OPERATING AND SERVICE MANUAL
Contents
1. Figure 2 15 ene NY AINE BLOWER BEARINGS Bearings must be checked during each periodic maintenance inspection Bolts and set screws should be checked for tightness and the bearings may need lubrication The following is intended only as a guide to aid you in setting up your own schedule LUBRICATION GUIDE FOR BLOWER BEARINGS Operating conditions Bearing Temp F Grease Interval Clean 32 120 6 10 months 120 150 1 3 months 150 200 1 4 weeks Dirty 32 150 1 4 weeks 150 200 Daily 1 week Moisture 32 200 Daily 1 week MOTOR BEARINGS Motor bearings in a clean environment should be lubricated every 2 to 3 years Under more severe conditions of dirt or moisture lubrication may be required every 6 months to 1 year Typical motor bearing lubrication procedure follows Remove fill and drain plugs Clean drain port of hard grease with wire if necessary Add grease cavity should be no more than full Start motor and let run for 10 minutes Wipe off any drained grease and replace fill and drain plugs a a Avoid adding an excessive amount of grease since this a common cause of motor failure BLOWER Ensure that blower hub is securely fastened to shaft Inspect blower wheel and blades for signs of damage or cracks Clean blades if necessary to maintain proper balance and performance Avoid use of excessive grease on blower bearings that can coat fan blades and attract dirt 16 ame2. CABINET Titan Air TA series equipment comes with either a galvanized finish or a painted finish In both cases the minimum gauge metal used is 18 ga BT AIRFLOW SWWITCHOPERATION BURNER PROFILE AIR PRESSURE DROP ANSI standards Z 83 4 CSA 3 7 M99 amp Z 83 18 2000 require manufacturers to monitor air moving across the burner for both high and low conditions Titan Air utilizes air pressure drop across the burner to satisfy this requirement Certification testing demonstrated that the burner will function properly between a low pressure drop of 0 2 w c and high pressure drop of 0 95 w c The standards also mandate that the switches cannot be adjustable This makes air pressure drop across the burner profile a very important factor at initial start up The design burner pressure drop at standard air conditions is 0 60 w c and will change as the temperature of outside air increases or decreases from 70 F In order for the burner to operate within the range of the air flow monitoring switch set points the pressure drop should be as close to 0 60 w c as possible Air pressure drop across the burner profile is dependent on OA temperature When the burner is off pressure drop will climb significantly during cold weather The burner is always off on initial start up Therefore if the burner profile air pressure drop is above 0 70 w c during a warm weather start up it may exceed 0 95 w c during a cold weather start up in nor
3. Check Programmer At beginning of cycle terminal 3 is energized or an internal diagnostics test for the Micro controller has failed Check Amplifier Diagnostic problem with amplifier has been found Amplifier Auto Check The amplifier is checked every 8 seconds by the micro computer to assure it is responding properly Check Blown Fuse At the end of pilot try for ignition no flame is detected and no power is present on terminal 3 indicating the fuse located on chassis is blown Check Scanner The UV self check scanner UV equipped units only is producing flame pulses during the shutter closed period due to a malfunctioning shutter or a run away UV tube 18 aT AM START UP PREP GENERAL START UP INFORMATION Even though Titan Air equipment is tested at the factory it is not the type of equipment you can throw the switch and walk away from A complete start up procedure must be performed The factory cannot duplicate the conditions the equipment will see in the actual installation i e gas pressure static pressure desired control settings etc For this reason there are field adjustments that have to be made Performing a complete start up procedure will help ensure that correct adjustments are made and correct operation is verified A step by step start up procedure is provided on subsequent pages While working through the start up procedure record information on the start up checklist and return to Titan Ai
4. EGNOS FIREYE MICRO M SERIES LED INDICATING LIGHTS STANDARD OPERATION gt Operating Control Energized whenever the burner control switch is on and power is applied to terminal 7 in the flame safeguard gt Interlock Illuminated solid when power is applied on terminal 6 in the flame safeguard to indicate that the air flow switch and other control amp limit switches are closed This light flashes once per second if the user has selected the fan only mode Summer or if an airflow switch or other safety circuit switch is open gt PTFI Illuminated only during the pilot trial for ignition period gt Flame Illuminated when flame signal is detected gt Alarm LED will flash once per second when an alarm condition is detected FIREYE MICRO M SERIES LED INDICATING LIGHTS ALARM MODE Symbol Legend A Flashing Light or Solid Light Light Off Une Fregueney Noise ersed O merae O O pier nion comta O O remera O Faserame senay O O mon O meoc O o om 17 ane EGNOS Line Frequency Noise Detected At start up the MICRO M measures the AC line to determine if the input is 50 Hz or 60 Hz and set its flag accordingly As the system is running line frequency is constantly monitored Outside interference causing a momentary shift in line frequency could be from S
5. Lifting plates or extended channel DAMPER SECTION REMOTE CAULKING HN Mount accessories with all access doors and OR GASKET damper motors facing same direction as unit MATERIAL access doors by others Intake or discharge damper should be mounted at the wall or ceiling inside building Mount All components must be caulked to prevent Indoors water from entering system Re caulk lift Fiad assembled aa SECC len Note Discharge damper maybe DISCHARGE Accessories should be supported after aii i M j Solve tangas or DAMPER installation supports by others a i TA 233 through TA 242 feature 2 piece accessories that need to be assembled supported and sealed in the field Intake dampers have two motors to wire INTAKE FILTER 2 DAMPER Make sure gas piping and electrical service INTAKE HOOD SECTION _ MOTORS does not interfere with any door opening and or filter removal Note Due to infinite installation possibilities a section of duct or transition may be required for proper accessory mounting These items are the responsibility of others INTAKE Recommend the use of flex connector between DAMPER unit and duct work Note All main power wiring must be sized and installed in accordance with applicable local state or federal codes Low voltage wiring must be run in separate conduit or shielded cable TA 233 through 242 Filter sections are accessed from both sides Split must seal 11
6. outdoors The high outlet temperature mode is designed to serve an unoccupied space and some equipment will re circulate air across the burner to achieve the high discharge temperature Total pressure rating of the blower includes allowance for the pressure drop through the primary air handling unit including the burner together with pressure losses at the inlet screen inlet damper filters outlet damper if used plus the external pressure rating of the system BURNERS Burners are purchased in 6 and 12 straight lengths and 12 tee sections and are assembled to meet the BTU requirements of each piece of equipment According to national safety standards the following factors could influence safe operation of a direct fired air make up unit and must be interlocked to either prevent the burner from firing or shut it down if unsafe conditions occur 1 AIR SOURCE If a damper is used it must be interlocked to prove it is open before the blower can start 2 BLOWER STARTER VED INTERLOCK A contact proving that the blower starter is energized or VFD is operating must be incorporated to prevent burner operation when the blower is not operating 3 AIRFLOW SWITCHES Monitor the air flow pressure drop across the burner The switches one high differential and one low differential will not allow burner to operate if air pressure drop across burner is outside of the high and low set points amie NSS ose OAON 4 HIGH TEMPE
7. NOTICE This product is intended for use in a process heating application requiring separate modes of operation not including comfort heating Compliance with the standard for Direct Gas Fired Industrial Air Heaters ANSI Z83 4 2000 when used in the spray cycle which implies use in habitable spaces is noted with the exception of the high temperature limit control function at 185 F or less Operation in the baking or cure mode is intended for non habitable spaces only This product has not been evaluated for effluent levels in the baking mode The maximum allowable discharge temperature in the baking mode is 200 F The high temperature limiting device will not allow temperatures in excess of 250 F Minimum fresh air requirements are not defined by the certifying agency in the baking mode This heater has provisions for connection of interlocking devices to require operation of a ventilation system during any heating operation and to prevent operation if inhabited or if access is allowed to the heated space Other interlocking requirements may apply ame NN yO 24 MONTH WARRANTY Titan Air Inc hereby warrants its products against defects in material and workmanship for a period of 24 twenty four months from date of shipment Start up checklist is due back within 30 thirty days of start up or 120 days from date of delivery for 24 month warranty to be effective After 30 thirty days and up until 60 sixty days a 12
8. discharge temperature sensor Field installation of the discharge temperature sensor in the discharge ductwork results in a better measurement of the average supply air temperature For paint booth applications the sensor should typically be located as close to the booth s supply air plenum as possible Utilize shielded cable for field installed discharge sensor wiring FIELD WIRING Power supply wiring should be routed from a dedicated branch circuit per schematic Depending upon how the equipment was ordered a single point power connection may be subdivided to individual loads or multiple power supply circuits may be required If an intake or discharge damper was ordered as a loose accessory it will have to be mounted and the actuator must be wired The remote panel must be mounted in a convenient location and wired to the unit Interlocks between the exhaust unit and possibly spray booth will have to be connected by field wiring Carefully review the schematic and associated schematic symbol legend Note that legend may be on the parts legend sheet rather than on the schematic Many codes require that low voltage wiring be routed in separate conduit from line voltage wiring If low voltage wiring is routed with 120 VAC control voltage wiring it must be placed in shielded cable s with appropriate insulation rating Even if low voltage wiring is routed in separate conduit very low voltage sensor outputs and actuator control signals should b
9. the base larger bases will have 2 adjustment bolts Loose belts will slip Excessive belt tension will shorten belt and bearing life Use a belt tension tester and associated tables to determine proper tension Re tension after the first day of operation with new belts and periodically thereafter Common belt tension gauges will specify a force required to produce a deflection of 1 64 per inch of span The force required to achieve this deflection is typically in the range of 3 Ibs for A belts 5 lbs for B belts and 15 Ibs for 5V belts See Figure 1 below Note that optimal belt tension is the lowest tension at which the belts will not slip under peak load Peak load typically occurs at start up SHEAVE ALIGNMENT With the use of a straight edge sheave alignment can be checked quickly and accurately One of the sheaves will have to be loose on its shaft in order to make adjustment Adjust until all 4 points are in contact with the straight edge see Figure 2 Repeat on the other side of sheaves and then re tighten If a face width variation exists measure the difference between each side of the narrowest sheave and adjust until both sides are an equal distance from the straight edge Motor Base Deflection 1 64 L per inch of span ee Lae aF KA 7 Oo oO Figure 1 Straight Edge
10. to the size of the duct at the connection to the equipment A properly designed duct transition from the blower outlet to a larger duct is recommended for long ducts or ducts with numerous elbows On heaters mounted outdoors discharge ductwork should be insulated to minimize condensation during the off cycle in cold weather A fresh air intake hood with bird screen is required Discharge duct should be common to both blowers on twin blower units Individual ducts for each blower are not recommended On a heater mounted indoors with through the roof intake a mushroom type intake hood is recommended to prevent moisture entrainment When using through the wall intake duct the intake louver should have adequate moisture baffling characteristics All intake ductwork exposed to the heated space should be insulated ene NY SON SOUND CONTROL Flexible connectors are recommended on at least one ductwork connection Vibration isolators that mount between the unit and support structure are optional and can be supplied with the equipment for installation by others Another option is internal isolation of the blower motor assembly with internal flexible connections between the blower housing and the unit structure Appropriate insulation on the interior of ductwork significantly reduces sound levels DISCHARGE TEMPERATURE SENSOR BULB INSTALLATION amp WIRING The installing contractor may be responsible for field installation of the
11. verbal or written understanding which may not be in total accordance with this expressed warranty Warranted parts must be returned to Titan Air Inc within 60 days to receive credit PURPOSE APPLICABILITY This manual is intended to provide installation operating and service information on Titan Air s TA Series H O T High Outlet Temperature air make up units Other types of equipment including TAP Series H O T units are covered in other manuals A packet of reference materials for a specific unit tracked by its Serial Number is generally included with this Operating and Service Manual The reference materials include Unit Specifications Parts Lists Gas Train and Burner Specifications Electrical Schematic and a Sequence of Operation A start up checklist is also included in this packet Review the reference materials for a specific unit and note any optional equipment or controls which are not specifically addressed in this manual prior to attempting start up or service work The information and recommendations contained in this publication are based on general observation and are not intended to supplant requirements of federal state or local codes having jurisdiction These codes should be reviewed before installation of equipment All units must be installed in accordance with national state or local codes It is the responsibility of the purchaser at the time of order to specify any and all code or insurance requirements t
12. with and parallel to the air flow By virtue of velocity impact and suction generated by the diverging shape of the combustion baffles air is induced through the air ports into the combustion zone The air supply is constant even though only that which mixes with the gas takes part in combustion When a very small quantity of gas is admitted to the burner sufficient mixing takes place in the low fire slot where combustion takes place Since the low fire zone is contained within the burner casting it is effectively shielded from uncontrolled air entry As the gas supply is increased the flame progresses into the intermediate fire zone where an additional supply of air is available At higher or full capacity mixing occurs at the larger air ports of the high fire zone augmented by air flowing over the end of the baffles On a reduction of gas supply the reverse sequence takes place the flame recedes to a location of lesser air supply until the low fire zone is reached The burner is suitable for a turndown range of approximately 30 to 1 AIR SUPPLY The supply fan is typically positioned to draw air across the burner Air flow across the burner must be substantially straight laminar and velocity must be within the proper range to develop the desired turndown and capacity When providing ventilation for an occupied space the direct fired burner is designed to operate in an air make up heater with all air crossing the burner taken directly from
13. CR controls VFD s etc Flame Fail PTFI No flame signal present at the end of pilot trial for ignition period Fault Unknown A catch all message when under certian high noise conditions the lockout message may become garbled and not translatable into any existing message Amplifier Count Fail A message used to detect a failed amplifier module that would generate an inordinate amount of pulses to micro computer usually due to a shorted transistor or oscillating electronic filter Flame Fail MTFI No flame signal present during main burner trial for ignition period Flame Fail Standby Flame signal present for a constant 60 seconds while control is in standby or off condition Interlock Open Interlock safety circuit terminal 6 has been detected open for longer than ten minutes during the purge cycle or during main flame period on MEP 562 Interlock Closed If selected by dip switches air flow or interlock switch terminal 6 is closed 30 seconds after the start of a cycle or when terminal 7 is closed Titan Air does not use this function Chassis Opto Opto coupler located on chassis has been found to be defective Opto couplers are checked every 1 2 cycle of the AC main s to ensure they are off during the negative 1 2 cycle Flame Fail Auto If dip switches selected for non recycle no flame is detected during the run cycle or main flame period Check Chassis At beginning of cycle terminal 5 is energized
14. RATURE LIMIT A manual reset high temperature limit control must be utilized to prevent high temperature situations caused by excessive fuel pressure or lack of air flow 5 FLAME SAFEGUARD Monitors the combustion process during ignition and operation for safe conditions 6 HIGH GAS PRESSURE SWITCH Monitors gas pressure to the burner This de energizes the burner in the event gas pressure increases above its set point The burner s design and flexibility coupled with proper controls make direct fired air make up equipment the safest and most efficient method of tempering outdoor air GAS CONTROLS Titan Air TA Series equipment is constructed to meet A N S I Z83 4 CSA 3 7 1999 standards Components in the gas delivery manifold on standard equipment include two manual shut off valves gas pressure regulator two safety shut off valves and an electronic gas modulating valve The pilot control includes a shutoff valve gas pressure regulator and a pilot solenoid ELECTRIC ELECTRONIC CONTROLS Titan Air H O T units typically come standard with the following items disconnect switch starter and overload assembly s or variable frequency drive s control power transformer if a 3 wire system air proving switches high temperature limit electronic flame safeguard and electronic flame modulation with remote setpoint adjustment Many other options including low temperature limit inlet duct stat and operating lights are available
15. UIPMENT ARRIVAL When the air make up unit arrives be sure to inspect for shipping damage The equipment was thoroughly inspected before leaving the factory and the driver signed for it Read the bill of lading and verify that all of the items listed are accounted for Any damaged or missing items should be reported to the transporter immediately DO NOT SEND DAMAGED FREIGHT BACK TO TITAN AIR All claims must be filed with the transporter Be sure to take photographs and get the drivers signature to confirm the damage The driver will have a number for you to call to file a claim Request a written inspection report from the claims inspector to substantiate any necessary claim Be sure to open the unit access doors and inspect for internal damage If for some reason you are unable to install the equipment immediately be sure that the equipment is protected from the elements Water damaged parts are not covered by Titan Air s warranty If the equipment is stored for an extended length of time be sure to completely check over the unit for any internal damage which may have been caused by excessive condensation Also check for any damage caused by rodents and be sure to eliminate any dust that may have built up on the components while the unit was in storage CAREFULLY AND THOROUGHLY READ TITAN AIR S PRODUCT WARRANTY Each unit is tested at the factory prior to shipping Because we are not able to simulate exact field conditions and sometimes actua
16. aT ITArhy AIR INCORPORATED OPERATING AND SERVICE MANUAL Serial Number For technical service or repair FIRST CALL INSTALLING CONTRACTOR SECOND CALL Titan Representative XXX YYY ZZZZ FINAL CALL Titan Air Inc 715 597 2050 Please have serial number available when calling FN warma PY nonce LOW TEMPERATURE LIMIT If this heater is to be installed in an area of potential freeze up and a low temperature limit was not ordered one should be installed to Improper installation adjustment alteration service or maintenance can cause property damage injury or death READ all maintenance instructions thoroughly before installing or ne provide freeze protection in the event of a servicing equipment burner shut down I N FOR YOUR SAFETY WIN NOTICE IF YOU SMELL GAS For outdoor equipment with a variable frequency 1 Open window doors drive VFD factory mounted in the unit main power 2 DO NOT switch electrical switches should remain on at all times especially during cold 3 Extinguish any open flame weather Even if the unit will not run at night or over 4 Immediately call vour gas supplier from a weekend main power should remain on to allow E ENETH U PP internal VFD self heating which extends VFD service life an area away from gas smell The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this heater is HAZARDOUS H O T UNIT
17. ance with local codes or in the absence of local code according to ANSI 2223 1 If the heater is to be installed in an airplane hanger refer to ANSI NFPA 409 If the heater is to be installed in a parking garage refer to ANSI NFPA 88A If the heater is to be installed in a service garage refer to ANSI NFPA 88B For installations in Canada refer to CAN CGA B149 Vv Vv VY V WV Adequate exhaust and or relief must be provided to prevent over pressurizing the served space when the heater is operating at its rated capacity gt If in doubt regarding the application of the direct fired heater contact the sales representative or the factory POSITIONING THE HEATER Locate the heater exactly level making certain minimum clearance required by local codes is maintained between the heater and any combustible materials See name plate on unit for minimum recommended clearances ene NY SON CURBING OUTDOOR MOUNTING The use of a full perimeter curb or mounting rails under the heater is recommended The only openings in the roof should be for the supply air duct return air duct if required gas and electrical connections if applicable These openings must be sealed properly after installation Titan Air ships all curbs unassembled and un insulated Installing contractor supplies gaskets cant strips insulation etc GAS PIPING Gas piping must be sized and installed in accordance with applicable codes It must be able to deli
18. e routed in shielded cable NOTE All field wiring must conform to N E C and or any state or local codes SUPPORT OF ACCESSORIES Most Titan Air equipment is supplied with loose accessories i e damper hood discharge diffuser or filter section If an intake hood is supplied by others the design shall minimize entry of snow rain and include an intake screen to meet ANSI standards Intake accessories on large equipment may be shipped in two pieces for field assembly Two damper actuators may need to field wired on large equipment as well It is the responsibility of the installing contractor to support accessory items from a rigid point or points to ensure solid mounting POST INSTALLATION Caulking is required between all parts prior to assembly and seams must be re caulked after assembly Air make up units shipped in multiple sections will include a high quality caulk tape and caulk tubes Caulk tape is applied between sections with exterior caulking applied after the unit sections have been joined Sealing integrity should be rechecked on a yearly basis Water damaged parts are not covered by Titan Air s warranty 10 ene LN On split units contractor is responsible for interconnection of components DISCHARGE Service DAMPER Disconnect INTAKE HOOD w BIRDSCREEN or HOOD FILTER COMBO 7 SN BLOWER ACCESS p x GAS TRAIN Reese E INTAKE FILTER
19. ed oxygen for combustion A series of strategically sized and placed holes provide air to the combustion zone See Figure 1 Indicated Flame Length High Fire Zone High Fire Intermediate Air Ports Zone Progressive Air Supply Intermediate Ports Low Fire yee Fire Air Ports Zone Aluminum Manifold 4 AIR FLOW Note Low fire air ports in casting are only present on Midco burners Figure 1 The direct fired burner is designed to operate at an air velocity across the burner of 2450 fom with maximum manifold gas pressure as stated on unit rating plate Two speed H O T units feature a damper with actuator and controls to maintain proper velocity across the burner profile as air volume changes Single soeed H O T units have slide plates on either side of the burner to allow manual adjustment of the burner profile area Because of the air pattern air ports and kinetic energy of the air moving across the burner the direct fired burner has the capabilities of a 30 1 turn down ratio The high fire rate can be as much as 30 times the low fire rate amie NSS ose ONAION BURNER OPERATING PRINCIPLES The direct fired burner is designed to operate in a cabinet of flowing fresh air Fuel gas is fed directly to the burner kinetic energy of the airstream furnishes combustion air It will function properly at the design velocity and pressure associated with ventilating systems The burner must be installed to fire
20. ene LN supported Mount Indoors by others DISCHARGE SERVICE Disc DISCONNECT DISCHARGE E DIFFUSER mounted indoors Duct work between AMU or discharge damper and discharge diffuser is supplied by others OUTSIDE AIR Recomend the use of flex FILTER SECTION connector between optional slides unit and duct work into unit Diffuser should be supported at 2 points by others an example shown Turning vanes are adjusted and secured in the field All components must be caulked to prevent water from entering system Recaulk lift plates after installation Unit Stand Oe Nut Washer Make sure piping and electrical service does not interfere with any door opening and or filter removal Recoment the use of flex connector between unit and duct work Cement For indoor units the stand must be enclosed sometimes height is increased Atransition by others must then be made from enclosed stand intake opeing to the intake damper or louver a size variation may exist Intake damper should be PAD ATTACHMENT DETAIL mounted at the building wlal or ceiling by others 12 LLITAN AIR INCORPORATED BLOWER _ MOTOR S s DISCHARGE DAMPER mounted indoors SERVICE e DISCONNECT Ea wi a i ELECTRIC Gane OUTSIDE AIR ACCE Ta FILTER SECTION optional slides REOR into unit ai P Larger units have m
21. hat may dictate the addition of components to the equipment in order to comply with those requirements Only qualified personnel who have experience with the installation and operation of industrial commercial direct fired equipment should attempt to service Titan Air equipment enw Ne iSO eOMENS Page WARRANTY 1 TABLE OF CONTENTS 2 GENERAL INFORMATION 3 gt Equipment Arrival gt Components AIR FLOW SWITCH OPERATION T INSTALLATION 8 gt Installation and Field Wiring Overview TYPICAL ASSEMBLY DRAWINGS 11 MAINTENANCE 14 FLAME FAIL DIAGNOSTICS 17 START UP PREPARATION 19 VALVE LEAK TEST 20 SPECIFIC EQUIPMENT DETAILS pages not numbered Unit Specification Unit Drawing Sequence of Operation Parts Legend Sheet Schematic Start Up Procedure Troubleshooting optional YVY YYYYVY Note that operating and service manuals are occasionally requested prior to production of a unit These manuals will be marked Pre Production Release on the front cover The final copy of the operating and service manual for a specific unit will be sent with the unit Additional copies of the manual for a specific unit are available A detailed unit specification sheet parts legend sheet schematic sequence of operation and start up procedure are provided in the start up section of each operating and service manual generated for a specific unit Selected vendor cut sheets on components will also be included amie NSS ose ONAION EQ
22. ing 1 Check filters and clean or replace as needed Lube bearings Check belts and belt tension Check all hardware bearings etc for tightness Check settings for all controls Check duct connections for leaks Re caulk seams if needed Check burner and flame rod clean if necessary Perform complete start up procedure once per year prior to heating season oot ool oy FILTERS Dirty or clogged filters will restrict air flow which in turn affects the burner operation Therefore it is necessary to check filters on a regular basis Cleanable filters can be removed from the filter rack and sprayed with a low pressure water Always spray these filters in the opposite direction to air flow and apply new coating to filters when dry BURNER Maintaining the pilot assembly is essential to reliable operation During pre heating season maintenance the burner should be lit numerous times to confirm reliability If ignition system components require servicing pay attention to the following Handle porcelain spark rod and flame rod with care Small cracks lead to intermittent ignition problems 2 Midco burners utilize the pilot gas tube as a ground point for the ignition rod Keep this grounding point free from scale or other contaminant build up 3 Ignition wire routing should remain separated from sheet metal cabinet to maintain optimal spark strength 4 Dielectric grease is utilized inside of the ignition and flame sensor connection boots t
23. ing the closure tightness of the gas safety shutoff valve It should be performed by trained and experienced technicians This test should be part of the scheduled inspections and maintenance procedures 1 Close the upstream manual gas valve 2 Make sure manual test cock on leak test assembly is closed 3 Remove the test plug on leaving side of gas valve 4 Close the downstream manual gas valve 5 Open the upstream manual gas valve 6 Through the safety system enable the gas valve momentarily 7 Immerse a tube vertically into a jar of water 8 Slowly open the test cock on the leak assembly 9 Once the rate of bubbles through the test assembly stabilizes count the number of bubbles appearing during the ten second time frame Each bubble is approximately 0 001 cfh 10 Do this test for each shut off valve Reference below leak test assembly and leakage rate chart A B C D E DOWNSTREAM LEAK MANUAL CD TEST GAS COCK TAP GAS oe LLLA eee PRV A SSOV A UPSTREAM MANUAL F GAS COCK 4 4 IN 6 MM AU FLEXIBLE MANUAL TUBING TEST 1 4 IN 6 MM PETCOCK ALUMINUM OR COPPER PILOT JAR OR GLASS TUBING Ni fo WITH WATER i 1 2 13 MM CUT AT 45 DEGREE ANGLE Leakage SCCH in 10 Sec 10 bubbles 3 8 amp 1 2 3 4 amp 1 1 1 4 amp 1 1 2 457LP O A i B R 64gas 578 5H S O66 4 57LP_ 870 0S 4 57LP_ _ 484 20
24. l conditions are different than what was Stated on the order you may need to make some adjustments in the field This is why it is very important that only qualified personnel start up and service Titan Air equipment The start up checklist provided in packet with this manual must be filled out and returned to Titan Air in order to validate equipment warranty For a fee Titan Air personnel will travel to the job site supervise start up and provide operation and maintenance training for the equipment BLOWERS The typical blower s used in Titan Air equipment are AMCA rated industrial type forward curve D W D lI fans Backward incline backward airfoil and plenum plug fans are used occasionally Models TA 109 through TA 136 utilize a single blower while models TA 215 and TA 242 utilize twin blowers All blower wheels are mounted on a solid turned ground and polished shaft 9 and 12 blowers are supported with permanently lubricated ball bearings Larger blowers are supported by relubricatable pillow block ball bearings MOTOR amp DRIVE Rigid base T Frame motors are utilized The motor is mounted on an adjustable slide base Variable pitch motor sheaves are typically provided to allow airflow adjustment if the motor is no larger than 30 Hp amie NSS ose ONAION DIRECT FIRED HEATING Direct fired burners are designed to operate in a fresh flowing airstream Gas is fed directly to the burner and the airstream provides the need
25. mperature control is typical At least one additional setpoint is usually included for the high outlet temperature mode Titan Air units are typically supplied with a remote control panel This panel will include switching for blower amp burner operation and temperature setpoint s Timers are often included to automate the bake cycle Other options common for H O T units include controls to interlock with paint booth lights and compressed air solenoid as well as control a paint booth exhaust fan Some units feature operating lights discharge temperature display custom controls or contacts by others to enable blower and or burner operation Refer to the unit specification sheets parts list schematic sequence of operation and start up procedure for a specific unit to determine the control options included PRE INSTALLATION Inspect the equipment making sure all parts and accessories are on the job site Check equipment against order and packing list If the equipment has been sitting in storage for some time inspect it for moisture from condensation rain or snow and or dust accumulation Both can cause damage to electrical and electronic components as well as bearings and insulation INSTALLATION Care taken during the installation and start up is vital to the longevity and reliability of the equipment Confirm that gas and electric utilities match the rating on the equipment name plate gt This heater shall be installed in accord
26. o limit potential for moisture in the connection 5 Maintaining low pilot regulator output pressure typically produces reliable ignition Excess pilot pressure creates a gas rich region that will not ignite consistently 6 The pilot solenoid is disabled following main flame ignition The low fire setting must be high enough to maintain a proper amplified flame rectification signal Check that burner baffles are firmly attached to each other and to burner casting Do not use excessive force on screws in casting Clean baffles with wire brush if needed Burner orifices may need to be re drilled due to rust or other build up Burners with aluminum castings will rarely require orifice cleaning Use drill bit sizes listed below Fuel Type Burner Model Natural Gas Eclipse AH MA 2 4 mm Bit Natural Gas Midco HMA 2 or 2A 1 8 Bit Eclipse AH MA 2 0 mm Bit Midco HMA 2 or 2A 1 8 Bit Low Fire Air Ports Midco HMA 2 or 2A 43 Bit 14 ane NN TINEA BELT TENSION Proper sheave alignment and belt tension are critical to belt and bearing service life Incorrect belt tension or misalignment of sheaves can cause any of the following 1 Premature failure of bearings 2 Premature failure of belts 3 Reduced air volume 4 Noise and vibrations Each Titan Air unit has as standard equipment an adjustable motor base To adjust the belt tension loosen the motor hold down bolts and adjust the slide base with adjusting bolt s on the end of
27. ore legs Sealant goes between each section before assembly Bolts and caulking are in packing box Recaulk seams and lifting plates after assembly Unit Stand Ea Nut Washer Cement 2 PIECE UNIT ASSEMBLY DETAIL by others PAD ATTACHMENT DETAIL by others 13 UNIMACCESSORYANSTALFATION l Supported by others ___ _ DISCHARGE DIFFUSER mounted indoors Duct work between AMU or discharge damper and discharge diffuser is supplied by others Recomend the use of flex connector between unit and duct work Diffuser should be supported at 2 points by others an example shown Turning vanes are adjusted and secured in the field All components must be caulked to prevent water from entering system Recaulk lift plates after installation Make sure piping and electrical service does not interfere with any door opening and or filter removal For indoor units the stand must be enclosed sometimes height is increased A transition by others must then be made from enclosed stand intake opening to the intake damper or louver a size variation may exist Intake damper should be mounted at the building wall or ceiling ene NY AINE GENERAL MAINTENANCE As with any equipment or machinery a maintenance program should be implemented A well maintained unit will perform efficiently for many years Equipment maintenance should include the follow
28. r to validate the equipment warranty The start up checklist is provided on cardstock with Titan Air s address pre printed on one side Because most component failures occur during start up it is very important that the function of every component be checked out during start up It is just as important that the start up technician realize the malfunction of a component may be caused by other factors i e air flow gas pressure field wiring etc and should fully investigate a component malfunction and its cause before replacing the component Titan Air checks out all returned components and has found approximately 70 of returned parts are in full operational condition This history has proven that a little extra time invested in troubleshooting will often save the considerable investment in parts time and paperwork associated with replacing components SUGGESTED TOOLS AND INSTRUMENTS NEEDED FOR START UP Volt Ohm Meter Ammeter Tachometer Thermometer Gas pressure gauge 10 to O to 10 of water column typical scale Air differential pressure gauge 2 to 0 to 2 of water column typical scale Standard Hand Tools Additional items for Maxitrol Series 14 or 44 temperature controls gt 10 000 Ohm potentiometer gt watt 10 000 Ohm resistor gt watt 2 000 Ohm resistor Additional items for FX Series temperature controls gt 1 070 Ohm resistor Supplied 19 rS NS Na Valve Leak Test This is a test for check
29. thern regions Such a high air pressure drop would open the high airflow switch and prevent burner ignition The following chart will aid in equipment set up at outside air temperatures different from 70 F when the unit is operating with the burner off The chart gives pressure drops at various temperatures equivalent to 0 60 w c at 70 F Note that two speed H O T units feature controls to maintain pressure drop across the burner as air volume changes Either high speed and low speed mechanical adjustments of damper actuator travel or a dual pressure switch assembly are used to control burner air pressure drop Burner profile air pressure drop should be measured on high speed with the burner profile dampers near the full open position If the burner profile dampers open less than 50 on high speed the unit is probably delivering less than full rated airflow Burner Profile Air Pressure Drop at Various OA Temperatures Burner Off OA Burner Temp Profile Drop OA Burner OA Burner Temp Profile Drop Temp Profile Drop 0 76 10 0 68 0 75 15 0 67 0 74 20 0 73 0 72 30 0 71 35 65 70 15 0 65 0 64 95 100 105 45 50 0 68 55 0 63 0 62 0 62 O K A N O1 ene NY SON CONTROLS Control systems can be designed to meet specific requirements Numerous temperature controls are available Since H O T units usually temper outside air to replace the air exhausted from a paint booth modulating discharge te
30. twelve month warranty will be observed All warranties are null and void if start up checklist is not received within 60 sixty days from start up or 120 days from date of delivery NO EXCEPTIONS WILL BE MADE Titan Air Inc reserves the right at Titan Air Inc s option to replace or repair free of charge any part proven by Titan Air Inc to be defective Prompt notification of defective part must be given to Titan Air Inc and defective part must be returned freight prepaid within 30 thirty days of notification WARRANTY INCLUDES ONLY PARTS SUPPLIED BY TITAN AIR INC INCIDENTAL COSTS AND LABOR CHARGES SHALL BE THE RESPONSIBILITY OF OTHERS This warranty does not cover fuses belts filters or water damaged parts which are the result of improper storage or installation This warranty is void in event the product is improperly installed and or operated under conditions other than normal published ratings improperly maintained misused or not in compliance with applicable codes or not in accordance with Titan Air Inc s operating instructions This warranty is void if attempts to correct or repair any alleged defective part or parts are made by unauthorized personnel without Titan Air Inc s written approval In no event shall Titan Air Inc be held liable for any damage incidental or consequential arising from the installation performance or operation of the product This warranty supersedes voids and or is in lieu of any other
31. ver the specified CFH and gas pressure at full flow Refer to unit nameplate or unit specification sheets for specified CFH and gas pressure Care must be taken with the gas piping to prevent problems at start up and later during operation Before the union between the supply line and the unit is connected the supply line should be cleaned out to remove any foreign material dirt rust metal shavings etc Refer to unit nameplate to determine the minimum gas supply pressure required to attain the maximum specified gas All suitable gas controls regulators and valves equipped with a diaphragm in this device are furnished with an ANSI approved vent limiter If local codes require these components be vented to the outside it is the responsibility of the installing contractor The heater and its individual shut off valve must be disconnected from the gas supply piping system during any pressure testing in excess of 72 PSIG The heater must be isolated from the gas supply piping system by closing its individual shut off valve during any pressure testing of the supply system at pressures equal to or less the 1 2 PSIG During start up the technician should perform a gas leak check on all valves and piping during the heater s normal operation DUCTWORK Ductwork must be sized and installed in accordance with applicable codes and standards A size variation may exist from recommended duct size to unit flange size Recommended duct size applies
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