AA154700 - Attachment 2 - Technical Exhibit 2.pdf

OPERATION AND MAINTENANCE MANUAL

BULLET TRAP DRAG CONVEYOR

INFORMATION

MAYFRAN 2 1/2" Pitch Drag Conveyor

Mayfran International, Incorporated P.O. Box 43038 6650 Beta Drive

Cleveland, Ohio 44143

(440) 461-4100 tel.

(440) 461-5565 fax

Mayfran International, Incorporated Installation / Operation / Maintenance Manual

TABLE OF CONTENTS

Drag Conveyor information

Safety information

Safety Information…………………………………………………………………………………………………..3

Startup procedures

General instructions and rules prior to equipment start-up

Maintenance & Adjustments

Maintenance schedule

Lubrication

Gear reducer

Adjustments

Belt chain adjustment

Tightening the belt chains

Loosening the belt chains

Spare Parts

Variable Speed Inverter Operation

Trouble shooting

Overview

Overload faults

Troubleshooting guide

BULLET TRAP DRAG CONVEYOR INFORMATION

MACHINE INFO

Customer:

Mfg. Year:

Serial No:

Voltage/Phase

Cycle:

Inspected by:

YOUR WARRANTY PERIOD

Mayfran’s Warranty is given on the following page.

Your Warranty period: _________ through _________

CUSTOMER SERVICE / PARTS ORDERS

If you have any questions or need to order parts, please contact Mayfran International at:

(440) 461-4100 Fax: (440) 461-5565 8:00 a.m. to 5:00 p.m. (EST)

THIS GUIDE IS COPYRIGHTED

All rights are reserved. This manual may not, in whole or in part, be copied, photocopied, reproduced or reduced to any form of electronic medium or machine readable form without prior consent, in writing from:

Mayfran International, Incorporated P. O. Box 43038 Cleveland, OH 44143

Information in this manual is subject to change and is furnished to supplement, not modify the terms and conditions of Mayfran’s order acknowledgment and/or signed contract with the customer.

SAFETY INFORMATION

DO NOT operate any machinery without reading and understanding this manual completely.

DO NOT operate any machinery unless fully trained and qualified by the owner or end user.

DO NOT operate any machinery (or any portion of this machinery) unless all personnel are clear of any rotating or moving parts (or parts that may potentially move or rotate).

DO NOT operate any machinery unless all guards and/or emergency stops are in place and functioning as designed by Mayfran.

DO NOT operate any machinery in applications other than the specific application for which the machinery was designed.

DO NOT perform any maintenance, repairs or adjustments on this machinery without first locking out all electrical controls.

DO NOT lubricate any machinery without first locking out all electrical controls.

DO NOT clean this machinery or the areas adjacent to or below the machinery without first locking out all electrical controls.

DO NOT remove any covers or guards without locking out all electrical controls.

DO NOT perform any maintenance or repairs on power lines feeding this machinery without first locking out power at the source.

DO NOT remove or cover any warning labels.

Adjustment, maintenance, cleaning and lubrication should be carried out only by personnel trained by the owner or end user in the operation of all associated conveyors and process equipment. Personnel should be trained in OSHA compliant lock-out / tag-out and electrical safety procedures. Records of training should be maintained by the owner or end user. Records of training for the safe operation of this machinery must also be maintained. Never should adjustment, maintenance, cleaning or lubrication be performed without following proper safety procedures.

Operators should be instructed to report any impairment of guards, emergency stop, or safety switches to their supervisors.

THE SAFETY INFORMATION CONTAINED HEREIN MUST BE COMMUNICATED BY THE CUSTOMER,

OWNER, OR END USER TO ALL PERSONNEL WHO WILL ACTUALLY OPERATE, MAINTAIN, REPAIR,

OR ADJUST THIS MACHINERY, OR WHO ARE ASSIGNED TO WORK IN THE VICINITY OF THIS

MACHINERY.

SAFETY INFORMATION, continued

Chip Processing Equipment should be used to process only the material for which it was specifically designed.

Casings, guards and other safety devices shall not be removed, bypassed, or disengaged during system operation.

Personnel should not climb on the components of a system unless the equipment is expressly designed to support people and function as a work area.

Only trained operators should be permitted to operate the Chip Processing Equipment.

All necessary guards, switches and other safety devices shall be installed so that a loss of power to the equipment shall not render the guards, switches or safety devices inoperative.

Emergency controls shall be installed so that they cannot be overridden from other locations.

Guards shall be kept in place at all times unless the electrical power is off and the system is locked out.

All repairs and services shall be performed by qualified personnel. Before repairs, tests or services are begun, all power controls shall be locked out in accordance with OSHA compliant procedures.

After a machine has been repaired, tested or serviced, it shall not be operated until all guards and safety devices have been reinstalled, all maintenance equipment has been removed and a visual inspection of the machine and immediate area has been completed.

Material should not be discharged onto a screw feed conveyor that is not operating. Material accumulations may inhibit the equipments safe operation.

When working on the Chip Processing Equipment, be sure to turn the electrical disconnect OFF and LOCK OUT the power to the equipment.

MAYFRAN INTERNATIONAL, INCORPORATED WILL NOT BE RESPONSIBLE FOR ANY WORK

PERFORMED, OR ALTERATIONS MADE TO ANY OF ITS PRODUCTS UNLESS PRIOR

APPROVAL HAS BEEN GRANTED BY AN AUTHORIZED MAYFRAN REPRESENTATIVE. ANY

SUCH WORK PERFORMED WILL VOID ANY AND ALL WARRANTIES AND LIABILITIES. ALL

WARRANTIES AND LIABILITIES SHALL ALSO BE VOID IF PARTS UNIQUE TO MAYFRAN

INTERNATIONAL ARE PURCHASED FROM A SOURCE OTHER THAN MAYFRAN

INTERNATIONAL.

All information provided in this manual is for the purpose of customer education only, and is subject to change without notice.

START UP

Before the conveyor is started, the following items should be checked to ensure proper operation of the conveyor.

1.) Check the interior of the conveyor for obstructions such as wooden shipping braces etc. that may have gotten in during shipment. Remove all obstructions.

2.) Check for proper belt adjustment. See the “ BELT ADJUSTMENT ” section of this manual for tensioning requirements and adjustment instructions.

3.) Check belt direction. The lower strand of belt should be moving in a direction that is towards the head shaft. Conversely, the upper strand will be moving away from the head shaft , or towards the tail shaft.

If the belt is traveling in the wrong direction, reversing any two leads on the motor will reverse its direction. See figure #1.

4.) Check for the breather plug in the gear reducer drive. It should be in the upper most port on the reducer and it should be open to atmosphere.

Figure 1

MAINTENANCE & ADJUSTMENTS

MAINTENANCE SCHEDULE

By far, the most important maintenance activity is to keep the conveyor clean. Cleaning the conveyor on a regular basis will ensure that the reducer, motor and electronic motion sensor will perform as they were designed. It is recommended that the end users maintenance manager produce their own preventative maintenance schedule based on the following chart. Accurate records of any maintenance performed must be kept. This table is not all inclusive, and should be used as a general guideline only. It should be adjusted for shift usage, and environmental conditions.

MAINTENANCE OPERATION INTERVAL

Inspect drag cleats/wipers for wear or damage Weekly

Check for proper belt adjustment Monthly

Oil drive chain and sprockets Monthly

Check belt tracks for material build-up Quarterly

Grease headshaft bearings Semi-Annually (no.2 lithium based grease)

Check reducer oil level-change if required* Semi-Annually, change every 2500 hrs of operation *Note: Change oil in reducer after initial 40 hrs. of operation

LUBRICATION

A vital maintenance item is to ensure that the drive components are kept well lubricated. This will help prevent unneccessary down time due to early failure.

GENERAL LUBRICATION GUIDELINES

1. Use grease from tightly sealed containers. Grease should be free from impurities such as dirt, metal particulate or moisture.

2. Wipe grease fittings clean before adding grease.

3. A small amount of grease at frequent intervals is more preferable than a large amount at longer intervals. However, the proper amount and interval can only be determined by experience.

4. Bearings should be greased with a white lithium based grease such as Mobilux EP-2, Texaco Molytex 2 or equal. Do not mix different types of grease. Mixing grease may cause chemical reactions that diminish the greases ability to lubricate the bearings. Use one manufacturer and stay with that brand.

GEAR REDUCER

LUBRICATION

The reducers will be filled to the proper level with lubricant when shipped from the factory. However, the oil level should be checked periodically. Also, when checking the oil level, make sure that the vent plug is clean and functioning properly. The lubricant should be changed every 6 months or 2500 hours of operation. In unusually severe or harsh environments, the lubricant should be changed on a more frequent basis. The unit holds approximately ½ pint of oil.

REDUCER LUBRICATION CHART

MANUFACTURER

AMBIENT TEMPERATURE

15°- 60°F AGMA Compound No.7

AMBIENT TEMPERATURE

50°-125°F

AGMA COMPOUND NO.8

Amoco Oil Co. Worm Gear Oil Cylinder Oil #680

Chevron Usa, Inc. Cylinder Oil #460x Cylinder Oil #680x

Exxon Co. Usa Cylesstic Tk-460 Cylesstic Tk-680

Gulf Oil Co. Senate 460 Senate 680d

Mobil Oil Corp. 600w Super Extra Hecia Super

Shell Oil Co. Valvata Oil J460 Valvata Oil J680

Sun Oil Co. Gear Oil 7c Gear Oil 8c

Texaco Honor Cylinder Oil 650t Cylinder Oil

Union Oil of California Steaval A Worm Gear Lube 140

ADJUSTMENTS

The drag conveyor requires only a few simple adjustments to keep it operating at peak performance.

BELT CHAIN ADJUSTMENT

Proper belt chain tension is critical to the reliable operation of this conveyor. The belt chains will loosen up after the initial run-in period, and after long periods of continued use as components begin to wear. A sure sign of an improperly tensioned belt chain is an observed jerking motion of the chains or cleats while running.

Loose belt chains may jam and cause damage to the conveyor. Over-tightened belt chains may cause excessive wear to the belt components, and create overloads on the drive.

To determine if the belt chains are properly adjusted, do the following:

1.) Position a cleat several inches prior to the headshaft in the direction of belt travel.

2.) Disconnect and lockout all power to the equipment.

3.) Press up from the underside of the conveyor firmly on the center of the cleat. Observe one of the following conditions:

3a.) If the cleat and chains collapse and stay collapsed, the chains are too loose.

3b.) If the cleat and chains spring back to their original position, the tension is correct.

3c.) If the cleat is unable to be depressed, the chains are to tight.

TIGHTENING THE BELT CHAINS

1.) Remove the chain guard cover from the drive. Loosen the chain guard back plate to allow for movement.

2.) Loosen the motor base mounting and adjustment bolts, and slide the base back to put some slack in the drive chain.

3.) Loosen the bearing mounting bolts slightly. Do not remove.

4.) Loosen the jam nuts on the take up bolts. Adjust the bolts inward to push on the bearing plates to tighten the belt chains. Adjust the bolts evenly on each side until condition “3b” is met above.

5.) Check headshaft for squareness to the machine. To do this, measure from the headshaft to the end of the head frame on each side. The dimensions should match.

6.) Tighten jam nuts on the take up bolts, and the bearing mounting bolts.

7.) Adjust the drive chain.

8.) Adjust the chain guard back plate so the sheave is centered in the large opening, and the reducer shaft is centered in the slot. Tighten in place.

9.) Replace the chain guard.

LOOSENING THE BELT CHAINS

Follow the above steps except step (4) four should read:

4.) Loosen the jam nuts on the take up bolts. Adjust the bolts outward to relieve pressure from the bearing plates to loosen the belt chains. Adjust the bolts evenly on each side until condition “3b” is met above.

3.) Loosen the belt chains slightly. Remove the cotterpin from the belt pin. Using a punch of less than

3/8" dia., carefully tap the pin from the chain. Perform this same procedure on the opposite side belt chain. Chains should now be separated.

4.) Remove the chain guard cover. Locate drive chain masterlink and separate chain.

5.) Loosen the two set screws holding the sheave onto the head shaft. Pull sheave from shaft.

6.) Remove the mounting bolts holding the headshaft assembly to the slotted take up angles.

Headshaft can now be removed from the take up slots. Do not lose the bearing push plates.

7.) Install new head shaft assembly, and reassemble the conveyor in reverse order.

VARIALBLE SPEED INVERTER OPERATION

Mayfran conveyor is supplied with a variable speed motor inverter with electronic jam. Review KB

Penta KBAC operation manual from web sight www.kbelectronics.com/manuals/kbac_manual.pdf

LOCAL JOG OPERATION

Power up inverter. Select “MANUAL” on KB Penta inverter. Push upward momentary “START” select which enables the jog “FORWARD/REVERSE” select. Manually select jog “FORWARD/REVERSE” to clear jam.

REMOTE AUTO START OPERATION

Power up inverter. Select “AUTO” on KB Penta inverter. Push upward momentary “START” select which enables a remote auto start. A remote auto start signal will start the conveyor. In some applications the remote auto start input is jumpered to start automatically when selected to “AUTO”.

SPEED REFERENCE

Conveyor speed reference is factory set at 50% (3FPM). It is preferred to increase speed if necessary.

Slower speed could cause overloading of conveyor or potential jams.

INVERTER ELECTRONIC JAM FAULT

“CL” parameter inside inverter is factory set at 100%. If overload or jam occurs, motor current will exceed the “CL” set point and inverter will fault, signaled by a flashing red LED. Do not increase “CL” without factory approval. A run status contact interlock is available t indicate conveyor running. Scrap material should not be feed into conveyor unless the conveyor is running.

TROUBLESHOOTING

OVERVIEW

Mayfran drag conveyors are designed to be the most reliable in the industry. However, problems may arise from time to time. Problems are normally discovered in one of two ways:

� A fault is indicated on the main control panel.

� The second indication that a problem exists is simply by the operator noticing that there is something different about the way the conveyor is operating; usually some sort of unusual noise or vibration. The only way to correct this problem is to examine the conveyor and determine the source.

It is imperative that any unusual noises or situations are identified, diagnosed, and corrected immediately to prevent serious damage from occurring.

OVERLOAD FAULTS

An electronic jam fault is caused by overloading or jam in the conveyor belt. After the motor inverter device is reset, and any obvious cause corrected, the component should be run in manual mode, and the amperage draw on the motor checked. Check the current setting “CL” on the motor inverter is set to 100%.

PROBLEM

POSSIBLE CAUSE SOLUTION

Motor does not start

Main power switch is not connected

Emergency stop button is working

Circuit breaker/overload is working

Connect power

Reset emergency stop button

Reset circuit breaker. Find cause of overload

Inverter electronic jam fault

Inverter jam fault caused by material build up in the conveyor

Loose belt chains jammed causing clutch overload

Drive component failure

Remove excess material.

Reset inverter fault, restart.

Retension belt chains

Investigate drive components for defective part(s)

Excessive amperage draw or motor inverter fault

Belt chains to tight

Excessive material jammed in belt chain or chain path

Retension belt chains

Clean chain and/or chain path

Excessive jams without material blockage

Loose belt chains Retension belt chains

Revision 12 – 11.19.2013

Installation & Operation Guide

Industrial Non Re-circulating Direct -Fired Heaters

Horizontal / Vertical and Single / Twin Blowers

FOR YOUR SAFETY

If You smell gas:

1. Open windows

2. Don’t touch electrical switches

3. Extinguish any open flames

4. Immediately call your gas supplier

FOR YOUR SAFETY

The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous!

WARNING!!

Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read the installation, operating and maintenance instructions thoroughly before installing or servicing this equipment.

ALWAYS disconnect power and gas before working on heater.

RECEIVING AND INSPECTION

Upon receiving unit, check for any interior or exterior damage, and if found, report it immediately to the carrier. Also check that all accessory items are accounted for and are damage free. Turn the blower wheel by hand to verify free rotation and check the damper (if supplied) for free operation.

NOTE TO INSTALLER

Please complete and return the Start-UP Checklist on the back of this manual to validate warranty

This manual should be reviewed with the customer and left with the equipment user

TABLE OF CONTENTS

WARRANTY

INSTALLATION

Gas

Electrical

Gas Connection Diagram

Copper Wire Ampacity

SEQUENCE OF OPERATIONS

Standard Sequence of Operation

Additional Sequence of Operation – All VFD Motor Control

VFD Preset Speeds

START-UP PROCEDURE

PROFILE ADJUSTMENTS

VFD Drive Installation & Programming Instructions

OTHER UNIT COMPONENTS

Flame Safety Control

High Temperature Limit

Electric Cabinet Heater

DC Flame Signal

TROUBLESHOOTING

MAINTENANCE

Burner Orifice Drill Size

START-UP CHECKLIST

WARRANTY

This equipment is warranted to be free from defects in materials and workmanship, under normal use and service, for a period of 12 months from date of shipment. This warranty shall not apply if:

• the equipment is not installed by a qualified installer per the manufacturer’s installation instructions shipped with the product

• the equipment is not installed in accordance with federal, state and local codes and regulations

• the equipment is misused or neglected

• the equipment is not operated within its published capacity

• the invoice is not paid within the terms of the sales agreement

• the Start-Up Checklist has not been filled in by a qualified technician and returned to the

Factory Service Department

The manufacturer shall not be liable for incidental and consequential losses and damages potentially attributable to malfunctioning equipment. Should any part of the equipment prove to be defective in material or workmanship within the 12-month warranty period, upon examination by the manufacturer, such part will be repaired or replaced by manufacturer at no charge. The buyer shall pay all labor costs incurred in connection with such repair or replacement. Equipment shall not be returned without manufacturer’s prior authorization and all returned equipment shall be shipped by the buyer, freight prepaid to a destination determined by the manufacturer.

Please complete and return the Start-UP Checklist on the back of this manual to validate warranty

INSTALLATION

It is imperative that this unit is installed and operated with the designed airflow, gas, and electrical supply in accordance with this manual. Any variance to these instructions may cause the unit to not perform to specifications and may cause severe damage to the unit or jobsite. Please call the service department at 866-784-6900 for assistance on warranty issues and technical support.

Inspection on Arrival

1. Inspect unit on delivery

2. Photograph any visible damage

3. Report any damage to the delivery carrier

4. Request a written inspection report from the

Claims Inspector to substantiate claim

5. File claims with delivery carrier

6. Check unit’s rating plate to verify proper electric and fuel type to meet job requirements

7. Compare unit received with description of product ordered

Unit Location

1. Do not locate any gas-fired equipment near corrosive or explosive vapors such as chlorinated or acid vapors

2. Avoid overhead power lines, or other utility access to prevent accidental contact or damage.

3. Provide clearance around installation site to safely rig and lift the equipment into its final position onto adequate supports. Refer to the manufacturer’s estimated weights.

4. Consider general service and installation space when locating the unit.

5. Locate the unit close to the space it will serve to reduce long, twisted duct runs.

6. Do not allow air intake to face prevailing winds. Air flow switch may trip in high winds.

7. Situate the unit above ground or at roof level high enough to prevent precipitation from being drawn into its inlet.

8. The inlet must also be located at least 10 feet away from any exhaust vents.

9. The heater inlet must be located in accordance with the applicable building code provisions for ventilation air.

10. All air to the heater must be ducted from the outdoors.

11. Recirculation of room air is not permitted. If in doubt regarding the application, consult the manufacturer.

12. The unit must have adequate structural support or the equipment or building could be damaged.

13. Do not alter or otherwise restrict combustion or ventilation openings.

14. Direct-fired units should not be installed downstream from cooling systems which use refrigerants for cooling.

COMBUSTABLE

CLEARANCES

The top, back, and front surfaces of this heater may not be installed less than 6 inches from combustible materials. The heater base may be installed on combustible surfaces.

SERVICE CLEARANCES

Allow 24 inches or greater minimum service clearance on all sides of this heater. Allow 48 inches or greater on the vestibule and blower door side.

Rigging

1. Horizontal units are supplied with four lifting lugs on the bottom corners of the casing.

2. Vertical units are supplied with four lifting lugs at the top corners of the casings.

3. Lift the unit and accessories separately, attach the accessories to the unit once the unit is in place.

4. The following diagrams represent the proper methods for lifting the unit and accessories.

5. Always use spreader bars to prevent damage to the unit casing.

FIGURE 1: SIZE 10, 12, 15, & 18 FIGURE 2: NO SPREADER BARS

FIGURE 3: WITH SPREADER BARS FIGURE 4: ACCESSORIES

CAUTION!!

These are unbalanced loads Lift equipment gently

Do not jerk

Spreader bars must be used and should extend past the edges of the equipment to avoid damage to the casing. Not using spreader bars may cause damage to the casing

Damage will result if the equipment is raised by the intake hood, blower, motor shaft, or bearings Use the provided lifting eyes and brackets on the unit

Curbs

The unit must have adequate structural support or the equipment or building could be damaged. The curb and unit must be leveled or the unit may leak or be damaged. Use gasket and caulk between the curb and unit. Use shims if necessary to level the unit. Screw or weld the unit’s base to the curb to avoid damage to the equipment.

The unit must have adequate structural support or the equipment or building could be damaged.

Screw or weld the unit’s base to the curb to avoid damage to the equipment.

The curb and unit must be leveled or the unit may leak or be damaged.

Accessories

Intake and discharge accessories are shipped loose and unassembled. When attaching the accessories to the unit use gasket, caulk, and #10 sheet metal screws on all seams. All accessories must be level.

Use gasket, caulk, and #10 sheet metal screws on all component intersections. Leaking may result if the intersections are not completed properly.

The accessories must be level and support legs attached to the hood and solid part of the roof.

Equipment that is not level or properly supported may leak or be damaged.

Split Units

1. Apply weather-proof gasket to the seam of the vertical or horizontal unit

2. Use provided fasteners to secure the seam of the unit using the provided pre-punched holes

a. Horizontal units internal channels and a formed frame

b. Vertical units have angles on the outside of the casing

3. Apply silicone to the outside edge of the seam

4. Field wire the discharge air sensor using a minimum 22 gauge wire

5. Mount the high temperature limit bulb to the blower housing

6. Mount the (optional) freeze control sensor to the blower housing

FIGURE 1: HORIZONTAL SPLIT ASSEMBLY FIGURE 2: VERTICAL SPLIT ASSEMBLY

Shipped Loose Intake or Discharge Dampers

In some cases an intake or discharge damper may be shipped loose. This may be requested by the customer or can be required because of larger units shipping size restrictions. Follow these instructions to attach and wire the shipped loose damper. Factory mounted dampers may be attached on the unit and will not require assembly or field wiring.

1. Attach the damper to the intake or discharge using gasket, caulk, and #10 sheet metal screws

2. Field wire the damper using the as built wiring schematic for the specific unit. Wiring may be different depending on the model and options selected.

3. Refer to the factory supplied wiring print to verify the field wiring terminals.

Ductwork

This fan was specified for a specific CFM and static pressure. The ductwork attached to this unit will significantly affect the airflow performance.

• Flexible ductwork and square elbows should not be used

• Transitions and turns in ductwork near the fan outlet will cause system effect and will drastically increase the static pressure and reduce airflow

• The Ductwork Sizing Chart shows the minimum fan outlet duct sizes and straight lengths recommended for optimal fan performance

• Units with twin blower must have a common discharge plenum

Follow SMACNA guides and recommendations for the re maining duct run. Fans designed for rooftop installation should be installed on a prefabricated or factory-built roof curb. Follow curb manufacturer’s instructions for proper curb installation. It is recommended an outdoor unit be installed on a curb and/or rail elevated so intake is not less than 20” above any surface. Be sure the duct connection and fan outlet are properly aligned and sealed.

Adequate building relief is necessary in order to prevent over-pressurizing the building when the heater is operating at capacity. This can be accomplished by establishing properly-sized relief openings, an interlocked exhaust system, or both.

Heaters installed with intake ductwork must be purged to replace at least four air changes of the volume of the intake duct.

In order to avoid hazards to other fuel-burning equipment in the building (i.e., when the heater is providing make-up air to a boiler room), the unit should be interlocked to open inlet air dampers or other such devices.

On outdoor installations, it is recommended that the discharge duct be insulated to prevent condensation during the “OFF” cycle in cold weather.

Units being installed in airplane hangars should be installed in accordance with the Standard for Aircraft Hangars, ANSI/NFPA 409. Units being installed in public garages should be installed in accordance with the Standard for Parking Structures, ANSI/NFPA 88A, or the Standard for Repair Garages, ANSI/NFPA 88B, and with CAN/CGA B149 Installation Codes.

Flexible connectors should be employed on all ductwork connections. Vibration isolators are optional and can be supplied in the loose parts package.

Ductwork Sizing Chart Single Blower Ductwork Sizing Chart Dual Blowers

Blower Size Duct Size (Inches)

Duct Length (Inches)

Blower Size Duct Size (Inches)

Duct Length (Inches)

10 14 x 14 30 222 77 x 28 66

12 16 x 16 36 225 88 x 32 75

15 20 x 20 45 227 96 x 36 81

18 24 x 24 54 230 104 x 38 90

20 26 x 26 60 233 116 x 44 99

22 30 x 30 66 236 122 x 44 108

25 32 x 32 75

27 36 x 36 81

Failure to undersize ductwork size or length may cause system affect and reduce the performance of the equipment.

Using the unit to support the ductwork may cause damage to the units casing.

30 38 x 38 90

33 44 x 44 99

36 44 x 44 108

Installation Examples

Figure 1: Horizontal Roof Top Installation

� Down discharge AMU reduces ductwork

� Hood weight supported by support legs

� Union, regulator, and shut-off

� Roof curb supports unit

� Intake facing away from prevailing winds

Figure 2: Vertical Outdoor Ground Installation

� Side discharge AMU reduces ductwork

� Support stand on concrete pad

� Union, regulator, and shut-off

� Filter section inside support stand

� Ease of serviceability on ground

Gas

Gas piping must be installed to conform with local building codes, or in the absence of local codes, the National Fuel Gas Code, ANSI Z223.1 (NFPA 54) – latest edition. In Canada, gas piping must be installed in accordance with CAN/CGA-B149.1 for natural gas units and CAN/CGA-B149.2 for propane units.

WARNING

Inlet gas pressure must not exceed pressure indicated on name plate.

Refer to the heater rating plate for determining the minimum gas supply pressure for obtaining the maximum gas capacity for which this heater is specified.

1. Always disconnect power before working on or near a heater. Lock and tag the disconnect switch or breaker to prevent accidental power-up.

2. Piping to the unit should conform to local and national requirements for type and volume of gas handled, and pressure drop allowed in the line. Refer to the Gas Engineer’s Handbook for gas line capacities.

3. The incoming pipe near the heater should be sized to match the connection on the outside of the unit. Unit inlet sizes are shown in the table to the right. Avoid multiple taps in the gas supply so the unit has a steady supply of gas at all times.

4. Install a ground joint union with brass seat and a manual shut-off valve external to the unit casing, as shown below, adjacent to the unit for emergency shut-off and easy servicing of controls.

5. Provide a sediment trap, as shown below, before each unit and where low spots in the pipe line cannot be avoided.

6. Blow out the gas line to remove debris before making connections. Before starting the unit, purge line to remove air. Purge air from gas lines according to ANSI Z223.1-latest edition “National Fuel Gas Code,” or in Canada: CAN/CGA-B149.

7. All field gas piping must be pressure/leak tested prior to operating the unit. Use a soap solution or equivalent for leak testing.

The heater and its individual shut-off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of ½ PSI. During any pressure testing of the gas supply piping system at test pressures equal to or less than ½ PSI, the heater must be isolated from the gas supply piping system and its individual manual shutoff valve closed.

8. This unit requires the gas pressure to be within the unit’s minimum and maximum gas pressure ratings. If the pressure is greater than the maximum, the internal valve components will be damaged. If the pressure is below the minimum, the heater will not perform to specifications.

9. If installing on a paint booth application, a manual shutoff should be located for access in case of a fire or explosion at the heater.

Gas Connection Sizes

BTU Input

Gas Pressure (Inches W.C. & PSI) 7” – 14” 15” – 1# 1# - 5#

158,000 ½ ½ ½ 275,000 ¾ ½ ½ 549,999 ¾ ¾ ¾

1,099,999 1 ¾ ¾ 1,374,999 1 ¼ ¾ ¾ 1,649,999 1 ½ 1 1 1,924,999 2 1 1 2,474,999 2 1 ¼ 1 2,749,999 2 1 ½ 1 3,574,999 2 2 1 ¼ 4,124,999 2 2 1 ½ 5,224,999 2 ½ 2 2 5,774,999 2 ½ 2 2 7,974,999 2 2 8,524,999 2 ½ 2 9,624,999 2 ½ 2

11,274,999 2 ½ 2 11,824,999 3 2 12,924,999 3 2 ½ 16,847,999 3

Copper Wire Ampacity Wire Size AWG Maximum Amps

14 20 12 25 10 30 8 40 6 55 4 70

Gas Connection Diagram

Electrical

Before connecting power to the heater, read and understand this entire section. Wiring diagrams are furnished with each fan by the factory, and are attached to the door of the unit.

Disconnect power before installing or servicing fan . High voltage electrical input is needed for this equipment. This work should be performed by a qualified electrician.

Electrical wiring must be done in accordance with local ordinances and the National Electric Code, ANSI/NFPA70. Be sure the voltage and phase of the power supply and the wire amperage capacity conform to those listed on the motor nameplate. For additional safety information, refer to AMCA publication 410-96, “Recommended Safety Practices for Users and Installers of Industrial and Commercial Fans.”

1. Always disconnect power before working on or near a heater. Lock and tag the disconnect switch or breaker to prevent accidental power-up.

2. A dedicated circuit should supply the units electrical disconnect with circuit protection, according to the National Electric Code.

3. Make certain that the power source is compatible with the requirements of your equipment. The heater nameplate identifies the proper phase and voltage of the motor.

4. Units shipped with an optional remote panel have two electrical circuit. It is important to run the motor wires in a conduit separate from the remote control wiring. The DC wires from the unit temperature controller, located in the control drop, should be either in shielded cable or run in a separate conduit.

5. Before connecting the heater to the building power source, verify the power line wiring is de-energized.

6. Secure the power cables to prevent contact with sharp objects.

7. Do not kink power cable and never allow the cable to come in contact with oil, grease, hot surfaces or chemicals.

8. Before powering up the heater, check fan wheel for free rotation and make sure that the interior of the heater is free of loose debris or shipping materials.

9. If necessary, the original wire supplied with the heater may be replaced with type TW wire or the equivalent.

Remote Control Panel

For units with the remote control panel, a terminal strip inside the panel matches the termi nals in the heater unit. Consult the as built wiring print supplied with the equipment. Most remote panels and VAV applications have signal wiring which needs to be shielded cable or in a separate conduit to avoid voltage interference.

Power Supply Wiring

The units input power supply is listed on the unit nameplate. If the units power supply does not match the unit nameplate contact the service department for a new wiring print and parts.

Paint Booth Applications

If a low temperature control is not an integral part of the heater, it is recommended that one be installed in areas where freeze protection is needed in the event of a burner shutdown. The space should be ventilated following a bake cycle to purge any contaminants and cool product prior to personnel entering the space. If the unit was supplied with paint booth controls from the factory, refer to the schematic for installation of the interlock to disable spraying equipment unless the heater is operating in ventilation mode. Refer to electrical schematic for interlock to disable facility lighting within the process space during the bake cycle.

SEQUENCE OF OPERATIONS

Description of Operation

Designed for indoor or outdoor installation, the Direct Fired Gas Heater draws fresh outside air over a gas-fired burner. The unit is equipped to fire with natural or propane gas. Units are designed for modulated firing of the burner, based on the discharge-air temperature or room temperature requirement.

Standard Sequence of Operation

1. With disconnect in ON position and the remote control panel (or other device) calling for unit operation, power is supplied to the damper motor, if equipped.

2. When the damper motor approaches the OPEN position, the damper-end switch closes, energizing the motor contactor and powering the blower motor or enabling the VFD if equipped.

3. Power is supplied to the damper motor through the low-temperature limit control, if equipped. After ten minutes, the low-temperature limit control disables the unit if discharge temperature is continually below the temperature setting on the low limit control.

4. When the low airflow switch and high airflow switch (VFD only) are proven, the flame safety relay is energized through the high-temperature limit control, the optional low and/or high gas pressure switches, and the burner on/off intake air thermostat. The pilot valve opens, and the ignition transformer energizes.

5. After the flame rod detects flame, the main valves are energized and the ignition transformer de-energizes.

6. The temperature control system monitors the discharge air and modulates DC voltage to the modulating valve to maintain desired discharge temperature.

Additional Sequence of Operation – All VFD Motor Co ntrol

1. During lower speeds, the low-speed potentiometer increases the resistance going to the modulating valve to limit temperature rise.

2. VFD contacts are included in the burner control circuit to disable the burner should a fault condition occur in the VFD.

VFD by Others and VAV Choke Off Profile Bypass Damp er As the VFD increases and decreases speed the profile air flow switch modulates the VAV bypass damper motor to maintain proper pressure drop across the burner profile.

Factory VFD Profile Bypass Damper The VFD produces a 0-10vdc or a 4-20ma signal to the profile damper motor which modulates the profile damper’s opening to maintain the burner profile pressure drop. The range of this modulation must coincide with the VFD operating range.

VFD Preset Speeds

1. Inputs are made to the VFD to engage programmable pre-set speeds. A factory-supplied VFD wiring and programming instruction sheet comes with every unit. Consult the as-built schematics and the VFD manual for additional information.

Manual Potentiometer Adjustment – VFD and Choke-Off Dampers

1. A 10k-15k ohm potentiometer may be field supplied and installed if remote manual control is required for the VFD. See VFD manual for proper installation.

2. A 135 ohm potentiometer is used for remote manual control of choke-off vav dampers.

Static Pressure Control (Photohelic) – VFD and Chok e-Off Dampers

The VFD or Choke-off dampers can be controlled by a building static pressure control. This controller will sense the difference between pressure inside the building, and pressure outside the building and will control the operating speed of the VFD or position of choke-off dampers to maintain the pressure setting on the controller. The controller has two set points and an indicator. The two set points are a minimum desired static pressure point, and a maximum static pressure point.

When building static pressure is below the minimum setting, the VFD will increase the blower RPM or choke-off damper will open to increase airflow. If the building static is above maximum setting, the VFD will decrease the blower RPM or close choke-off dampers. When building static pressure is between the minimum and maximum settings, no signal is given to change VFD speed or choke-off damper position.

See additional wiring and installation information on the static pressure controller and outdoor sensor.

The static pressure controller can be ordered to be shipped loose or mounted inside the unit to reduce field wiring and assembly.

Static Pressure Controller Installation Instruction s

Avoid locating the front of the static pressure controller in sun light or other areas with high ambient light or corrosive levels. Bright light shining on the photocells can cause false actuation of the load relays.

The static pressure controller should be zeroed out before attaching the low and high pressure hoses.

The zero adjustment is located between the minimum and maximum dials.

Using the supplied rubber tubing the high side of the static pressure controller should be plumbed to the inside of the building. The low side of the static pressure controller should be plumbed to an outdoor sensor.

Outdoor Sensor

Use the installation instructions shipped with the outdoor sensor.

START-UP PROCEDURE

� Check for signs of damage. Do not operate if damage exists and contact your manufactures sales representative. Units are easier to fix before the equipment is installed.

� Check all installation clearances.

Clearance from Combustibles Clearance for Serviceability Top: 6” Sides: 6” Base: 0” Unit: 24” Service Accesses: 48”

� Check that the unit has been set level and secured.

� Unit must have adequate structural support or the equipment or building may be damaged.

� Curb and unit must be leveled or the unit may leak or be damaged.

� Gasket and caulk the seam between the curb and unit base � Screw or weld the unit’s base to the curb to avoid damage to the equipment.

� Check that the accessories are set level and secured.

� Accessories must have adequate structural support or the equipment or building may be damaged � Gasket, caulk, and screw each accessory to unit seam

� Check that the unit’s intake and discharge are free of debris � Check that the filter are installed in the (optional) filter section or intake hood in accordance to the air flow direction � Check that the unit’s ductwork size and length match the minimum ductwork size chart � Check that all field wiring has been completed in accordance to the factory supplied wiring diagram

� Field wires are shown as dashed lines on the wiring prints

� Check that all terminal screws are tight and that wires are in place � Check pulley alignment. Correct if necessary

� Check that the power supply matches the nameplate voltage, phase, and amperage � Record the voltage on the Start-Up Sheet

� Check that the gas type and pressure matches the nameplate type and pressure � Check that the gas type and pressure matches the nameplate type and pressure � Contact the service department is the power or gas supply needs to be changed in the field. Different parts might be necessary for the change

� Turn the remote panel switch to OFF if blower and burner service switches were supplied

� Set the temperature set point dial to the maximum � Turn the main power disconnect ON

� Bump the blower motor starter to check the blower wheel rotation

� The decal is located on the blower housing � If the rotation is backwards turn off the power and correct the wiring � The rotation can be corrected by interchanging two legs of 3 phase (must be between vfd and motor on vav units)

ROTATION

DECAL

� Turn the blower service switch or remote control device to ON. The (optional) intake or discharge damper motor will start to open. Once the damper is 90% open the damper motor internal end switch will close and energize the blower motor starter.

� Check that the motor amp draw is less than the FLA (full load amps) of the blower motor.

� The fan RPM may need to be reduced to decrease motor amps.

� Opening the driver (motor) pulley decreases RPM and motor amps.

� Closing the driver pulley increases

RPM and motor amps.

� Record the motor amps on the Start-

Up Sheet.

� If the RPM was adjusted in the field use a tachometer to record the new RPM on the Start-Up Sheet.

� Check the belt tension after any RPM adjustments. See the belt tension detail.

� Check the air flow pressure drop.

� The air flow switch on single speed units is a low air flow switch only and opens below 0.15 in w.c.

� The target pressure drop range for the single speed unit is 0.40 – 0.50 in w.c.

� Do not adjust airflow switches � Use the profile plates or blower RPM to increase or decrease the pressure drop.

� Record the pressure drop on the Start-Up Sheet.

� Close the burner gas shut off valve � This will allow the unit to fire the pilot only and will be opened at a later time

� Set the Burner Intake On Off Switch is set above the outside air temperature

� Turn the burner service switch or remote control to ON

� The Fireye Flame Safety Control energizes the ignition transformer and pilot gas valve � After the pilot flame is established, the main gas valves will open

� At this time the pilot will be the only flame in the burner � The pilot regulator should be adjusted so the pilot flame signal is stable 6-18 VDC

BLOWER

SERVICE

SWITCH

CLOSE VALVE

SET DIAL 10

DEGREES ABOVE

OUTDOOR TEMP

� Use the DC terminals on the flame safety to read the pilot flame signal

� Record the pilot flame signal in the Start-Up Sheet � Record the low and high fire flame signal on the Start-Up Sheet

Setting High Fire

� Open the Burner Gas Shut Off Valve

� Measure the intake air temperature.

� Add the intake air temperature to the units nameplate design temperature rise.

� This result will be the desired high fire discharge temperature.

Example: Intake Temp 70 F Design Temp Rise 72 F Discharge Temp 142 F

PILOT REGULATOR

OPEN VALVE

GAS TYPE: NATURAL

MAX. TEMP. RISE: 140 F

DESIGN TEMP. RISE: 72 F

MAX. DISCHARGE TEMP.: 80

F

POSITIVE TERMINAL

NEGATIVE TERMINAL

� Use the Amplifier to override the heater into high fire.

� On discharge temperature control amplifier remove the #4 wire � On the space temperature control amplifier remove the #2 and #4 wire � On the M-Series adjust the set-point to be

160 F � Adjust the manifold gas pressure to achieve the desired discharge air temperature.

� See the details for the high fire pressure adjustment locations.

� On manifolds with an MR212 modulation valve, adjust the small regulator inside the MR212 modulation valve

� On manifolds with either an M511 or M611 modulation valve, adjust the regulator located before the main gas valves

� On manifolds with a combination gas valve, adjust the regulator under the brass cap on the combination gas valve.

� Measure the discharge temperature using a thermometer. Laser thermometers are not as accurate as a thermocouple type.

� If the discharge ductwork outlet is hard to reach, you may feed a thermocouple into the mixing tube inside the blower discharge.

Setting High Fire – Manifold Pressure Method

� Turn the burner service switch OFF � Measure the manifold pressure with the burner in high fire as described above � Adjust to match design manifold pressure on nameplate � Measure discharge temperature and calculate temperature rise as described above to account for variances in airflow from design

HIGH FIRE

HIGH FIRE

HIGH FIRE

MR212

M511 & M611

36C68

GAS TYPE: NATURAL

MAX. TEMP. RISE: 140 F

DESIGN TEMP. RISE: 72 F

MAX. DISCHARGE TEMP.: 80

F

Setting Low Fire

� Disconnect power to the amplifier or modulating valve

� Adjust the low fire setting on the modulation valve so the flame is full length of burner without dark spots � See the details for the low fire pressure adjustment locations � Use the burner observation port on the end of the unit to view the flame size � Replace all amplifier wires in the place they were removed to set high and low fire � Additional capacity is provided via a low fire bypass when MR212 low fire capacity is insufficient. Additional adjustment is made via the R400S regulator installed in the low fire bypass.

Final Start-Up

� Set the Burner Intake On-Off Thermostat to the desired temperature to disable burner

� This will automatically open the burner circuit when the outside air is above the selected temperature

� Turn the blower and burner service switches OFF � Now the unit will be operated from the control panel only

� Operate the unit from the remote panel checking the lights, switches, set-points, and optional thermostats or timers

� Review the proper operation and sequence of operation with the customer to ensure that the unit is operated properly and that the customer does not misuse the equipment

� Complete the Start-Up Sheet and fax it to the service department to validate the warranty

START-UP PROCEDURE VARIABLE AIR VOLUME

The Start-Up procedure for variable air volume units is the same as the single speed unit except there are additional steps for checking burner pressure drop and setting high/low fire. Use the single speed procedure along with these additional steps for the vav start-up procedure.

� Check the air flow pressure drop through entire airflow range.

� The air flow switch on vav units is a low (0.15) and (0.65) high switch � Do not adjust airflow switches � Use the profile plates, choke-off dampers or VFD to increase or decrease the pressure drop.

� Record the pressure drops on the Start-Up Sheet.

� Verify the flame limiting device is functioning properly in low speed on units with a vfd.

� Verify low fire setting at minimum flow rate as well.

LOW FIRE

M511 & M611

LOW FIRE

MR212

PROFILE ADJUSTMENTS

The Direct-Fired Gas, make-up heater requires the correct air flow velocity across the burner. The air flow switch monitors the profile pressure differential, and will open the burner circuit if pressure difference is not within the allowed range. The air flow switches have low and high pressure settings for variable air volume units. The pressure drop should not be near the minimum and maximum of the air flow switch.

Profile adjustment may be required to fine tune the burner profile pressure drop. See the specifications and instructions below on air balancing a 100% fresh air heater.

Single-Speed Profile

The pressure drop should be checked with the burner OFF if ambient temperature is greater than 60 degrees Fahrenheit. If the ambient temperature is lower than 60 degrees Fahrenheit, the burner should be operating and discharging approximately 70 degrees Fahrenheit. An extra set of airflow probes have been installed to ease in checking profile differential.

Disconnect power and close all gas valves before an d while making burner profile adjustments.

Single-Speed Profile

If the pressure drop is too low, adjust the profile opening to be smaller, which will increase the pressure drop.

If the pressure drop is too high, adjust the profile opening to be larger, which will decrease the pressure drop.

Variable Air Volume Profile

VAV Profile

In low speed, adjust the burner profile opening smaller to increase pressure drop or larger to lower pressure drop.

VAV Profile

In high speed adjust the bypass damper opening larger to decrease the pressure drop and smaller to increase the pressure drop.

VFD Drive Installation & Programming Instructions

-Before installing the VFD drive, ensure the input power supply to the drive is OFF -The power supply and motor wiring of the VFD must be completed by a qualified electrician

-The programming of the VFD must be completed by a qualified HVAC…