach drip rail to each side using five TEK self tapping screws for each drip ra
127. it Skid B 650 Ib 700 40 100 110 120 110 80 26 140 140 B 1000 kg 3175 18 1 45 4 49 9 54 4 49 9 36 3 11 8 63 5 63 5 2000 Ib 1400 230 60 220 190 210 150 120 26 N A 340 kg 638 104 3 272 99 8 86 2 95 3 68 54 4 11 8 154 2 B 3000 Ib 1650 300 60 270 240 260 160 160 26 N A 365 kg 748 4 136 1 272 122 5 108 9 1179 72 6 72 6 11 8 165 6 Dampers Stand Model piesa Inlet Mogel 53 Dampers 9 Lower B 650 Ib 160 190 60 B 1000 B 2000 105 100 34 41 kg 72 6 86 2 272 kg 454 15 4 18 6 Ib 150 46 61 B 3000 kg 68 20 9 277 Table 7 Motor Weights Size HP 3 5 7 5 10 15 20 25 30 kW 2 2 3 7 5 6 7 5 11 2 14 9 18 6 22 4 Ib 69 77 120 164 231 269 339 398 kg 31 3 34 9 54 4 74 4 104 8 122 0 153 8 180 5 TEFC Ib 135 133 200 219 316 395 510 545 kg 61 2 60 3 90 7 99 3 143 3 179 2 231 3 2472 NOTE Inlet variation of screen mesh without filters has equal weight as inlet hood with filters Inlet dampers for MUA style use both the upper and lower dampers for B 2000 and B 3000 Inlet dampers for FR AM and VAV styles only use the upper damper for B 2000 and B 3000 Model B 650 B 1000 damper weights apply to both discharge and inlet 14 of 149 SECTION 5 SPECIFICATIONS Table 8 B Series Selection Guide Motor HP at Noted dBA at Noted Heat Output Max Minimum Inlet Airflow Model External Static External
128. l B 350 Idle not powered Call for Heat received from Thermostat Power to module and self check Trial for Ignition timer started Spark ON Flame Close Pilot Gas Proved Valve before trial for ignition timer expires YES Spark OFF Open Main Gas Valve Flame Stabilization 2 seconds Call for Heat ends Close Main Gas Valve and Pilot Gas Valve Open Pilot Gas Valve Spark OFF Flame Lost Close Main Gas Valve and Pilot Gas Valve SECTION 18 SEQUENCE OF OPERATION Wait for Call for Heat to be removed Activate Alarm contact s optional More than 5 flame losses Lockout 113 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 74 RM7890 Flame Control B 650 and B 1000 Operating Controller and Limits 114 of 149 MASTER SWITCH LED Display Burner Start Flame Signal INTERMITTENT PILOT IGNITION ES IGNITION E FLAME DETECTOR PRE IGNITION INTERLOCK Initiate Initial Powerup Only Standby Safe Start Pilot Flame Establishing Period 10 Sec Main Flame Establishing Period Run Standby Power Power Pilot Flame O Main O Alarm Ignition Power Pilot Flame e Main O Alarm Power Pilot Flame Main O Alarm Intermittent Pilot Main Valve Limits and Burner
129. lable for all models in the horizontal configuration 9 2 Leg Mounting Horizontal Air Handler B 350 B 3000 The 46 116 8 cm legs must first be mounted to the air handler before being mounted to the concrete slab or floor To attach the legs with the air handler must first be lifted with the provided lifting lugs See Page 17 Section 6 1 for safe lifting practices In each corner of the bottom of the air handler four leg mounting holes will be found See Page 24 Figure 17 The legs can now be mounted one at a time to the inside of the corner by removing the hardware that occupies each of the bolt locations Place the leg on the inside of the corner and attach with the previously removed hardware Missing hardware needs to be added at each bolt location The required hardware is a 5 16 18 x 1 grade 5 bolt a 5 16 flat washer and a 5 16 18 grade 5 flange nut 24 of 149 On models B 2000 and B 3000 there is a bracket on the inside of each corner that is held in place by the two bolts closest to the corner This bracket must be removed when the leg is attached to the air handler Bracket can be discarded once legs are attached FIGURE 17 Leg Mounting Holes B 350 B 3000 To attach the legs to a concrete slab the base of each leg is equipped with two 1 holes Studs capable of accepting 5 8 nuts must be installed in the concrete slab For stud positioning See Page 25 Figure 18 The air handler may now be p
130. laced down over the slab studs The legs should then be bolted down with 5 8 nuts See Page 25 Figure 19 SECTION9 LEGS FIGURE 18 Stud Positioning Model Part Number Weight Ibs Weight kg B 350 77040 301 W 26 0 11 8 NOTE Weight shown reflects per each leg B 650 and B 1000 B 2000 77040 301 W 26 0 77040 301 W 26 0 11 8 B 3000 77040 301 W 26 0 FIGURE 19 Leg Bolt Detail 46 10 5 116 8cm 26 7 cm 1 0 2 5 cm 25 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 10 INDOOR SUSPENSION MOUNTING HORIZONTAL AIR HANDLER A WARNING Crush Hazard Use proper lifting equip ment and practices Lack of blower assembly Crush Hazard Check blower assembly per maintenance section Crush Hazard Hanging hardware must support equipment weight Do not hang by lifting lugs maintenance can cause excessive vibration Excessive vibration can cause support failure Failure to follow these instructions can result in death injury or property damage A WARNING Falling Hazard Use proper safety equipment and practices to avoid falling Severe Injury Hazard Use proper lifting practices and equipment Cut Pinch Hazard Wear protective gear during installation operation and service Equipment and accessories are heavy Edges are sharp
131. le 20 Deflection Force Belts in Ibs Belt Motor Sheave TYPE B X Cross Dimension Range High HP Section in cm Min Max Min Max 3 4 4 2 4 5 1 2 5 3 4 8 B 4 4 5 6 5 1 8 7 1 8 6 1 2 9 1 8 5 8 8 6 6 3 8 8 3 4 73 8 10 1 8 NOTE If drive belts squeal during start up increase belt tension to the highest allowed value Re check tension during each inspection See Page 124 Section 20 for additional information 19 2 3 Air Temperature Sensing The sensing probe is factory mounted in the blower housing Not included if customer orders BMS ready 118 of 149 19 3 Electrical 1 Check motor starter for proper overload set tings The overload setting should meet full load amps FLA of motor 2 Measure the supply voltage with the air handler off and then on For a system that is powered with three phase power measure the voltage of each phase 3 Verify correct blower rotation 4 While the blower is running and the burner is off measure the total system current draw with an ammeter Measure the system current draw again after the burner adjustments are made and with the burner and blower both on 5 If applicable compare all variable frequency drive VFD programming parameters with specifications provided on electrical drawing 19 4 Airflow The air flow switches are factory calibrated safety devices for burner air flow If an air flow switch d
132. lectrical connection to air handler must be in accordance with the following codes United States Refer to National Electrical Code NFPA 70 latest revision Wiring must conform to the most current National Electrical Code local ordinances and any special diagrams furnished Canada Refer to Canadian Electrical Code CSA C22 1 Part 1 latest revision 4 6 Venting 10 of 149 The venting must be installed in accordance with the requirements within this manual and the following codes United States Refer to NFPA 54 ANSI Z223 1 latest revision National Fuel Gas Code Canada Refer to CSA B149 1 latest revision Natural Gas and Propane Installation Code 4 7 High Altitude These air handlers are approved for installations up to 2000 609 6 m in the US and 4500 1371 6 m in Canada without modification Consult factory if US installation is above 2000 609 6 m or Canadian installation is above 4500 1371 6 m SECTION 5 SPECIFICATIONS SECTION 5 SPECIFICATIONS Table 8 Dimension and estimated weight tables apply to both The legend below details abbreviations used in this upright and horizontal units of the same model section and applies to Page 11 Figure 5 through Unless otherwise requested all direct fired air Page 14 Figure 8 Return Air RA is only for FR handlers are set up to accept an external static Fixed Recirculation and AM Air Managemen
133. ludes the high temperature limit switch and the low and high airflow pressure switches Once the burner control circuit is satisfied then the flame control module will execute the burner ignition sequence Once the pilot flame is ignited and sensed by the UV scanner the flame control module will open the safety shutoff valve to ignite the main flame When the safety shutoff is opened 115 VAC is applied to the Burner On light and T3 transformer the secondary side supplies 24 VAC to the temperature control amplifier The temperature control amplifier controls the modulating valve based on the discharge temperature monitor and also the room temperature monitor in the case of a DTC remote panel 112 of 149 The air handler will run when the thermostat calls for heat 18 3 1 Flame Control The flame control is a safety device and not servicable See Page 113 Figure 73 through Page 115 Figure 75 for detailed sequence of operation The RM 7890 and RM 7897 must be configured prior to replacement This is done by removing certain configuration jumpers on the upper left corner of the flame control located behind the blue cover See Page 112 Figure 72 and Page 112 Table 19 FIGURE 72 Honeywell Safeguard Jumpers Selectable Configuration Jumpers Table 19 Site Configuration Jumper Options Jumper Number 7890 7897 JR1 Intact Intact JR2 Remove Remove JR3 Intact Intact FIGURE 73 S8600 Flame Contro
134. ly reset B 350 will reset upon power restoration See the Trouble Shooting Guide Page 136 Section 22 17 5 5 Discharge Temperature Sensor This device senses the discharge temperature of the air at the blower The discharge temperature sensor FIGURE 38 Wiring Diagram Key Notes 1 Wire Over 24vac To Be A Minimum Of 16 Awg Flexing Type Mtw 105c 600v Or Equivalent Colors 115vac Phase red Neutral white Ground green Colors 24vac Blue Control Wire To Be A Minimum Of 20 Awg Type Belden 5401fe Cmr 75c Shielded Or Equivalent Power Supply And Motor Wires To Be Sized To Nfpa79 Latest Edition Colors All Voltages Phase s black Ground green Terminals Located In Control Panel Only Terminals Located In Control Panel And Connected To The Remote Panel Terminals Located In Remote Panel Only Wire s Located In Control Panel Wire s Located In Remote Panel Shielded Wire s One End Grounded Relay Motor Starter Coil Associated With M1 Contacts Normally Open Contact Associated With M1 Coil Normally Closed Contact Associated With CR2 Coil D Indicator Light On Remote Panel z 80 of 149 reports the discharge temperature to the temperature control amplifier which modulates the burner to the temperature set on the remote panel selector Should this system fail the manual high temperature limit switch will turn the burner off BMS ready air handlers do not come equipped with this sensor an
135. n and service of gas fired heating equipment or your gas supplier NOT FOR RESIDENTIAL USE cM Bananza C US 1100 Seven Mile Road NW LisTEO Comstock Park MI 49321 Telephone 1 616 726 8800 rtek Fax 1 616 726 8807 Toll Free 800 255 3416 CANADA 100 OUTSIDE AIR ONLY www bananza com 2015 Roberts Gordon LLC P N BN121100NA Rev C 07 15 POUR VOTRE SECURITE Si vous sentez une odeur de gaz Ouvrir les fen tres N essayer pas d allumer un appareil N utiliser pas d interrupteurs lectriques N utiliser pas de t l phone dans votre batiment Eteindre flamme nue Quitter le b timent e BANANZA B Series ui m 5 Windle vote cure oc L appareil de traitment de l air e qaz Suivre les instructions du fournisseur CO m D u sli 0 n d i re cte y d u g aZ D 0 u r de gaz iier les applications industrielles d incendie AAVERTISSEMENT Manuel d installation d op ration et d entretien Risque d incendie Garder tous les objets liquides ou vapeurs B 350 infl bles la dist inimale d inflammables la distance minimale de B 650 l unit de chauffage requise avec les mat riaux combustibles B 1 000 Certains objets prendront feu ou exploseront s ils sont plac s proximit de l unit de B 2000 chauffage Le non respect de ces instructions peut B 3000 entrainer la mort des blessures corporelles ou des dommages mat riels A ATTENTION In
136. n on an upright air handler that is stand mounted the filter section must be installed in the stand prior to placing the air handler See Page 22 Section 8 for proper stand mounting Place the filter section so that the outward flange is on the top side Set the filter section into the stand Place 1 2 foam tape supplied by others along the perimeter of the top of the flange Place the air handler in the stand per the stand mounting instructions 43 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 12 INLET HOOD A WARNING Crush Hazard Falling Hazard Severe Injury Hazard Cut Pinch Hazard Use proper lifting Use proper safety Use proper lifting Wear protective gear equipment and equipment and practices and equip during installation practices tices to avoid falling ment operation and service Equipment and accessories are Edges are sharp heavy Failure to follow these instructions can result in death injury or property damage Inlet hoods are shipped unassembled and must be assembled prior to installation The inlet hood may be installed either onto the inlet of the air handler or to an outside wall After installing an inlet hood all hardware must be torqued according to recommended specifications on Page 9 Table 1 In addition all seams must be caulked provided by others Part numbers ending with W indicate that the part can be ordered with either an unpainted galvanized
137. nd AM B 2000 and B 3000 3A 2 1 RD2 62 e FR uses upper only MUA uses upper with a mechanically connected lower Models B 350 B 650 and B 1000 B 2000 Part Number 77019 301 80900 80920 Description Inlet Damper Inlet Damper MUA Inlet Damper FR AM VAV Inlet Damper MUA Inlet Damper FR AM VAV Inlet Damper 80920U B 2000 77530 B 3000 77830U B 3000 17 8 5 Motorized Discharge Damper The motorized discharge damper is mounted in the duct downstream from the discharge opening of the air handler When the air handler fan is turned on the damper motor is energized and opens the damper The damper motor has an auxiliary switch that prevents the blower from starting until that damper has opened sufficiently to allow the required air volume to pass through the air handler 100 of 149 Mounted On Discharge Side Description Discharge Damper Discharge Damper Discharge Damper Discharge Damper Models B 350 B 650 and B 1000 B 2000 B 3000 Part Number 77014 301 77018 301 80922 2 778372 17 8 6 Control Enclosure Heater The control enclosure heater is an electric heater that keeps the temperature in the control enclosure within the range for the control components This option is intended for extremely cold climates but recommended for installations below 15 F 9 C The air handler controls are rated to perform at tempera
138. ndlers weight and the required reach See Page 17 Figure 9 For air handlers weight see Page 12 Table 8 and Page 12 Table 4 for model B 350 See Page 14 Table 6 and Page 14 Table 7 for models B 650 B 3000 6 1 2 Lifting a Horizontal Air Handler All Models Lift the air handler into place installing appropriate hardware supplied by others into all lifting lug holes on the unit base For model B 350 lifting lug holes are 1 5 3 81 cm diameter For models B 650 B 3000 lifting lug holes are 2 0 5 1 cm diameter Use spreader bars to ensure that the lifting cables clear the sides of the air handler The air handler must be kept level during the lift to prevent tipping twisting or falling If lifted improperly product damage may occur Next refer to the applicable portions of Page 79 Section 7 through Page 26 Section 10 for specific mounting instructions For mounting of accessories refer to the applicable portions of Page 29 Section 11 through Page 69 Section 14 FIGURE 9 Lifting a Horizontal Air Handler a CEST 17 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL 6 1 3 Lifting an Upright Air Handler B 350 B 3000 All air handlers are shipped in the horizontal position Prior to lifting an upright air handler the following steps must be performed See Page 18 Figure 10 Step 1 The air handler must be lifted using the two lifting lugs on the top of the discharge end and the two l
139. noid NOTE Vent valves must be piped to the atmosphere outside the structure and in accordance with applicable codes FIGURE 35 XL Compliant Manifold B 650 B 3000 Vent to Atmosphere p Block Valve Alternate With Actuator Inlet High Gas Pressure Regulator Optional Safety Shut Off Valve With Actuator Vent to Atmosphere m Vent Manual Gas Valve Vent to Atmosphere Val Mai alve Main Modulating Valve With Union H Pressure Regulator 1 n Manual bv ua Burner 1 1 Low Gas Pressure Switch Ps I E High Gas Pressure Switch T T Vent to Atmosphere gt Manual Gas By Others Valve Pilot Pilot Regulator Pilot Solenoid NOTE Vent valves must be piped to the atmosphere outside the structure and in accordance with applicable codes 76 of 149 16 4 Gas Piping The gas manifold extends through the side of the control cabinet for models B 350 B 3000 The factory piping terminates with a female pipe connection in the manual gas v
140. ntrol Wiring 90 of 149 AIR HANDLER MOTOR PHOTOHELIC PNEUMATIC DIAGRAM PROFILE PLATE PRESSURE PROFILE PLATE BURNER BEFORE AFTER VED PROGRAM PARAMTERS 25HP OR LESS C1 01 20 ACCEL TIME SEC C1 02 20 DECEL TIME SEC d2 02 50 MINIMUM HZ 50 30HZ 1 03 10 H1 04 11 H1 05 0F H1 07 0F V1000 ONLY L2 01 1 L5 01 5 VED PROGRAM PARAMTERS 30HP OR MORE B1 02 1 C1 01 25 C1 02 25 D2 02 50 D4 01 1 E1 01 VOLTS E2 01 AMP H1 03 10 H1 05 11 SECTION 17 ELECTRICAL FIGURE 49 Additional Control Wiring for VAV Style B 2000 B 3000 VFD TERMINALS VARIABLE AIR VOLUME CONTROLLED BY THE DDC P N VAV DDC SN 52 53 50 DECEL 52 N ACCEL DECEL ACCEL 53 CONTACTS WIRED BY OTHERS TO FUSABLE DISCONNECT PHOTOHELIC PNEUMATIC DIAGRAM PROFILE PLATE PRESSURE PHOTOHELIC 1 LOCATED INSIDE CONTROL ENCLOSURE CONTROLS DIFFERENTIAL PRESSURE ACROSS BURNER PRESET AT 0 75 LOW AND 0 90 HIGH NOTE MOTOR STARTER OVERLOAD AND M1 62 AUXILIARY CONTACT IS REPLACED MODU WITH RM1 RELAY LATING Ome LOW DAMPER PROFILE PLATE BURNER S3 21 VED PROGRAM PARAMTERS 25HP OR LESS C1 01 20 ACCEL TIME SEC C1 02 20 DECEL TIME SEC 48 d2 02 50 MINIMUM HZ 50 30HZ MODULATING H1 03 10 H1 04 11 H1 05 0F H1 07 0F V1000 ONLY REGULATING L2 01 1 L5 01 5 VALVE Damper Switch VED PROGRAM PARAMTERS 30HP OR MORE B1 02 1 C1 01 25 C1 02 25 D2
141. o low fire first Then rotate the adjustment screw until there is a continuous blue ribbon across the entire burner A counter clockwise rotation increases the flame size Low fire temperature rise must not exceed 12 F 7 C Tighten locking screw when finished Reconnect any wires that were removed for adjustment Once gas pressure and high low fire adjust ments are made the gas setup is completed All taps and instruments must be removed and all caps and plugs must be replaced Table 23 Burner Mode by Amplifier Type Amplifier Type High Fire Mode Low Fire Mode Remove wire 16 from Remove wire 45 from ter Series 14 minal 4 on the amplifier terminal 48 on the amplifier Remove wires 40 and 45 Remove wire 16 from Series 44 from terminals 2 and 4 terminal 9 on the on the amplifier amplifier Set BMS to max fire or remove input wires 40 and Remove wire 16 from SC11 Signal 41 from terminals 6 and terminal 1 on the Conditioner 5 and connect 9VDC signal battery to the signal condi tioner j Remove wire 16 from I Disconnect selector ribbon I Series 94 a terminal 2 on the cable from the amplifier P amplifier Remove wire 16 from terminal 2 on the amplifer Set system to maximum temperature 19 6 Safety Shut Off Valve Check After the initial start up and gas pressure adjustment verify gas soundness of each SSOV Safety Shut Off Valve This check must be repeated after th
142. ock the panel with the roof panel in front of it For inlet hoods with permanent aluminum mesh filters continue to Step 12 3 9 For inlet hoods with birdscreen no filters continue to Step 12 3 8 For inlet hoods with moisture limiter continue to Step 12 3 10 59 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 12 3 8 Install birdscreen mounts into inlet hood opening Description Part Number Mount birdscreen into brackets and secure with self Birdscreen 90740052 90740053 tapping screws and washers Birdscreen Mount 13205091 13305087 Fender Washer 95211550 TEK Screw 13404 For Model B 3000 only Step 12 3 9 Snap Fastene Double Sided Filter Rail ti 4 LP aM NOR QY Screws Attach the double sided filter rails horizontally to the face of the inlet hood using two 10 24 x bolts and 10 24 nuts on each side When attaching the Description Part Number filter rails insert the bolt from the inside of the filter Double Sided Filter Rails 13205066 13305066 rail to allow for maximum clearance for the filters 10 24 x 1 2 Bolt 27000 Attach the filter clips with TEK self tapping screws oe First remove the washer as the washer will restrict Snap Fastener 20698 13404 20900 the filter clip making it difficult to open NOTE Inlet hoods with birdscreen does not require filter
143. oes not close the problem may not be the air flow switch It could be an indication of an air flow problem incorrect blower rotation duct restrictions etc 19 4 1 Differential Pressure In order to verify proper airflow across the burner the differential pressure across the profile plate needs to be measured Attach a manometer to the pressure test ports where the pressure switch is attached and measure the differential pressure with a manometer This reading must be 0 9 in wc 0 1 in wc 2 24 mbar 0 25 mbar To adjust the differential pressure that was measured in the step above use the adjustable sheave To decrease the speed of the blower and the differential pressure turn the adjustable half of the sheave outward decrease diameter To increase the speed of the blower and the differential pressure measured at the burner rotate the adjustable half of the sheave inward increase diameter Both sides of the sheave must be turned equal multiple grooves must be adjusted equal After any adjustment it is necessary to re check the alignment belt tensions and verify that all sheave set screws are tightened to the specified torque value before engaging the blower See Page 119 Table 21 and Table 22 Typically all sheaves have two set screws to secure the sheave to the motor shaft Some sheaves may be press fit onto the motor shaft On the two belt sheaves there are four setscrews that hold the size adjustment On the
144. on Bottom Side of Angle for height adjustment 1 4 Bolt Clip to angle and to unit sideskin floor SECTION 10 INDOOR SUSPENSION MOUNTING HORIZONTAL AIR HANDLER Weight Ibs Weight kg 13 5 9 1 2 X 13 Threaded Rod and Nuts Supplied by Others Suspension End Suspension End Description Part Number B 350 Suspension Kit 77045 301 Suspension Angle Assembly 77045 201 7 20 1 Bolt 20813 74 20 Nut 20630 1 4 Washer 20503 NOTE Flush angle to end of unit 27 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 21 Indoor Suspension B 650 and B 1000 1 2 x 18 Threaded Rod and Nuts Not Supplied by manufacturer Suspension End Suspension MON Gasket Tape Single Nut Provided by others Description Part Number B 650 and B 1000 Suspension Kit 77046 301 Suspension Sides 77047 103 Suspension Ends 77047 106 1 2 13 x 1 Bolt HHCS 20524 Nut Flange 1 2 13 20493 3 4 x 1 8 Gasket Tape 92700017 Model Weight Ibs Weight kg B 650 and B 1000 140 63 5 28 of 149 SECTION 11 FiLTER SECTION SECTION 11 FILTER SECTION A WARNING Crush Hazard Falling Hazard Severe Injury Hazard Cut Pinch Hazard Use proper lifting Use proper safety Use proper lifting Wear protective gear equipment and equipment and practices an
145. on of internal parts 5 Check for 24VAC at amplifier terminals 8 amp 9 6 Measure resistance per item 2 7 Remove wires connected to amplifier terminals 1 2 amp 3 Mea sure resistance across wires 1 amp 3 then 2 amp 3 Meter should read greater than 2500 ohms 8 Follow procedures outlined in PRELIMINARY CIRCUIT ANALY SIS Sections amp 11 in Maxitrol product information sheet 9 See Valve Adjustments Section 19 5 10 Measure manifold pressure as outlined in Section 19 4 11 Follow procedures outlined in PRELIMINARY CIRCUIT ANALY SIS sections amp Il in Maxitrol product information sheet 12 Remove wires connected to amplifier terminals 4 amp 5 Set T244 or TD244 to maximum setting Measure resistance across wires Meter should read 6000 ohms 1000 T244 If TS244 TD244 are used meter should read 4500 ohms 1000 TS244 and 2100 ohms 150 TD244 13 Follow procedures outlined in PRELIMINARY CIRCUIT ANALY SIS Sections IV in Maxitrol product information sheet 14 Compare sensed temperature reading at T8144 with average discharge air temperature 15 Follow procedures outlined in PRELIMINARY CIRCUIT ANALY SIS Sections IV in Maxitrol product information sheet 16 Remove button Plate and inspect valve and seat 17 Inspect plunger should be smooth and clean and operate freely in solenoid sleeve 18 Measure resistance per item 7 19 Read inlet pressure at valve
146. ontinuously to maintain a constant space temperature as selected on the Selectrastat dial The burner flame modulates and varies the discharge air temperature to maintain the space temperature ON SUMMER Mode Only the blower operates continuously to provide unheated air The burner remains off regardless of temperatures on the temperature selection dial and thermostat FAN ON indicator Indicates that the air handler is supplying power to the blower motor via the M1 motor starter BURNER ON indicator Indicates that the air handler has supplied power to open the main gas safety shut off valve BURNER LOCKOUT indicator The burner control module has experienced a fault and will need to be reset The burner control module must be reset at the air handler Refer to Page 124 Section 20 and Page 136 Section 22 to determine the cause of the fault CHECK FILTER indicator The airflow in the air handler is insufficient to activate the low pressure switch This is most commonly caused by dirty filters but could also indicate other obstructions in the air stream 111 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL Table 18 Factory Preset Schedule on TH8110 Thermostat Monday Friday Saturday Sunday Time Temperature Fan Setting Time Temperature Fan Setting 6 00 AM 68 F Fan On 6 00 AM 62 F Fan Auto Wake The air handier will run continuously The air handler will r
147. or starter BURNER ON indicator Indicates that the air handler has supplied power to open the main gas safety shut off valve BURNER LOCKOUT indicator The burner control module has experienced a fault and will need to be reset The burner control module must be reset at the air handler Refer to Page 124 Section 20 and Page 136 Section 22 to determine the cause of the fault CHECK FILTER indicator The airflow in the unit is insufficient to activate the low pressure switch This is most commonly caused by dirty filters but could also indicate other obstructions in the air stream 18 2 3 Deluxe Temperature Control DTC Remote This control is typically used for providing automatic day night space heating The burner flame modulates and varies the discharge air temperature to maintain the space temperature set on the Selectrastat dial The 7 day programmable touchscreen thermostat provides nighttime setback for unoccupied space heating SECTION 18 SEQUENCE OF OPERATION AUTO WINTER Mode Occupied time Blower and burner cycle operate continuously to maintain a constant space temperature as selected on the Selectrastat dial The burner flame fully modulates and varies the discharge air temperature to maintain the space temperature Unoccupied time Blower and burner cycle on and off to maintain space temperature as selected on the touchscreen thermostat night setback ON WINTER Mode Blower and burner operate c
148. or the AM and VAV style air handlers See Page 97 Figure 57 for B 650 and B 1000 See Page 97 Figure 58 for models B 2000 and B 3000 FIGURE 56 CO2 Sensor Interlock for FR and MUA Style 48 I 69 49A CO2 Sensor 49 note 8 Modulating Regulating Valve Q This Replaces The MRV Wiring Located On The Main Diagram CO2 Sensor Wiring By Others Part Number 13205105 Models FR and MUA FIGURE 57 CO2 Sensor Interlock for AM and VAV Style B 650 and B 1000 Description CO2 Sensor Interlock Building Pressure Switch or Photohelic Modulating Damper Motor wo L Relay CR7 Connections Are Located Between The Damper Motor And The Building Pressure Switch or Photohelic 1 CO2 Sensor 63 e HV Operation Damper Is Forced Into 100 Outside Air Until CR7 Is Energized By The CO2 Sensor Allowing The Damper To Modulate When The CO2 Sensor Reaches The Set Point The Sensor Contacts Will Open Deenergizing CR7 CO2 Sensor Wiring By Others Part Number 13205106 Models B 650 and B 1000 Description CO2 Sensor Interlock FIGURE 58 CO2 Sensor Interlock for AM and VAV Style B 2000 and B 3000 62 CRE oa 120 4 Building Pressure Switch or Photohelic Modulating 7 9 1 Damper Motor 7 CR7 L3 60 60A L Relay CR7 Connections Are Located Between The Damper Motor And The Building Pressure Switch or Photohelic
149. orizontal Mount Horizontal Mount Filter Box Horizontal Mount Horizontal Mount 7 Uu Air Handler re Air Handler External Support TOP VIEW TOP VIEW Without Filter Section With Filter Section With Filter Section Without Filter Section Air Handler Air Handler T Upright Mount Filter Box 7 Upright Mount For an air handler without a filter section On the inlet of the air handler install horizontal and upright mounts The mounts will be installed via angles open towards the outside of the air handler For an air handler with a filter section First attach the filter section to the air handler Then bolt the inlet hood horizontal and upright mounts to the inlet of the filter section with the angles opening towards the inside of the filter section Upright mounts P N 13505090 are attached with five 3 8 16 bolts P N 20517 and flat washers P N 20515 each the receiving riv nut P N 91120106 will be factory installed on the air handler or filter section Horizontal mounts P N 13505091 are attached using five TEK self tapping screws P N 13404 Prior to installing the mounts seal the gap between the mating surfaces of the air handler filter section and the mounts with the provided foam tape P N 92700017 When installing the top horizontal mount directly to the air handler without a filter section foam tape should N
150. per has four outward turned flanges Based on air handler style damper may include upper and lower damper FIGURE 27 Motorized Inlet Damper B 350 B 1000 AIR FLOW wg nix NOTE 1 CONTRACTOR INSTALLER MUST MAKE APPROPRIATE ALLOWANCES FOR DUCT CONNECTIONS 2 NUMBER OF LOUVERS WILL VARY 3 MOUNTED UPSTREAM OF AIR HANDLER MOUNTS DIRECTLY TO AIR HANDLER PRE INSTALLED Weight Ibs kg B 350 77019 301 40 18 1 Model Part Number B 650 B 1000 80900 60 272 67 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 28 Motorized Inlet Damper B 2000 and B 3000 d 4 UPPER DAMPER LOWER DAMPER NOTE 1 CONTRACTOR INSTALLER MUST MAKE APPROPRIATE ALLOWANCES FOR DUCT CONNECTIONS 2 NUMBER OF LOUVERS WILL VARY 3 MOUNTED UPSTREAM OF AIR HANDLER MOUNTS DIRECTLY TO AIR HANDLER PRE INSTALLED Part Number Style Dampers Used Weight Ibs kg 80920 77530 MUA Upper and Lower 75 34 107 48 1 80920U 68 of 149 77530U FR AM VAV Upper Only 34 15 4 46 20 9 SECTION 14 DISCHARGE HEADS AND SPLASH PLATES SECTION 14 DISCHARGE HEADS AND SPLASH PLATES A WARNING Crush Hazard Use proper lifting equipment and practices Falling Hazard Use proper safety equipment and prac
151. peration is noted only over a small range of 2 or 3 volts the vol age source may contain surges Consult factory 21 Sensed temperature will vary from TD114 dial settings This is intentional 22 Correct wiring 23 See calibration procedure 24 Move TS114 to location where average representative temperature can be sensed 25 TD114 dial setting then check thermostat setting and or check wir ing for shorts 26 Replace modulator head if less than 40 ohms 27 Correct wiring if short is found 28 Reset to correct temperature 29 If on high fire control can do no more Heater unable to furnish ad ditional heat to raise temperature 141 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL 22 6A44 Amplifier Field Service Checklist SYMPTOM POSSIBLE CAUSE No gas flow 1 Continuous low fire electronics ok Continuous Low Fire electronics problem Incorrect Low Fire 9 10 Continuous Minimum Discharge Air Temperature 11 Incorrect Max or Min Discharge Air Temperature Continuous High Fire electronics ok H Continuous High Fire electronics problem Incorrect High Fire Continuous Maximum Discharge Air Temperature Burned out Transformer No Voltage to Amplifier Incorrect Space Temperature 27 28 se a 12 13 18 24 25 26 Valve improperly installed Open circuit in modulator coil Plunger missing jammed or improperly installed
152. plosion Hazard Fire Hazard Falling Hazard Burn Hazard Cut Pinch Hazard Turn off gas Keep all Use proper safety Allow equipment Wear protective supply to flammable equipment and to cool before gear during equipment before objects liquids practices to avoid service installation service and vapors the falling operation and minimum required Internal compo service clearances to Do not use any nents of combustibles part of equipment equipment may Edges are sharp away from as support still be hot after equipment operation Some objects will catch fire or explode when placed close to equipment Failure to follow these instructions can result in death injury or property damage 136 of 149 SECTION 22 TROUBLESHOOTING 22 1 Initial Checks When encountering any abnormal operation or fault conditions of the equipment all troubleshooting should start with the following initial checks If a problem is discovered in these initial checks it must be corrected before moving on in the trouble shooting 1 Compare voltage and phase of supply power on site with rating plate information 2 plied wiring diagram Review wiring between remote panel and control panel Do the electrical connections match the sup Compare gas type and supply pressure on site with rating plate information Check for proper blower rotation on air handler and any exhaust blowers Blowers powered with a three phase motor can be reversed by swapp
153. plus pressure drop of the valve see Maxitrol capacity chart 16 Read manifold pressure using manometer and compare with recommen dation of equipment manufacturer 17 Adjust sensitivity control counter clockwise 18 Connect test resistor as described in Preliminary Circuit Analysis in Maxitrol product information sheet Turn TD114 selector dial so heater goes through its entire modulating range 19 Temporarily wire each of TD114 T8114 and MR212 externally and ob serve heater equipment operation 20 With test resistor connected per item 18 and TD114 locally connected per item 19 turn TD114 selector dial through entire modulating range Ob serve D C voltage across modulator terminals 21 Inlet Air Sensor changes 1 for each 3 5 5 or 8 outside temperature change from 60 pre determined turndown varies with model used 22 Check wiring diagrams per maxitrol product 23 Sensed temperature thermometer next to 75114 does not correspond to TD114 setting 24 Sensed temperature thermometer next to T8114 does not represent average discharge air temperature 25 Remove Override Thermostat lead from terminal 2 of TD114 information sheet 26 Measure resistance across modulator terminals with red lead wires disconnected 27 Inspect wiring 28 Check Override Temperature Selector of TD114 29 Check for high fire Maximum manifold pressure specified for heater SECTION 22 TROUBLESHOOTING REMEDY 1
154. positive space pressure room or duct This null pressure switch is mounted in the control enclosure More or less outdoor air is brought into the space to satisfy the pressure setpoint Most installations require a setpoint of 0 02 in wc to 0 03 in wc to achieve adequate pressure control in the building space 5 16 diameter tubing connected to the positive pressure port of the switch must run to the inside of the building 5 16 diameter tubing connected to the negative pressure port of the switch must run to the outside of the building 18 1 4 Variable Air Volume VAV Style The VAV style air handler uses a building pressure sensor to detect differential pressure between the outside and the heated space The air handler will deliver 100 outside air and will not deliver return air The air handler will ensure proper air velocity over the burner by using a photohelic air sensor to measure the pressure drop across the burner and by using a damper to modify the airflow when a pressure change is required A second photohelic air pressure sensor is used to measure the differential pressure between the outside and the heated space Most installations require a setpoint of 0 02 in wc to 0 03 in wc to achieve adequate pressure control in the building The second pressure sensor is used to provide a control signal to the variable frequency drive that in turn controls the blower speed 5 16 diameter tubing connected to the positive pressure por
155. r installed OK 145 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL The following procedures reference pages and tables from the B Series Installation Operation and Service Manual P N BN121100NA Contact the local BANANZA independent distributor or Bananza for a manual At Start up Verify proper belt tension and sheave alignment per instructions on Page 117 Section 19 2 1 OK Verify proper torque on all sheaves per table on Page 118 Section 19 2 2 OK Air Temperature Sensing 1 The sensing probe is factory mounted in the blower hous ing Advance to next section Electrical Page 78 Section 17 1 Check all motor starters for proper overload settings The overload should not exceed Full Load Amps for the motor A 2 What is the supply voltage to the air handler Air Hander Off 1 2 3 Air Hander On 1 2 3 3 Verify correct fan rotation OK 4 What is total system current draw Motor current draw Burner Off Burner and motor current draw 5 Compare all variable frequency drive VFD programming parameters with specifications provided on electrical drawing OK 6 For VFD systems make sure to set programming parame ters for proper overload protection See VFD Instruction Manual OK 7 If more than one exhaust motor is used with each motor must have its own overload protection OK Differential Pressure Page 77 Section 16 5 1 1 In order to ve
156. r of bends Do not downsize the pipe from the origination point must be same size or larger Make sure vent line is free from obstructions Do not group lines together into a common header The outside termination must have a weatherproof cap or be directed downward for protection from the elements and must be screened to prevent the entry of any objects SECTION 16 GAs PIPING FIGURE 32 ANSI FM XL Compliant Manifolds B 350 Alternate Inlet High Gas Pressure Regulator Optional For ANSI Compliant Manifolds and supplied for and XL Compliant Manifolds Vent to Atmosphere FM and XL Manifold Regulator With Dual Safety Shut Off Valve Manual Gas Modulating Valve Valve Main JL eror x HHB 1 Manual Gas Valve Burner Burner Manual Gas Valve Pilot By Others Combination Valve NOTE Vent valves must be piped to the atmosphere outside the structure and in accordance with applicable codes FIGURE 33 ANSI Compliant Manifold B 650 B 3000 Alternate Inlet Safety Shut Off Valve High Gas Pressure Regulator Optional Safety Shut Off Valve Manual Gas Valve Main Union By Others Valve With Pre
157. ration and service Equipment and accessories are heavy Edges are sharp Failure to follow these instructions can result in death injury or property damage Failure to follow these instructions can result in injury Replacement parts list is for general direct fired applications and MAY NOT BE APPLICABLE for your specific unit configuration Before ordering replacement parts please contact factory to make sure that the replacement parts are the direct replacement for your specific unit FIGURE 85 Control Panel Layouts LOW AIRFLOW PRESSURE SWTICH OPTIONAL RELAY HIGH AIRFLOW 1 gt PRESSURE SWTICH ooooopopoo 111 1 PL 1 LL FLAME AMPLIFIER diee cie 23 t BURNER CONTROL ELECTRICAL OPTIONAL TERMINALS EQUIPMENT AND d 53 FLAME rZ TERMINALS i AMPLIFIER IGNITION CONTROL 24V TRANSFORMER MODULE IGNITION TRANSFORMER eme y well El 131 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL Table 27 Control Panel
158. re heavy Edges are sharp Failure to follow these instructions can result in death injury or property damage 65 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL 13 1 Discharge Damper Discharge dampers are shipped loose Discharge dampers are designed to be mounted downstream of the air handler in ductwork A qualified contractor installer must make appropriate allowances for duct connections To install the discharge damper on an interior wall drill holes every 8 20 5 cm in the flanges on all four sides of the discharge damper to accommodate lag bolts provided by others Discharge dampers are not recommended to be mounted directly to the air handler FIGURE 26 Motorized Discharge Damper B 350 B 3000 AIR FLOW NOTE1 CONTRACTOR INSTALLER MUST MAKE APPROPRIATE ALLOWANCES FOR DUCT CONNECTIONS 2 NUMBER OF LOUVERS WILL VARY 3 MOUNTED DOWNSTREAM OF AIR HANDLER IN DUCT WORK DOES NOT MOUNT DIRECTLY TO AIR HANDLER FIELD WIRED TO PROVIDED TERMINALS ON CONTROL PANEL Weight Ibs kg B 350 77014 301 inl s3 a 25s 3 B2 40 18 1 Model Part Number B 650 B 1000 77018 301 C 60 272 B 2000 809222 100 45 4 B 3000 775372 150 68 66 of 149 SECTION 13 DAMPERS 13 2 Inlet Damper Inlet dampers are factory mounted to the inlet of the air handler covering the inlet opening The inlet dam
159. re protected from degradation Maintain clearances from vehicles parked below the air handler See Page 10 Section 4 4 3 2 Purge of Supply Duct If this heating unit is to be installed indoors and its outdoor air supply ducted from outdoors ANSI Standards Z83 18 and Z83 4 require that all supply duct shall be purged a minimum of four times prior to any ignition attempt If the volume of the outdoor air supply duct exceeds the heating unit s ability to complete the required four air changes prior to ignition you must contact the factory to purchase an extended purge card of the appropriate duration to meet this requirement 3 3 Hardware Unless otherwise specified all hardware must be torqued to settings on Page 9 Table 1 Note Inlet hood opening shall not be installed with inlet opening facing into the prevailing wind direction in order to help prevent the possibility of moisture entrainment SECTIONS CRITICAL CONSIDERATIONS Table 1 Recommended Torque Settings Bolt Head Grade Marking QQ Grade Marking 8 8 Nut Grade Marking Bolt Size Grade 2 Grade 5 10 24 27 inelb 42 inelb 1 4 20 65 inelb 101 inelb 5 16 18 11 ftelb 17 ftelb 3 8 16 19 ftelb 30 ftelb Bolt Head 8 8 Nut Grade Marking Bolt Size Grade 8 8 Grade 10 9 M5 6Nm 9Nm M6 10Nm 15Nm M8 25Nm 35Nm M10 50Nm 75Nm M12 85Nm 130Nm M16 215Nm 315Nm 9 of 149 B SERIES INSTALL
160. rflow at the burner and to set high fire gas pressure On air handlers equipped with a M611 modulating valve Model B 350 the pressure tap is located on a tee between the M611 valve and the burner See Page 71 Figure 36 and Page 123 Figure 81 On air handlers equipped with the MR212 modulating valve Models B 650 B 3000 the pressure tap could be located on the downstream side of the MR212 valve on a T fitting coming off the outlet pressure tap on the MR212 valve or between the MR212 valve and the burner See Page 77 Figure 37 and Page 122 SECTION 16 GAs PIPING Figure 79 FIGURE 36 Plug Tapping B 350 Modulating Valve Plugged Taping To Measure Burner Pressure rA Burner Manual Gas Valve Burner FIGURE 37 Plug Tapping B 650 B 3000 Modulating Valve a Manual Gas Valve Burner Burner Plugged Taping 16 6 Line Pressure Test Leak Testing The air handler and its individual shut off valve must be disconnected from the gas supply piping systems during any pressure testing of that system at test pressures in excess of 14 in wc 34 9 mbar The air handler must be isolated from the gas supply piping system by closing its individual manual gas valve that is located immediately upstream of the safety shut off gas valve 77 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 17 ELECTRICAL A DANGER Electrical Shock Hazard Disconnect electric before service
161. rify proper airflow across the burner the dif ferential pressure across the profile plate needs to be measured Attach a manometer to the pressure test ports where the pressure switch is attached and measure the differential pressure with a manometer This reading must be 0 9 in we 0 1 in we 2 24 0 25 mbar Record differential box pressure in wc mbar Burner Pressure Page 77 Section 16 5 2 1 Apressure tap between the Maxitrol modulating valve and the burner is used to measure negative airflow at the burner and to set high fire gas pressure This tap could also be located on the Maxitrol valve itself manual shut off valve or T fitting See unit data plate on control enclosure door for high fire setting 2 Record burner pressure with inlet manual gas valve off and blowers on in wc mbar Gas Piping and Initial Pressure Setting Page 77 Section 16 4 1 Perform a pressure test on all gas supply lines to air han dler per local codes OK 2 Verify supply pressure does not exceed maximum rated gas pressure as stated on the rating plate OK 146 of 149 3 Setthe supply gas pressure at the step down regulator normally outside of the enclosure if one is installed according to the rating plate inlet gas pressure specifica tions Fuel Type Pressure f 4 Only after performing steps 1 3 open the main gas valve and close the manual gas valve downstream of the MR valve Set the burner switch to on Verify pilot pre
162. ring Replace Reset the flame control module at the unit and proceed to the next step observing the unit to indicate at which step lockout condition occurs No PILOT flame UV flame sensor indicating presence of flame before ignition Flame indicator light present Is there 5VDC on UV flame amplifier Separate spark wire and UV scan ner wires Replace UV flame sensor UV flame amplifier or burn control No spark Check wiring from burner control to ignition transformer Check high tension wire to spark plug Replace ignition transformer No gas Open manual gas shut off valves Check wiring from burner control to pilot gas valve Verify inlet gas pressure Adjust pilot gas pressure Replace pilot gas valve Check burner pilot opening for obstruction Pilot flame does not stay lit Improper pilot gas pressure Adjust pilot gas pressure UV flame scanner does not dedect flame Is there 5VDC on UV flame amplifier Replace UV scanner Replace UV flame amplifier UV flame scanner dirty Clean UV scanner 138 of 149 SECTION 22 TROUBLESHOOTING Burner continued PROBLEM POSSIBLE CAUSE SOLUTION Manual shut off valve closed Open manual shut off valve Check wiring from burner control to Safety Shut Off Valve not operating Is there SSOV positive gas pressure downstream of SSOV Verify inlet gas pressure Replace SSOV Verify minimum gas supply pressure as per data
163. roblem Continuous High Fire electronics ok Incorrect Maximum Fire Erratic or Pulsating Flame Incorrect Discharge Air Temperature Burned out Transformer Discharge Air Temperature too Low when T115 is Opera tive 140 of 149 Modulating valve improperly installed Short circuit or no voltage to the amplifier Open circuit in TD114 Remote Temperature Selector circuit or wiring Short circuit in T5114 Discharge Air Sensor circuit or wiring Faulty amplifier Short circuit or open circuit in Modulator Coil Plunger missing jammed or improperly installed Incorrect by pass metering valve adjustment Excessive negative burner pressure Short circuit in TD114 Remote Temperature Selector circuit or wiring Open circuit in TS114 TS10765 Discharge or Inlet Air Sensor Circuit or wirir Jumper not connected across amplifier terminals 2 and 3 Foreign object holding valve open Plunger jammed Inlet pressure too low Incorrect outlet pressure adjustment of Pressure Regulator Hunting Erratic air patterns or improper TS114 location Wiring is run next to high voltage switching circuits causing induced voltage Faulty Amplifier or erratic voltage supply Inlet Air Sensor is used Incorrect Wiring System out of calibration Improper TS114 location Room Override Thermostat circuit closed Short circuit in modulator coil Short circuit between
164. rt Number Gasket Material 13205035 Filter Access Door 13X05025 Hinge 20500 10 24 Bolt 27000 10 24 Nut 20698 Hinge Spacers 13205032 10 24 X 34 Bolt 21699 14 20 Grip Nut 20499 14 Washer 20503 Bolt Holes 14 20 Bolt 20504 Push Nut 20505 40 of 149 SECTION 11 FILTER SECTION 11 4 Filter Section Support Assembly The filter section support assembly is used to add additional support to the air handler accessories that are not supported by the roof curb in a horizontal configuration support leg for use with standard 46 116 8 cm legs provided by others For Models B 650 B 3000 when the air handler has both a filter section and an inlet hood a filter section support assembly or its equivalent must be used B 650 and B 1000 B 2000 B 3000 Description iom 77412 001 77412 002 77412 003 Quantity Quantity Quantity Filter Box Support Base B 650 and B 1000 77408001 1 N A N A Filter Box Support Base B 2000 77408002 N A 1 N A Filter Box Support Base B 3000 77408003 N A N A 1 Filter Box Support Leg LS B 650 B 3000 77408011 1 1 1 Filter Box Support Leg RS B 650 B 3000 77408012 1 1 1 Filter Box Support Ext LS RS B 650 B 3000 77408021 2 2 2 Filter Box Support Brace B 650 And B 1000 77408031 1 N A N A Filter Box Support Brace B 2000 77408032 N A 1 N A Filter Box Support Brace B 3000 77408033 N A N A 1 Screw Tek3 12x3 4 Washer 13404 11 14 16 1 4
165. s 57000 Attach to the bottom pan assembly with two 10 24 3 0 24 Nut 56098 bolts 10 24 nuts Step 12 2 13 Inner Support Moisture Limiter Rail Side Cover Place the moisture limiter inner support rail under the top Description Part Number flange of the moisture limiter frame side cover and to the top of inner Support Rail 13505097 the inlet hood Attach to the top of the inlet hood using nine TEK Screw 13404 10 24 x 1 2 bolts and nine 10 24 nuts Attach to the left side 10 24 x 7 Bolt 27000 10 24 Nut 26098 of the frame using two 10 24 x 1 2 bolts and two 10 24 nuts 52 of 149 Step 12 2 14 Insert the 3 pieces of 12 30 5 cm x 60 152 4 cm SECTION 12 INLET HoOD Limiter Media moisture limiter media mm the right side hs the Description Part Number long dimension running top to bottom Moisture Limiter Media 90740001 Step 12 2 15 Place the moisture limiter frame side cover in order to have the flange at the top overlap the top of the frame Attach to the inlet hood rain gutter using eight TEK screws Attach to the bottom pan assembly and top with two 10 24 x 1 2 bolts and 10 24 nuts each Attach front stiffeners to the left and right side of the moisture limiter frame using four TEK screws for each support Outer Support Rail Moisture Limiter Side Cover Description
166. s or snap fasteners 60 of 149 SECTION 12 INLET HoOD Step 12 3 10 NOTE Double sided filter rails or filter clips are not required for inlet hood with moisture limiter Caulk the seams between the inlet hood and the air handler filter section and on the open sides of the J bends that lock the roof panels together Step 12 3 11 When attaching the drip rail ensure that the drip rails are positioned above the filter clips using the provided holes in the sidewall panels Attach drip rail to right side of inlet hood starting with the lower drip rail using five TEK self tapping screws Attach the upper right side rail by sliding it inside the lower drip rail where they overlap use five TEK self tapping Fall Upper Fight 13805092 Screws Attach drip rail to left side of inlet hood starting with Drip Rail Upper Left 18305093 the lower drip rail using five TEK self tapping Screws Attach Drip Rail Lower Right 18305094 the upper right side drip rail by sliding it inside the lower drip Drip Rail Lower Left 13305095 rail where they overlap use five TEK self tapping screws TEK Screw 19404 Apply caulk to the drip rails before attaching to the side panels Description Part No For inlet hoods with permanent aluminum mesh filters continue to Step 12 3 12 For inlet hoods with birdscreen no filters the instructions end here For inlet hoods with moisture limiter continue to St
167. seal the bottom seam Caulk provided by others the side and bottom seams between the filter section and air handler If the filter section was installed prior to completing the filter section assembly return to the filter section assembly instructions to complete the assembly See Page 33 Figure 11 2 5 for Models B 650 and B 1000 or Page 39 Figure 11 3 6 for Models B 2000 and B 3000 SECTION 11 FiLTER SECTION FIGURE 23 Filter Section Installation on Horizon tal Air Handler B 650 B 3000 Filter Section Air Handler 11 6 Filter Section Installation Upright Air Handlers 11 6 1 Filter Section Installation B 350 For installation directly onto the inlet of the air handler remove the hardware on the inlet surface of the air handler that would prevent the filter section from being mated to the inlet of the air handler Use the provided shims one bottom and two sides to reduce the size of the gap between the air handler and the filter section Re install the hardware that was removed through the filter section and the shims to mate the air handler to the filter section Caulk provided by others the sides roof and bottom seams between the filter section and air handler Install the filters in proper orientation See Page 130 Section 20 6 and attach the filter access door Secure filter access door in the closed position 11 6 2 Filter Section Installation B 650 B 3000 To install a filter sectio
168. single belt sheaves there are two set screws to hold the size adjustment Table 21 Motor Sheave Drive Torque Specifications Torque Settings Setscrew Size Allen Wrench insLbs ft Lbs 1 4 1 8 87 13 5 16 5 32 120 IE 3 8 3 16 290 242 Table 22 Motor and Blower Bushing Torque Specifications Torque Settings Bolt Size on Bushing imLbs abe 10 60 5 1 4 108 9 5 16 192 16 3 8 360 30 1 2 720 60 19 4 2 Burner Pressure 1 A pressure tap is used to measure differential at the burner and to set high fire gas pressure On air handlers equipped with a M611 modu lating valve Model B 350 the pressure tap is located on a tee between the M611 valve and the burner See Page 77 Figure 36 and Page 123 Figure 81 On air handlers equipped with the MR212 modulating valve Models B 650 B 3000 the pressure tap could be located on the downstream side of the MR212 valve on a T fitting coming off the outlet pressure tap on the MR212 valve or between the MR212 valve and the burner See Page 77 Figure 37 and Page 122 Figure 79 Measure the burner pressure with the inlet manual gas valve off Open the manual shut off located between the modulating valve and the burner Turn the blower on and record the negative pressure on a u tube manometer or gas pressure gauge This reading is used for high fire burner pressure adjustment After taking the b
169. ssemble or install any accessories or associated duct work using best building practices To properly size supports and hanging materials To ensure heater is placed in an approved application 6 of 149 2 1 Wall Tag A laminated wall tag is available for the heater as a permanent reminder of the safety instructions and the importance of the required clearances to combustibles Please contact Bananza or your BANANZA independent distributor to obtain the wall tag Affix the tag on a wall near the heater e g thermostat or control system A copy of the wall tag P N 91040116 is illustrated on the back cover For an immediate solution you may affix this copy on the wall near the heater Know your model number and installed configuration Model number and installed configuration are found on the rating plate and in the Installation Operation and Service Manual See Page 3 Figure 1 through Page 4 Figure 3 2 2 Corrosive Chemicals A CAUTION Product Damage Hazard Do not use equipment in area containing corrosive chemicals Refer to appropriate Material Safety Data Sheets MSDS Failure to follow these instructions can result in product damage Bananza cannot be responsible for ensuring that all appropriate safety measures are undertaken prior to installation this is entirely the responsibility of the installer It is essential that the contractor the sub contractor or the owner identifies the presence of
170. ssure and flame signal of 5 0 VDC _ To adjust pilot flame set pilot regulator to 1 0 in wc 2 5 mbar natural gas or 0 5 in wc 1 25 mbar L P gauge pressure 5 Open both manual gas valves at air handler Force the burner into high fire See Page 121 Table 23 Burner Mode By Amplifier Type Read the gas pressure at the MR valve and set according to the determined high fire gas pressure in Table The small cap screw is for high fire on MR212 valve only Take a reading of the temperature rise Temperature rise must be in accordance with Page 121 Table 24 High Fire Discharge Temperature F C Manifold Pressure for Maximum Input from rating plate Burner Pressure High Fire Gas Pressure Setting There are three critical items to consider before adjusting low fire A Low fire adjustment does not regulate gas pressure B If the low fire adjustment screw is set to maximum high fire regulation problems will occur C The burner control system must be forced into low fire per Maxitrol s instruction for the given amplifier temperature control system See Page 121 Table 23 Burner Mode By Amplifier Type 6 Low fire is set at the MR212 valve using the adjustment screw under the large cap screw or on the M611 valve using the brass adjusting screw on the side The burner must be forced into low fire first The low fire ribbon across the burner must be adjusted OK Once gas pressure and high low fire adjustments are made
171. ssure Regulator Manual Gas Valve Burner Manual Gas Valve Pilot By Others Combination Valve 75 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 34 FM Compliant Manifold B 650 B 3000 Alternate Inlet High Gas Pressure Regulator Optional Safety Shut Safety Shut Off Valve Off Valve Vent to Atmosphere Visual Indicator Manual Gas Vent to Atmosphere Valve Main n Modulating Valve With 1 1 Pressure Regulator By Others n fI md Manual Gas Valve Burner I U U I i Ps High Gas Pressure Switch Vent to Atmosphere y y LI LI Manual Gas By Others Valve Pilot Pilot Regulator Pilot Sole
172. stallateur Prenez le temps de lire et comprendre ces instructions avant toute installation Linstallateur doit remettre au propri taire un exemplaire de ce manuel L installation l ajustement l alt ration le d marrage ou l entretien inad quat peuvent causer la mort des blessures ou des d g ts mat riels Lire entierement le manuel d installation d op ration et d entretien avant l installation ou l entretien de cet quipement Propri taire Gardez ce manuel dans un endroit s r pour fournir des informations au r parateur en cas de besoin L installation doit tre effectu e par un installateur prouv contractant qualifi dans l installation et la maintenance du systeme de chauffage par infrarouge activ au gaz Concus pour les applications non r sidentielles Bananza 1100 Seven Mile Road NW c US Comstock Park MI 49321 CM SISTER T l phone 1 616 726 8800 Fax 1 616 726 8807 Inte rtek Num ro sans fra s 800 255 3416 Canada seulement avec 100 d air externe www bananza com 2015 Roberts Gordon LLC P N BN121100FC Rev C 07 15 TABLE OF CONTENTS SECTION 1 Air Handler Safety 1 1 1 Description of Operation 1 1 2 Inspection and Setup 1 1 3 Safety Labels and Their Placement 1 1 4 California Proposition 65
173. state of adjustment of the equipment are compatible If filters are not installed via inlet hood or filler section an air strainer provided by others must be installed on the inlet of the air handler with openings less than or equal to 5 8 16 mm in diameter Air inlets must be installed in such a manner that their lowest edge is 19 500 mm above any surface This applies to roof curbs upright stands and suspended air handlers 6 1 Lifting an Air Handler 6 1 1 Preparing to Lift the Air Handler Prior to lifting the air handler the following steps must be performed 1 Remove all packaging or banding that attached the air handler to the skid and ensure that the air handler is no longer bound to the skid 2 Remove all of the accessories or packages that were shipped on the same skid inside the air handler or inside the control enclosure 3 Inspect the air handler to e Verify that there is no damage as a result of shipping e Ensure that it is appropriately rated for the utilities available at the installation site SECTION 6 LIFTING AN AIR HANDLER SECTION 6 LIFTING AN AIR HANDLER A WARNING e Verify that the lifting lugs are intact undamaged and secured to the air handler e Ensure factory installed hardware is torqued as specified 4 Prepare the installation location to be ready to accept the air handler i e roof curb mounting stand or legs 5 Verify the lifting equipment can handle the air ha
174. sure switch The low gas pressure switch must be set to the minimum required gas pressure as indicated on the data plate The high gas pressure switch must be set to 1 in w c 2 5 mbar above high fire setting established during commissioning If either switch senses a pressure which is lower low gas pressure switch or higher high gas pressure switch than its set point then the switch will open and lock out shutting the burner down The switch will have to be reset manually once the condition has been corrected 17 5 4 Flame Control This device will check for both pilot flame and main flame within the burner When a flame signal from the pilot flame is available it will allow the main gas valve to open Models B 350 B 1000 operate with intermittent pilot 79 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL pilot stays lit during burner operation Models B 2000 B 3000 operate with interrupted pilot pilot turns off after flame is established The flame sensor observes main flame only Model B 350 uses a flame rod to detect the flame minimum flame current 1A Models B 650 B 3000 use an ultraviolet UV light scanner 5 0 Vdc flame signal If a pilot flame is not present the electrical signal cannot be sent and the pilot burner gas valve will close The relay is equipped with a 10 second trial for ignition If ignition does not occur the flame safeguard relay will lockout and must be manual
175. t pressure ESP of 1 in wc 2 5 mbar The external Styles 2 static pressure is us 2 of all any OAT Oulside Air attached ductwor ee Page 16 able 9 or static CE Control Enclosure RA Return Air optional pressure accessories If more external static GC Gas Connection RD Right Discharge pressure is required this needs to be requested with End Discharge TD Top Discharge the order as required motor horsepower HP may LD Left Discharge OH Opposite Hand increase from the specifications given on Page 15 FIGURE 5 B 350 Upright Model Dimensions Lifting Lug One Each Corner Customer Supplied Duct Location See Page 73 Table 11 s Filter Access FILTER SECTION OPTIONAL Filter Access a N OPTIONAL b END VIEW SIDE VIEW Table 2 B 350 Dimensions Model 5 2 in 1 000 32 3 60 3 28 3 10 4 6 8 111 5 27 0 117 3 1 5 8 0 9 3 1 8 31 35 2 30 0 25 0 38 4 5 3 14 175 74 cm 3 000 82 0 153 2 71 9 26 4 17 3 29 2 68 6 297 9 3 8 20 3 23 6 14 6 7 9 89 4 76 2 63 5 97 5
176. t 13305094 1 1 1 Drip Rail Lower Left 13305095 1 1 1 TEK Screw 13404 150 B 2000 165 B 3000 175 B 2000 152 B 3000 162 5 16 18 x 1 Bolt HHCS Grade 5 20507 26 26 26 3 8 Flatwasher 20515 14 14 14 3 8 16 x 1 Bolt Hex Grade 5 20517 14 14 14 5 16 Flat Washer 95211600 26 26 26 5 16 Nut Flange 20509 26 26 26 Be Aluminum Mash Filter 20629 B 2000 10 B 3000 5 N A N A 20 x 25 x 1 Permanent Aluminum d 20628 B 2000 0 B 3000 10 N A N A 20 x 20 x 1 10 24 KEPS Nut 20698 16 16 16 A1 Snap Fastener 20900 10 N A N A 10 24 x 1 2 HMS Bolt 27000 16 16 16 Fastener Rivnut 3 8 16 91120106 14 14 14 Foam Tape 92700017 20 6 m 20 6 m 20 6 m Birdscreen 9074005X N A 1 N A Birdscreen Mount 13305087 N A 4 N A Fender Washer 1 4 x 1 95211550 N A 16 N A Bottom Rail ML THHHHHE N A N A 1 Left Side Cover ML 13X05078 N A N A 2 Right Side Cover ML 13X05079 N A N A 2 Top Front Panel 3 ML 13X05096 N A N A 1 Inner Rail ML 13X05097 N A N A 1 Outer Rail ML 13X05098 N A N A 1 Moisture Limiter 12 x 96 x 5 5 90740002 N A N A B 2000 4 B 3000 5 use on model B 3000 Inlet Hoods only For model B 2000 P N 13205095 for model B 3000 P N 13305100 Note In the above chart an X in a part number indicates a digit that changes based on model Replace the X with a 2 for model B 2000 replace the X with a 3 for model B 3000 For further clarification reference individual chart of components in each
177. t Hood Installation to Wall Use lagbolts to install the inlet hood to an exterior wall Once the inlet hood is in place the edges must be sealed to the wall with the proper sealant For models B 650 B 3000 assemble the hood prior to mounting then mount as described below 12 4 2 Inlet Hood Installation to Air Handler B 350 First remove the hardware in the top drip edge of the air handler Tuck the top flange of the hood behind the top drip edge See Page 64 Figure 25 Replace the hardware screw together the top drip edge of the air handler top flange of the inlet hood and the air handler wall panel NOTE After installing the inlet hood all hardware must be tightened with a torque wrench The roof side and bottom seams must be caulked supplied by others 12 4 3 Inlet Hood Installation to Air Handler B 650 B 3000 Inlet hoods are assembled onto the air handler For Models B 650 and B 1000 See Page 46 Step 12 2 1 For Models B 2000 and B 3000 See Page 55 Step 12 3 1 FIGURE 25 Inlet Hood Positioning Inlet Hood Air Handler 64 of 149 SECTION 13 DAMPERS SECTION 13 DAMPERS A WARNING Severe Injury Hazard Cut Pinch Hazard Use proper lifting Wear protective gear during installation operation and service Crush Hazard Falling Hazard Use proper lifting Use proper safety equipment and equipment and practices and equip practices tices to avoid falling ment Equipment and accessories a
178. t distributor 7 1 Roof Curb Assembly and Installation Assemble roof curb according to the assembly drawing on Page 20 Figure 11 Supplied hardware must be torqued to recommended specifications on Page 9 Table 1 Place the curb on the roof in the position in which it will be installed Check that the diagonal measurements are within 1 8 8 mm of each other To ensure a weatherproof seal between the air handler and the curb the curb must be level with no twist from end to end Shim level as required and secure curb to roof deck using best building practices The curb is self flashing Install roofing material as required NOTE Check the installation location to ensure proper clearances to combustibles and clearance for access See Page 8 Section 3 1 19 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 11 Roof Curb Assembly 19 48 3 cm NOTES Curb is shipped unassembled All dimensions are outside dimensions Curb material is 16 gauge galvanized steel Nuts and bolts 3 8 x 1 are furnished Caulk all joints before assembling Seam in roof curb for models B 2000 and B 3000 When measuring dimensions and include the top mounting flange width on both sides Model B 350 Part Number 75 Caulk required for outside perimeter of roof curb at bolted joints End piece top flange is flush with side top flange End Panel Inlet or discharge Sy er No Brackets mo
179. t of the pressure sensor must run to the inside of the building 5 16 diameter tubing connected to the negative pressure port of the pressure sensor must run to the outside of the building SECTION 18 SEQUENCE OF OPERATION Table 17 Configuration Chart Handler Air Flow Air Volume Control Configuration Make Up Air MUA 100 Outside Air Constant Non adjustable ratio of Fixed Recirculation FR 20 outside air and Constant 80 return air Adjustable ratio of 20 outside air and 80 Building Pressure Air Management AM return air to 100 out Constant Controls Outside side air and 0 return Return Air Ratio air Varane Variable Air Volume VAV 100 Outside Air 50 V olume 100 Requirement FIGURE 71 Air Handler Styles MUA MAKE UP AIR All Models FR FIXED RETURN All Models AM AIR MANAGEMENT 650 and 1000 VAV VARIABLE AIR VOLUME B 650 and B 1000 lt FLOATING FLOATING DAMPER e DAMPER AM AIR MANAGEMENT B 2000 and B 3000 VARIABLE AIR VOLUME B 2000 and B 3000 Floating Damper Floating Damper 109 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL 18 2 HVAC Remote Panels and Panel Options The remote panel should be mounted in the conditioned space in a convenient location for controlling the air handler Do not locate a remote panel that contains temperature sensing equipment in an area directly affe
180. t requirements If any of the original control wire supplied with the air handler must be replaced replace it with type MTW 105 C 600 V 16 gauge wire or equivalent except for 78 of 149 temperature control wiring which must be a minimum of 20 AWG Type Beldon 5401FE CMR 75C shielded or equivalent For all other wires replace with the equivalent size and type of wire that was originally provided with the air handler 172 Remote Panel The remote panel must be wired as shown on the electrical schematic For wire gauge sizes see Page 78 Table 13 All power supply and motor wiring must be minimum type THWN with a 167 F 75 C temperature rise 172 1 Remote Panel Mounting Distance If the interconnection wiring between the remote panel and the air handler control enclosure is run in a single conduit the wire run can be as long as 100 30 m For longer wire runs consult the factory If the interconnection wiring between the remote panel and the air handler control enclosure is run in two conduits separating the shielded cable and the 120 V power supply for the remote panel the wire run can be as long as 200 60 m For longer wire runs consult the factory Care should be used to avoid running the interconnect wiring near large industrial loads or high voltage wire runs as that may further limit the length of the interconnect wire run Table 13 Control Voltage Wiring For All Control Systems Volts Wire Gaug
181. ter rail to the bottom panel with seven TEK self tapping screws Line up with provided holes near the inlet end of the filter section Outside Inside 38 of 149 SECTION 11 FILTER SECTION Step 11 3 5 Attach the remaining filter rails with four TEK self tapping screws two on each side Ensure that the rails face into the filter section Description Part Number Filter Rail 13X05030 NOTE For easier installation the filter section TEK Screw 13404 may be mounted to the air handler at this point prior to the addition of filters and access door Refer to Page 43 Section 11 5 for installation instructions Step 11 3 6 Load filters into the filter section Check that each filter in in the proper orientation For permanent aluminum mesh filters Verify the arrow on the side of the filter points in the direction of the airflow For disposable polyester filters 7 Verify the white side is facing the inlet lt and the blue side is facing the discharge end The end rows of filters need to be installed first NOTE When the filter section is installed on the air handler the top of one row of filters will support the bottom of the above row Description Part Number Permanent Aluminum Mesh Filters 20629 and or 20628 Disposable Polyester Filters 23628 23631 39 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANU
182. the upcoming sections These configurations are available on all air handlers except the B 350 which is only available in the MUA style For a comparison of these configurations See Page 109 Table 17 and Page 109 Figure 77 18 1 1 Make Up Air MUA Style The MUA style air handler has a constant speed blower that is designed to deliver a constant volume of air to the heated space This style air handler supplies 100 outside air to the heated space and is not capable of supplying return air 108 of 149 18 1 2 Fixed Recirculation FR Style The FR style air handler has a constant speed blower that is designed to deliver a constant volume of air to the heated space In all cases however the air being delivered directly over the burner for combustion must always be 100 outside air The air handler delivers 20 outside air and 80 of return air The outside air is heated then mixed with the return air prior to being delivered to the heated space 18 1 3 Air Management AM Style The AM style air handler has a constant speed blower that is designed to deliver a constant volume of air to the heated space A building pressure sensor is used to detect the differential pressure between the outside and the heated space The total volume of air delivered by the air handler may at times consist of 0 to 80 return air An automatic control is provided for the outdoor air and return air dampers A null pressure switch is used to sense a
183. ting surfaces of the air handler filter section and the mounts with the provided foam tape P N 92700017 When installing the top horizontal mount directly to the air handler without a filter section foam tape should NOT be used In this case the hardware on the lip of the air handler roof panel should be removed the mount slid under the lip and hardware re installed Foam tape to be used on remaining three sides To install inlet hood on an exterior wall drill holes every 8 20 3 cm in the flanges of the inlet hood and mount with lag bolts provided by others 55 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 12 3 2 dii 1 Left 7 panel 1 Right Attach an innermost sidewall panel 1 to each side attaching flange using seven TEK self tapping screws NOTE Flanges face inward Step 12 3 3 Description Part Number Left Side Panel 1 13205080 18305080 TEK Screws Right Side Panel 1 13205081 13305081 13404 Bottom Rail For Model B 2000 Attach the bottom panel to the bottom mounting flange with seven TEK self tapping screws Attach to each side panel with two TEK self tapping screws For Model B 3000 Attach bottom panel to the bottom mounting flange with nine TEK self tapping screws Attach to each side panel with two TEK self tapping screws NOTE Ensure that the side tabs of the bottom panel are to the inside of the side panels 5
184. tion dampers ductwork discharge heads etc Additional static pressure beyond that ordered will affect the performance of the air handler and lessen the air volume that can be delivered Proper engineering methods need to be employed when calculating duct and component static pressure i e 2009 ASHRAE Handbook Fundamentals Chapter 21 Accessory pressure drops are available on Page 16 Table 9 The system ductwork must comply with Sheet Metal and Air Conditioning Contractors Nationals Association SMACNA or any other recognized standards As a general rule all discharge ducts should have a straight run of at least 3 hydraulic duct diameters after the air handler before adding any fittings elbows restrictions etc Return ducts should have the same straight run before attaching to the unit Hydraulic duct diameter for round ducts in inches Dh d Dh hydraulic diameter d round duct inside diameter Hydraulic duct diameter for rectangular ducts in inches Dh 2 H W H W 72 of 149 Dh hydraulic diameter H rectangular duct inside height W rectangular duct inside width The air handler is not designed to support the weight of ductwork Ductwork must be constructed in a fashion that is self supporting Ductwork should be straight elbows should be minimal and any transitions should be smooth Depending on the options ordered with the air handler flanges either external or internal may be provided to facilitate
185. tment l I Gas Outlet under cap FIGURE 81 Regulator B 350 Regulator Adjustment Below High Fire Adjustment Cap Gas Flow g Gas Flow Outlet Pressure Inlet Pressure Tap 1 8 NPT Tap 1 8 NPT 123 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 20 MAINTENANCE A DANGER Electrical Shock Hazard Severe Injury Hazard Disconnect electric before service Do not enter equipment while in operation More than one disconnect switch may be Equipment may start automatically required to disconnect electric from equipment Do not operate with door open Equipment must be properly grounded Installation operation and service must be done by a trained technician only Failure to follow these instructions can result in death injury or property damage A WARNING Explosion Hazard Falling Hazard Burn Hazard Leak test all components of Use proper safety Allow equipment to cool equipment gas piping equipment and practices to before service before operation avoid falling Internal components of Gas can leak if piping is not Do not use any part of equipment may still be hot installed properly equipment as support after operation Do not high pressure test gas piping with equipment connected Failure to follow these instructions can result in death injury or property damage 124 of 149 Prior to any maintenance or service of the air handler shut off lockout and t
186. torque set Screws Blower bearings do they turn freely Replace bearing s 137 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL 22 3 Burner PROBLEM POSSIBLE CAUSE SOLUTION Flame control does not try for ignition Burner Lockout Auxiliary contact M1 not closed Power on terminal 4 Properly mount contact or replace Burner winter switch closed Power on terminal 7 Replace switch High temp limit switch tripped Power on terminal 8 Manually reset or replace Low airflow pressure switch contacts not made Power on terminal 8A Check blower operation Reconnect tubes to pressure switch Clean pressure test tubes Check filters duct work for restric tions High airflow pressure switch contacts not made Power on terminal 9 Check blower FLA and compare to qata plate Cabinet pressure too high check system setup and for restrictions down stream of blower Optional Mild weather stat dial set to low Set dial higher Replace stat Optional High gas pressure switch Manual reset Verify gas pressure Optional Low gas pressure switch Manual reset Verify gas pressure No power between terminals 3 and L2 neutral or 6 and L2 neutral for RM7890A 5 and L2 neutral or 7 and L2 neutral for RM7897C of the burner control base Flame control defect Failure to ignite pilot or main flame Flame control failure Verify wi
187. ttach top inner filter rail to the inside of the top front panel using six TEK self tapping screws NOTE Ensure the rail is installed with the ends tight against the flanges of the sidewall panels and the angle opening toward the inside of the inlet hood 58 of 149 REVERSE INLET a Front Panel VIEW Bottom Rail Description Part Number Top Inner Filter Rail 13205068 13305068 TEK Screw 13404 SECTION 12 INLET HoOD Step 12 3 7 Top Back Panel 1 Attach top middle panel with five TEK self tapping screws on Description Part Number each side and with six 5 16 18 x 1 bolts 5 16 washers and 5 16 Top Middle Panel 2 13205076 13305076 E Top Back Panel 1 13205075 13305075 flange nuts at the J bend joint Screw 13404 For Model B 2000 Attach top back panel with five TEK self 5 16 18 x 1 Bolt 20507 tapping screws on each side seven TEK self tapping screws to 5 16 Flat Washer 95211600 the top mounting flange and with six 5 16 18 x 1 bolts 5 16 9 16 Nut Flange 20303 washers and 5 16 flange nuts at the J bend joint For Model B 3000 Attach top back panel with five TEK self tapping screws on each side nine TEK self tapping screws to the top mounting flange and with six 5 16 18 x 1 bolts 5 16 washers and 5 16 flange nuts at the J bend joint NOTE Ensure that the side tabs of the roof panels are to the outside of the side panels and that the J bends interl
188. tures as low as 30 F 34 C In environments where the air handler may be exposed to lower temperatures a control enclosure heater may be required TRANSFORMER PRIMARY CONNECTION y H4 B H1 e 2 230 x1 H3 208 H4 COMMON 120VAC TRANSFORMER BREAKER 250 VA 3 AMP ELECTRIC HEATER 120 V 60H Z 200 W THERMOSTAT SET TO 0 F Part Number Models Description Control Enclosure Heater 08110 All Models 17 8 7 Propane Switch Kit The propane switch kit provides the end user with the ability to run the air handler on either natural or propane gas When the end user wants to switch from natural to propane gas a switch field wired and provided by others will open contacts powering the modulating regulating valve Power will be sent through the propane switch kit where the signal will be reduced and then sent to the modulating regulating valve This will cause the modulating regulating valve to open less for the propane allowing for the same temperature rise SWITCH FIELD PROVIDED AND WIRED MODULATING REGULATING VALVE PROPANE SWITCH THIS REPLACES THE MRV WIRING LOCATED ON THE MAIN DIAGRAM ADJUSTMENTS 1 MAKE NORMAL HIGH AND LOW FIRE ADJUSTMENTS WITH SWITCH CLOSED AS OUTLINED IN THE MANUAL 2 OPEN SWITCH REMOVE THE BRASS CAP FROM RHEOSTAT AND ADJUST TO REDUCE HIGH FIRE SETTING REPLACE CAP
189. uggested Lubrication Period in Weeks Per Day 126 of 149 SECTION 20 MAINTENANCE Motors Inspection 1 Inspect motor every months 500 hours of operation which ever occurs first Keep the motor clean and vent openings clear Lubrication 1 Motors with grease fittings must be lubricated based on the table below Table 25 Motor Lubrication Intervals NEMA Frame Size Motor HP Rated at 1800 RPM Up to 210 incl 3 5 HP 6 000 hrs Over 210 to 280 incl 7 5 20 HP 4 750 hrs Over 280 to 360 incl 25 30 HP 3 700 hrs NOTE These intervals are based on severe duty Over lubricating bearings could result in reduced motor life 2 Ahigh grade ball or roller bearing grease must be used Recommended grease for standard service is Polyrex EM Exxon Mobil Other com patible greases include Texaco Polystar Rykon Premium 2 Pennzoil Pen 2 Lube and Chevron SRI 3 Motors without grease fittings are sealed for life and do not require re lubrication Instructions for Lubricating Before greasing be sure fittings are clean and free from dirt Remove grease relief plug or plate and using a low pressure grease gun pump in the required grease Do not over grease Overgreasing will reduce the service life of the motor Consult the motor manufacturer for grease capacity recommen dations as capacities vary by motor Relubrication intervals are specified in the table above After relubricating
190. uipment and cool before service practices to avoid falling Internal components of equipment may Do not use any part still be hot after of equipment as operation support Failure to follow these instructions can result in death injury or property damage A DANGER Electrical Shock Hazard Disconnect electric before service More than one disconnect switch may be required to disconnect electric from equipment Equipment must be properly grounded Failure to follow these instructions can result in death or electrical shock Receiving Inspection Check installation site to ensure all codes and engineering specifications are correct Place a check next to line items completed or enter data 1 Inspect air handler and all accessories for possible shipping damage NoDamage Damaged Specify on separate sheet Check packing list against items received OK Missing items _ Call factory Check all nuts bolts and fasteners to ensure they are tight _ Loose Specify Check sheaves set screws and bearing collars Make sure they are tight OK Loose Specify Compare voltage on unit rating plate to job site voltage Job Site Voltage Compare gas type and supply pressure on unit rating plate to job site gas supply Job Site Gas Supply Pressure Check lifting brackets to make sure they are tight and secure before lifting heater OK For FR AM models CO2 senso
191. un when the thermostat calls for heat Temperature controlled by Maxitrol stat Leave Unused Unused Return Unused Unused 5 00 PM 62 F Fan Auto 5 00 PM 62 F Fan Auto Sleep The air handler will run when the thermostat calls for heat 18 2 4 BMS Ready Control Option The BMS ready option provides inputs to receive control signals from a customer determined control system Each BMS input is capable of receiving a 4 20mA or 0 10VDC from the control system On all air handlers the burner modulation will be controlled by the control system For AM VAV style air handlers the control system can also control the modulating damper On DDC BMS ready systems no temperature control amplifier is installed Discharge temperature monitoring and modulation valve adjustment are completed by the customer supplied control system For optimum efficiency Bananza suggests to limit the discharge temperature to 160 F 18 3 Basic Air Handler Sequence of Operation While the control transformer is energized the secondary side supplies 115 VAC to the control circuit When the fan switch is in the on position the M1 motor starter is energized and starts the blower motor The M1 motor starter auxiliary contact supplies voltage to the burner switch and Fan On light When the burner switch is in the on winter position power is supplied to the flame control module and the burner control circuit The burner control circuit inc
192. unt to the outside of the panels Weight Ibs Weight kg 77351 201 34 B 650 and 77050 301 B 1000 110 B 2000 77250 301 150 49 9 68 0 B 3000 77532 160 72 6 7 2 Air Handler Mounting to Roof Curb After the curb has been installed the air handler may be placed on the curb See Page 21 Figure 12 After the air handler is in place the installer must fasten the air handler to the curb This is accomplished by drilling holes down through the floor of the air handler and into the curb At least three 12 sheet metal screws supplied by others equally spaced on each side must be used to attach the air handler to the curb After the curb has been installed the air handler may be placed on the curb There must be a 1 8 3 cm x 2 5 1 cm neoprene closed cell adhesive back gasket supplied by others between the top of the curb and the base surface of the air handler to prevent moisture from leaking into the building from either driving rains or melting snow The installer is responsible for tying the air handler to the curb per all applicable codes 20 of 149 SECTION 7 RooF CURB FIGURE 12 Curb Mounting Roof Curb Fastening Detail 21 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 8 UPRIGHT STAND A WARNING Crush Hazard Falling Hazard Use proper lifting Use proper safety equipment and equipment and prac practices t
193. ur contact points triangle touch the sheave surfaces IN or OUT adjustment of the motor sheave and or motor adjustment may be required 4 Pullthe string away from the motor sheave and then move it slowly back towards the sheave making sure the string remains straight while touching all contact points 5 Remove string before turning air handler on FIGURE 76 Sheave Alignment Correct Alignment nu Incorrect Alignment 117 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL 19 2 2 Belt Tension Belt tension should be checked with a belt tension gauge when one is available Follow the belt tension gauge instructions When a tension gauge is not available measure the belt span of the belts See Page 118 Figure 77 Allow for 1 64 0 40 cm of deflection for each inch of center distance length for the charted pounds of force Check Page 118 Table 20 for proper deflection force EXAMPLE A 40 101 6 cm shaft center distance would dictate 40 64 or 5 8 1 59 cm of deflection With a standard B belt and a motor sheave measuring between 5 8 14 7 cm and 8 6 21 84 cm the belt will have proper tension if a 5 8 deflection can be achieved with a minimum of 6 3 8 Ibs and a maximum of 8 3 4 Ibs of pressure as measured with a belt tensioning gauge FIGURE 77 Belt Tension S Menu LIH Length i T I Def ection 1 64 per nch of s 1 4 Tab
194. ure 11 5 for installation instructions 32 of 149 Step 11 2 5 Filter SECTION 11 FiLTER SECTION Slide filters into channels Verify proper filter orientation For permanent aluminum mesh filters Verify the arrow on the side of the filter points in the direction of the airflow For disposable polyester filters Verify the white side is facing the inlet and the blue side is facing the discharge end Description Part Number Permanent Aluminum Mesh Filters 20628 Step 11 2 6 Insulated Disposable Polyester Filters 23629 Install cage nuts into each of the four corresponding square holes two in stiffener two in header panel with the cages on the inside of the filter section Install insulated access cover and secure with four 4 20 screws 14 20 bolts and washers Access Cover Insert Screws Description Part Number Insulated Access Cover 77401 002 W 14 20 Screw 20499 7 20 Bolt 20504 Washer 20503 33 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL 11 3 Filter Section Assembly B 2000 and B 3000 B 2000 Filter Section Permanent Aluminum Mesh Filters Disposable Polyester Filters Description Part 13205022
195. urner orifices may need to be drilled to unplug any closed orifices See Page 129 Figure 82 through Page 129 Figure 84 Use a pin vise with the appropriate drill See Page 129 Table 26 to clean debris from the orifices An electric drill is not suggested because it is easy to snap drill bits off in the orifices See Page 75 Figure 32 through Page 76 Figure 35 6 Reinstall the UV scanner and the spark igniter The UV scanner should be installed only finger tight as over tightening can result in damaging the lens Reconnect the burner piping to the manifold at the union 128 of 149 SECTION 20 MAINTENANCE FIGURE 82 6 15 3 cm Straight Cast Iron Table 26 Burner Selections Model Length Style Qty Drill Size B 350 6 15 3 cm 6 15 3 cm Straight 1 47 B 650 1 ft 30 5 cm 12 30 5 cm Straight 1 47 B 1000 2 ft 61 cm 12 30 5 cm Straight 2 47 12 30 5 cm Straight 1 47 2000 3 5 ft 167 6 S153 cm Straight 47 12 30 5 cm Straight 1 47 B 3000 5 5 1676 r ap sccm Tee 3 43 47 Btu hr ft 800 000 FIGURE 83 12 30 5 cm Straight Cast Iron FIGURE 84 12 30 5 cm Tee Cast Iron 129 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL 20 6 Optional Equipment Dampers Check linkage when applicable and tighten set screws as required All moving parts of dampers should be cleaned and then thoroughly lubricated wit
196. urner pressure reading tem porarily leave the manometer attached to the 1 8 tap It will be used later to check high fire gas pressure SECTION 19 START UP PROCEDURES 19 5 Gas Piping and Initial Pressure Settings 1 Perform a pressure test on all gas supply lines to the air handler per applicable codes Make sure to isolate all gas controls before pressure testing the system Verify supply pressure does not exceed maxi mum rated gas pressure as stated on the rating plate Set the supply gas pressure at the step down regulator normally outside of the enclosure if one is installed according to the nameplate rating inlet gas pressure specifications Only after performing steps 1 3 above verify pilot pressure Place a u tube manometer or gas pressure gauge on the tee at the downstream side of the pilot pressure regulator Open the main gas valve and close the gas valve downstream of the MR valve Set the burner switch to on and adjust the pilot pressure regulator to 1 0 in wc for natural gas or 0 5 in wc for LPG Verify that the burner flame control has a flame signal of 5 0 VDC B 650 B 3000 See Page 119 Figure 78 FIGURE 78 Honeywell Flame Module Homeywell BURNER CONTROL BURNER FLAME CONTROL FLAME AMPLIFIER EA 5 0 VDC Negative Positive 119 of 149 B
197. vailable for Models B 350 B 3000 FIGURE 29 Three Way Discharge Head B 350 B 3000 SIDE VIEW Part Number Weight Ibs kg 77349 301 50 22 7 77049 301 80 36 3 77249 201 77549 201 120 160 54 4 72 6 69 of 149 B SERIES INSTALLATION OPERATION AND SERVICE MANUAL 14 2 Splash Plate Installation The splash plate is designed to hang directly from a horizontal air handler with a bottom discharge Before the splash plate can be installed on the air handler first drill four holes B 350 B 3000 in the air handler floor These holes should be approximately 5 8 15 9 mm in diameter to accommodate 1 2 hanger rods supplied by others These holes should be located as shown in the diagram on Page 71 Figure 31 To attach all of the hanger rods to the splash plate start by threading a flanged nut onto each hanger rod Then slip each hanger rod down through a hole located in each corner of the splash plate Next feed a flanged nut onto the rod below the splash plate See Page 70 Figure 30 The hanger rods should be attached to the air handler in the same manner as the splash plate with a flanged nut on both sides of the air handler floor Adjusting the nuts will level the
198. xiliary motor starter both used for controlling an exhaust fan or an enclosure heater or ground fault interrupt GFI receptacle are ordered the installer service technician must bring in separate power wires and fused disconnect provided by others to power these options The single point connection allows the installer service technician to bring only one set of power wires into the air handler Additional fusing is also provided to protect the variable frequency drive enclosure heater and or GFI 3 PHASE ONLY TOVFD 1 OPTIONAL TOVFD2 OPTIONAL FROM FUSABLE DISCONNECT L3 1 ON MAIN DIAGRAM s o o s BLOCK BREAKER 2 3 BREAKER TO 250 VA TRANSFORMER FOR OPTIONAL HEATER IN CONTROL ENCL TO 250 VA TRANSFORMER ON MAIN DIAGRAM Part Number Description Models Single Point Connection 13205XXX All Models 102 of 149 178 11 Service Receptacle Powered by Others Wired This option provides a service receptacle It includes ground fault interrupter GFI receptacle mounted on the interior or exterior of the control enclosure Power to the receptacle is supplied by the installer L3 L2 3 PHASE ONLY L1 BREAKER TRANSFORMER M j PRIMARY CONNECTION 2592 Hi H1 COMMON HV6 460V AAA A AU HVA 230V 1B HV3 208V 120 BR

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