Appendix C 25QA102.pdf

HVAC SYSTEM MAINTENANCE

U.S. ARMY CORPS OF ENGINEERS

OTTER BROOK LAKE

KEENE, NH

PERFORMANCE WORK STATEMENT

APPENDIX C

Training Manuals

Table Of Contents

1. Air Handling Unit

2. Cabinet Unit Heater

3. Mini Split

4. Boiler

5. Circulator Pumps

6. Heat Pump Water Heater

Training Manuals

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Routine Maintenance

Air Filters

Always install filters with directional arrows pointing toward the fan. For units with high efficiency filters (MERV 8 or MERV 13), the filters need to replaced with equivalent MERV-rated filters to maintain unit performance.

Fans

Inspecting and Cleaning Fans

Fan sections of air handlers should be inspected every six months at a minimum or more frequently if operating experience dictates. If evidence of microbial growth (mold) is found, identify and remedy the cause

WARNING

Hazardous Service Procedures!

Failure to follow all precautions in this manual and on the tags, stickers, and labels could result in death or serious injury.

Technicians, in order to protect themselves from potential electrical, mechanical, and chemical hazards, MUST follow precautions in this manual and on the tags, stickers, and labels, as well as the following instructions:

Unless specified otherwise, disconnect all electrical power including remote disconnect and discharge all energy storing devices such as capacitors before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized.

When necessary to work with live electrical components, have a qualified licensed electrician or other individual who has been trained in handling live electrical components perform these tasks.

WARNING

Rotating Components!

Failure to secure rotor or disconnect power before servicing could result in rotating components cutting and slashing technician which could result in death or serious injury.The following procedure involves working with rotating components. Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power can not be inadvertently energized.

Secure rotor to ensure rotor cannot freewheel.

Maintenance Checklist

Table 44.Maintenance Checklist

Frequency Maintenance Every week Observe unit weekly for any change in running condition and unusual noise.

Every month • Clean or replace air filters if clogged or dirty.

Every three to six months

• Manually rotate the fan wheel to check for obstructions in the housing or interference with fan blades. Remove any obstructions and debris.

• Check motor bracket torque.

• Inspect and clean drain pans.

• Inspect coils for dirt build-up. Clean fins if airflow is clogged.

Every year

• Inspect the unit casing for chips corrosion. If damage is found, clean and repaint.

• Clean the fan wheels. Remove any rust from the shaft with an emery cloth and recoat with L.P.S. 3 or equivalent.

• Inspect and clean drain pans.

• Check damper linkages, fan set screws, and blade adjustment. Clean, but do not lubricate, the nylon damper rod bushings.

• Clean damper operators.

• Inspect, clean, and tighten all electrical connections and wiring.

• Rotate the fan wheel and check for obstructions. The wheel should not rub. Adjust the center if necessary.

• Examine flex connections for cracks or leaks. Repair or replace damaged material.

WARNING

Rotating Components!

Failure to secure rotor or disconnect power before servicing could result in rotating components cutting and slashing technician which could result in death or serious injury. The following procedure involves working with rotating components. Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power can not be inadvertently energized.

Secure rotor to ensure rotor cannot freewheel.

WARNING

Rotating Components!

Failure to secure rotor or disconnect power before servicing could result in rotating components cutting and slashing technician which could result in death or serious injury. The following procedure involves working with rotating components. Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power can not be inadvertently energized.

Secure rotor to ensure rotor cannot freewheel.

BCX-SVX001G-EN 101

immediately. Refer to “Diagnostics and Troubleshooting,”

p. 108 for possible causes and solutions. To clean the fan section:

1. Disconnect all electrical power to the unit.

2. Wearing the appropriate personal protective equipment, remove any contamination.

3. Vacuum the section with a vacuum device that uses high-efficiency particulate arrestance (HEPA) filters with a minimum efficiency of 99.97 percent at

0.3 micron particle size.

4. Thoroughly clean any contaminated area(s) with a mild bleach and water solution or an EPA-approved sanitizer specifically designed for HVAC use.

5. Immediately rinse the affected surfaces thoroughly with fresh water and a fresh sponge to prevent potential corrosion of metal surfaces.

6. Allow the unit to dry completely before putting it back into service.

7. Be careful any contaminated material does not contact other areas of the unit or building. Properly dispose of all contaminated materials and cleaning solution.

Fan Motors

Inspect fan motors periodically for excessive vibration or temperature. Operating conditions will vary the frequency of inspection.

Torque Rating

Check and adjust fan wheel set screws whenever a component is removed or an adjustment is made. Refer to Table 45 for recommendations.

WARNING

Hazardous Voltage!

Failure to disconnect power before servicing could result in death or serious injury. Disconnect all electric power, including remote disconnects before servicing.

Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized..

Table 45. Recommended torques

Torque (in·lb) Ft·lb N·m Fan wheel screw 120-130 10.0-10.8 13.6-14.7

Table 46. BCHD/BCVD fan, filter, and mixing box general data

Unit Size 12 18 24 36 54 72 90 Nominal cfm 400 600 800 1200 1800 2400 3000 Air flow Minimum cfm 250 375 500 750 1125 1500 1875 Maximum cfm 500 675 1000 1600 2400 3000 4000 Fan data Fan wheel, in. (dia. x width) 9.5 x 4.5 9.5 x 4.5 9.5 x 6.0 9.5 x 6.0 12.6 x 9.5 12.6 x 9.5 12.6 x 9.5 RPM range 900-2300 900-2300 800-2000 800-2000 600-1500 600-1500 600-1500 Motor hp 1/2–1 1/2–1 1/2–1 1/2–1 1/2–3 1/2–3 1/2–3 Unit flat filter

(Qty.) Size (1) 12 x 24 (1) 12 x 24 (1) 16 x 25 (2) 16 x 20 (2) 20 x 20 (1) 20 x 20

(1) 20 x 25 (3) 16 x 25

Area, sq. ft 2.000 2.000 2.778 4.444 5.556 6.250 8.333 Velocity, ft/min. 200 300 288 270 324 384 360 Angle filter (Qty.) Size (2) 12 x 24 (2) 12 x 24 (2) 12 x 24 (2) 20 x 20 (4) 16 x 20 (6) 16 x 16 (6) 16 x 20 Area, sq. ft 4.000 4.000 4.000 5.556 8.889 8.889 11.111 Velocity, ft/min. 100 150 200 216 203 270 270 Bottom / top access filter box

(Qty.) Size (1) 12 x 20 (1) 12 x 24 (1) 16 x 25 (1) 16 x 20

(1) 16 x 16

(1) 16 x 20

(1) 20 x 20

(1) 20 x 25

(1) 20 x 20

(1) 16 x 25

(2) 14 x 25

Area, sq. ft 1.700 2.000 2.800 4.000 5.000 6.300 8.000 Velocity, ft/min. 240 300 288 300 360 384 375 Mixing box Damper opening width, in. 15.5 19.5 19.5 31.5 31.5 31.5 31.5 Damper opening height, in. 7 7 7 7 12.75 12.75 12.75 Area, sq. ft 0.753 0.948 0.948 1.531 2.789 2.789 2.789 Velocity, ft/min. 531 633 844 784 645 861 1076 Note: Minimum air flow limits apply to units with hot water or electric heat only. There is no minimum airflow limit on cooling on units. Maximum airflow limits are to help prevent moisture carryover.

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Table 47. BCCD fan and filter general data

Unit Size 24 36 48 60 Nominal cfm 800 1200 1600 2000 Airflow Minimum cfm 500 750 1000 1250 Maximum cfm 1000 1500 2000 2500 Fan data Fan wheel, in. (dia. x width) 9.50 x 6.00 9.50x 6.00 12.60 x 8.00 12.60 x 8.00 RPM range 800-2000 800-2000 600-1400 600-1400 Motor hp 0.50–1.00 0.50–1.00 0.50–1.00 0.50–1.00 Unit flat filter

(Qty.) Size (1) 12 x 24 (1) 18 x 24

(1) 18 x 20

(1) 12 x 20

(1) 18 x 24

(1) 12 x 24

Area, sq. ft 2.00 3.00 4.20 5.00 Velocity, ft/min. 400 400 380 400 Note: Minimum air flow limits apply to units with hot water or electric heat only. There is no minimum airflow limit on cooling only units. Maximum airflow limits are to help prevent moisture carryover.

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Table 48. BCHD/BCVD coil general data

Unit Size 12 18 24 36 54 72 90 Nominal cfm 400 600 800 1200 1800 2400 3000 Hydronic and DX coil data Area - ft2 0.89 1.11 1.67 2.67 4.00 5.00 6.67 Width - in. (a), (b) 8.00 8.00 12.00 12.00 18.00 18.00 24.00 Length - in. (d) 16.00 20.00 20.00 32.00 32.00 40.00 40.00 Velocity - ft/min. 450 540 480 450 450 480 450 Hydronic coil data - high capacity Area - ft2 0.89 1.11 1.67 2.67 3.89 4.86 6.25 Width - in. (a), (c) 8.00 8.00 12.00 12.00 17.50 17.50 22.50 Length - in. (d) 16.00 20.00 20.00 32.00 32.00 40.00 40.00 Velocity - ft/min. 450 540 480 450 463 494 480 1-row coil Minimum gpm (e) 1.00 1.00 1.00 1.00 6.10 6.10 7.90 Maximum gpm (f) 5.20 5.20 5.20 5.20 32.60 32.60 42.00 Dry coil weight - lb 4.40 5.20 6.60 9.30 17.60 20.40 25.80 Wet coil weight - lb 5.10 6.00 7.80 11.00 22.40 26.00 32.90 Internal volume - in3 19.40 22.20 33.20 47.10 132.90 155.10 196.60 2-row coil - high capacity Minimum gpm (e) 1.00 1.00 2.00 2.00 6.10 6.10 7.90 Maximum gpm (f) 5.20 5.20 10.40 10.40 32.60 32.60 42.00 Dry coil weight - lb 5.90 7.00 9.90 14.10 27.20 32.10 39.40 Wet coil weight - lb (kg) 7.20 8.40 12.30 17.60 36.10 42.50 52.60 Internal volume - in3 36.00 38.80 66.50 96.90 246.50 288.00 365.50 3-row coil - DX coil Internal volume - in3 50 60 96 141 225 269 381 4-row coil - standard capacity Minimum gpm (e) n/a n/a n/a n/a 8.80 8.80 11.70 Maximum gpm (f) n/a n/a n/a n/a 47.00 47.00 62.60 Dry coil weight - lb (g) n/a n/a n/a n/a 37.20 44.50 58.50 Wet coil weight - lb (g) n/a n/a n/a n/a 48.30 57.70 77.00 Internal volume - in3 (g) n/a n/a n/a n/a 307.40 365.50 512.30 4-row coil - high capacity Minimum gpm (e) 2.00 2.00 2.90 2.90 6.10 6.10 7.90 Maximum gpm (f) 10.40 10.40 15.70 15.70 32.60 32.60 42.00 Dry coil weight - lb 10.50 12.40 17.70 25.50 47.00 56.30 73.10 Wet coil weight - lb 13.10 15.50 22.50 32.50 62.70 74.90 97.90 Internal volume - in3 72.00 85.80 132.90 193.80 433.00 516.70 688.30 4-row coil - DX coil Internal volume - in3 65 78 123 182 287 346 484 6-row coil - standard capacity Minimum gpm (e) n/a n/a n/a n/a 8.80 8.80 11.70 Maximum gpm (f) n/a n/a n/a n/a 47.00 47.00 62.60 Dry coil weight - lb (g) n/a n/a n/a n/a 52.40 63.10 82.70 Wet coil weight - lb (g) n/a n/a n/a n/a 68.10 82.00 108.70 Internal volume - in3 (g) n/a n/a n/a n/a 434.80 523.40 720.00 6-row coil - high capacity Minimum gpm (e) 2.0 2.00 2.90 2.90 6.10 6.10 7.90 Maximum gpm (f) 10.4 10.40 15.70 15.70 32.60 32.60 42.00 Dry coil weight - lb 14.6 17.40 24.70 36.10 65.40 78.60 101.50 Wet coil weight - lb 18.2 21.80 31.50 46.10 87.80 105.60 137.00 Internal volume - in3 99.7 121.80 188.30 276.90 620.40 745.90 983.10 6-row coil - DX coil Internal volume - in3 94 114 176 265 411 500 689 Steam coil data Area - ft2 0.71 0.88 1.75 2.75 4.13 5.13 6.83 Width - in. (a) 6.00 6.00 12.00 12.00 18.00 18.00 24.00 Length - in. (d) 17.00 21.00 21.00 33.00 33.00 41.00 41.00 Velocity - ft/min. 26.00 25.00 18.00 17.00 17.00 16.00 16.00 1-row coil Minimum steam press - psig 2.00 2.00 2.00 2.00 2.00 2.00 2.00 Maximum steam press - psig 15.00 15.00 15.00 15.00 15.00 15.00 15.00 Dry coil weight - lb 16.70 18.70 32.50 41.10 57.40 64.80 84.90 Wet coil weight - lb 18.20 20.40 36.00 45.80 64.50 73.20 96.10 Internal volume - in3 41.70 47.70 95.30 130.80 196.10 231.60 308.70

(a) Coil width = Length in the direction of a coil header, typically vertical.

(b) “Hydronic and DX coil data” width dimensions apply only to DX coils (all unit sizes), 1-row standard capacity hydronic coils (unit sizes 012 through

036), and 4-row and 6-row standard capacity hydronic coils (054 through 090).

(c) “High-capacity hydronic coil data” width dimensions apply only to 1-row standard capacity hydronic coils (unit sizes 054 through 090) and 2-row, 4-row, and 6-row high capacity hydronic coils (all unit sizes).

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(d) Coil length = Length of coil in direction of the coil tubes, typically horizontal and perpendicular to airflow.

(e) The minimum waterflow at 1.5 fps tubeside velocity is to ensure the coil self-vents properly. There is no minimum waterflow limit for coils that do not require self venting.

(f) Maximum gpm limits are to prevent erosion and noise problems.

(g) DX coil height and width dimensions are same as comparable hydronic coils. Four- and six-row DX coil dry weight dimensions are same as comparable

4-row and 6-row hydronic coils. A 3-row DX coil dry weight is 25% less than a comparable 4-row hydronic coil. Internal volumes are approximately 6% less than comparable hydronic coils.

Table 49. BCCD coil general data

Unit size 24 36 48 60

Nominal cfm 800 1200 1600 2000

Hydronic coil and DX coil data Area - ft2 1.67 2.50 3.47 4.17

Width - in. (a) 12.00 18.00 20.00 24.00

Length - in. (b) 20.00 20.00 25.00 25.00

Velocity - ft/min 480 480 461 480

1 - row coil

Minimum gpm (c) 1.40 1.40 2.30 2.70

Maximum gpm (d) 7.10 7.10 11.80 14.10

Dry coil weight - lb 4.80 6.30 8.30 9.60

Wet coil weight - lb 6.20 8.30 10.90 12.70

Internal volume - in3 38.80 55.40 72.00 85.90

2 - row coil

Minimum gpm (c) 2.70 4.10 4.50 5.40

Maximum gpm (d) 14.10 21.20 23.60 28.30

Dry coil weight - lb 7.60 10.50 13.80 16.20

Wet coil weight - lb 10.00 14.10 18.60 21.90

Internal volume - in3 66.50 99.70 133.00 157.90

4 - row coil

Minimum gpm (c) 2.70 4.10 4.50 5.40

Maximum gpm (d) 14.10 21.20 23.60 28.30

Dry coil weight - lb 14.60 20.00 27.00 31.50

Wet coil weight - lb 19.40 27.20 36.90 43.30

Internal volume - in3 133.00 199.50 274.30 326.90

6 - row coil

Minimum gpm (c) 2.70 4.10 4.50 5.40

Maximum gpm (d) 14.10 21.20 23.60 28.30

Dry coil weight - lb 19.70 27.70 37.50 44.10

Wet coil weight - lb 26.70 38.10 51.80 61.10

Internal volume - in3 193.90 288.10 396.20 471.00

BCX-SVX001G-EN 105

Coils

All coils should be kept clean to maintain maximum performance.

Steam and Water Coils

To clean steam and water coils:

1. Disconnect all electrical power to the unit.

2. Wearing the appropriate personal protective equipment, use a soft brush to remove loose debris from both sides of the coil.

3. Install a block-off to prevent spray from going through the coil and into a dry section of the unit and/or system ductwork.

4. Mix a high-quality coil cleaning detergent with water according to the manufacturer’s instructions.

Note: If the detergent is strongly alkaline after mixing (PH

8.5 or higher), it must contain an inhibitor. Follow the cleaning solution manufacturer’s instructions regarding the use of the product.

5. Place the mixed solution in a garden pump-up sprayer or high-pressure sprayer. If a high pressure sprayer is to be used:

– Maintain minimum nozzle spray angle of 15 degrees.

– Spray perpendicular to the coil face.

– Keep the nozzle at least 6 inches from the coil.

– Do not exceed 600 psi.

6. Spray the leaving air side of the coil first, then the entering air side.

7. Thoroughly rinse both sides of the coil and the drain pan with cool, clean water.

8. Repeat steps 6 and 7 as necessary.

9. Straighten any coil fins that may have been damaged during the cleaning process.

10. Confirm the drain line is open following the cleaning process.

11. Allow the unit to dry thoroughly before putting it back into service.

12. Replace all panels and parts and restore electrical power to the unit.

13. Be careful any contaminated material does not contact other areas of the unit or building. Properly dispose of all contaminated materials.

Refrigerant Coils

To clean refrigerant coils:

1. Disconnect all electrical power to the unit.

2. Wearing the appropriate personal protective equipment, use a soft brush to remove loose debris from both sides of the coil.

3. Install a block-off to prevent spray from going through the coil and into a dry section of the unit and/or system ductwork.

4. Mix a high-quality coil cleaning detergent with water according to the manufacturer’s instructions.

Note: If the detergent is strongly alkaline after mixing (PH

8.5 or higher), it must contain an inhibitor. Follow the cleaning solution manufacturer’s instructions regarding the use of the product.

5. Place the mixed solution in a garden pump-up sprayer or high-pressure sprayer. If a high pressure sprayer is to be used:

– Maintain minimum nozzle spray angle of 15 degrees.

– Spray perpendicular to the coil face.

– Keep the nozzle at least 6 inches from the coil.

– Do not exceed 600 psi.

6. Spray the leaving air side of the coil first, then the entering air side.

7. Thoroughly rinse both sides of the coil and the drain pan with cool, clean water.

WARNING

Hazardous Voltage!

Failure to disconnect power before servicing could result in death or serious injury. Disconnect all electric power, including remote disconnects before servicing.

Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized.

WARNING

Hazardous Chemicals!

Failure to follow all safety instructions below could result in death or serious injury. Coil cleaning agents can be either acidic or highly alkaline and can burn severely if contact with skin occurs. Handle chemical carefully and avoid contact with skin. ALWAYS wear Personal Protective Equipment (PPE) including goggles or face shield, chemical resistant gloves, boots, apron or suit as required. For personal safety refer to the cleaning agent manufacturer’s Materials Safety Data Sheet and follow all recommended safe handling practices.

WARNING

Hazardous Pressures!

Failure to follow safety precautions below could result in coil bursting, which could result in death or serious injury. Coils contain refrigerant under pressure. When cleaning coils, maintain coil cleaning solution temperature under 150°F to avoid excessive pressure in the coil.

106 BCX-SVX001G-EN

8. Repeat steps 6 and 7 as necessary.

9. Straighten any coil fins damaged during the cleaning process.

10. Confirm the drain line is open following the cleaning process.

11. Allow the unit to dry thoroughly before putting it back into service.

12. Replace all panels and parts and restore electrical power to the unit.

13. Be careful any contaminated material does not contact other areas of the unit or building. Properly dispose of all contaminated materials and cleaning solution.

Coil Winterization

Water coil winterization procedures consist primarily of draining water from the coil before the heating season.

Trane recommends flushing the coil with glycol if coils will be exposed to temperatures below 35 degrees.

Install field-fitted drains and vents to permit winterization of coils not in use and to assist in evacuating air from the water system during startup. If draining is questionable because of dirt or scale deposits inside the coil, fill the coil with glycol before the heating season begins.

Individual coil types determine how to properly winterize the coil. To determine the coil type find the “Service Model No of Coil” on the coil section nameplate. The coil type is designated by the second and third digits on that model number. For example, if the model number begins with “DUWB,” the coil type is UW; if the model number begins with “DW0B,” the coil type is W.

Note: On many unit sizes, there are multiple coils in the coil section. Be sure to winterize all coils in a given coil section.

To winterize type D1, D2, WL, LL, UA, UW, UU, W, P2, P4, P8, WD, 5D, and 5W coils:

1. Remove the vent and drain plugs.

2. Blow the coil out as completely as possible with compressed air.

3. Fill and drain the coil several times with full strength glycol so that it mixes thoroughly with the water retained in the coil.

4. Drain the coil out as completely as possible.

5. To ensure no water remains in the coil, do not replace the vent and drain plugs until the coils are put back into service.

Note: Use care in removing header plugs from Type P2, P4, and P8 coils. Over-torquing may result in twisted tubes.

Moisture Purge Cycle

By it’s very nature, any HVAC unit with a cooling coil serves as a dehumidifier, reducing the surrounding air’s ability to hold water vapor as its temperature falls. This normally doesn’t present a problem when the unit is running.

However, when the fan stops, water vapor condenses on the cold metal surfaces inside the air handler and remains there until the air warms sufficiently to re-evaporate it.

This damp, dark environment—though temporary—can encourage the growth of mold, mildew, and other microbial contaminants.

Providing a moisture purge cycle 15 to 30 minutes after shutdown disperses the cold, humid air inside the air-handling system more evenly throughout the building.

This four-step cycle:

• Closes the outdoor air dampers.

• Turns off the cooling coil.

• Opens any variable-air-volume terminals connected to the air handler.

• Operates the supply fan for 10 to 15 minutes.

Air movement discourages water condensation and hastens re-evaporation of any condensate that does happen to form. This simple preventative measure effectively combats microbial growth and curbs moisture-related deterioration of air-handling components.

Cleaning Non-Porous Surfaces

If microbial growth on a non-porous insulating surface (closed cell insulation or sheet metal surface) is observed:

1. Disconnect all electrical power to the unit.

2. Wearing the appropriate personal protective equipment, use a brush for sheet metal surfaces or a soft sponge on a foil face or closed cell foam surface to mechanically remove the microbial growth.

Note: Be careful not to damage the non-porous surface of the insulation.

3. Install a block-off to prevent spray from going into a dry section of the unit and/or system ductwork.

NOTICE

Coil Freeze-up!

Failure to follow instructions below could result in coil damage. Drain and vent coils when not in use. Trane recommends glycol protection in all possible freezing applications. Use a glycol approved for use with commercial cooling and heating systems and copper tube coils.

WARNING

Hazardous Voltage!

Failure to disconnect power before servicing could result in death or serious injury. Disconnect all electric power, including remote disconnects before servicing.

Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized.

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4. Thoroughly clean the contaminated area(s) with an EPA-approved sanitizer specifically designed for HVAC use.

5. Rinse the affected surfaces thoroughly with fresh water and a fresh sponge to prevent potential corrosion of the drain pan and drain line

6. Repeat steps 4 and 5 as necessary.

7. Confirm the drain line is open following the cleaning process.

8. Allow the unit to dry thoroughly before putting it back into service.

9. Replace all panels and parts and restore electrical power to the unit.

10. Be careful any contaminated material does not contact other areas of the unit or building. Properly dispose of all contaminated materials and cleaning solution.

Cleaning Porous Surfaces

To clean a porous insulating surface (fiberglass insulation):

1. Disconnect all electrical power to the unit.

2. Wearing the appropriate personal protective equipment, use a vacuum device with a HEPA filter (99.97 percent efficient at 0.3 micron particles) to remove the accumulated dirt and organic matter.

Note: Be careful not to tear the insulation surface or edges.

3. Confirm the drain line is open following the cleaning process.

4. Allow the unit to dry thoroughly before putting it back into service.

5. Replace all panels and parts and restore electrical power to the unit.

6. Be careful any contaminated material does not contact other areas of the unit or building. Properly dispose of all contaminated materials and cleaning solution.

Drain Pans

The condensate drain pan and drain line must be checked to assure the condensate drains as designed. This inspection should occur a minimum of every six months or more often as dictated by operating experience.

If evidence of standing water or condensate overflow exists, identify and remedy the cause immediately. Refer to “Diagnostics and Troubleshooting,” p. 108 for possible causes and solutions.

To clean drain pans:

1. Disconnect all electrical power to the unit.

2. Wearing the appropriate personal protective equipment, remove any standing water.

3. Scrape solid matter off of the drain pan.

4. Vacuum the drain pan with a vacuum device that uses high-efficiency particulate arrestance (HEPA) filters with a minimum efficiency of 99.97 percent at

0.3 micron particle size.

5. Thoroughly clean any contaminated area(s) with a mild bleach and water solution or an EPA-approved sanitizer specifically designed for HVAC use.

6. Immediately rinse the affected surfaces thoroughly with fresh water and a fresh sponge to prevent potential corrosion of metal surfaces.

7. Allow the unit to dry completely before putting it back into service.

8. Be careful any contaminated material does not contact other areas of the unit or building. Properly dispose of all contaminated materials and cleaning solution.

WARNING

Hazardous Voltage!

Failure to disconnect power before servicing could result in death or serious injury. Disconnect all electric power, including remote disconnects before servicing.

Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized.

WARNING

Hazardous Chemicals!

Failure to follow all safety instructions below could result in death or serious injury. Coil cleaning agents can be either acidic or highly alkaline and can burn severely if contact with skin occurs. Handle chemical carefully and avoid contact with skin. ALWAYS wear Personal Protective Equipment (PPE) including goggles or face shield, chemical resistant gloves, boots, apron or suit as required. For personal safety refer to the cleaning agent manufacturer’s Materials Safety Data Sheet and follow all recommended safe handling practices.

MAINTENANCE

PERIODIC SERVICE

Because of the simple design of the steam and hot water unit heaters, they are nearly maintenance free.

However, depending on the environment, simple maintenance practices should be adopted.

these as often as necessary to remove any accumulation of lint and dirt. Check fan blades and remove dirt accumulation. If fan blades are not cleaned they tend to become unbalanced.

Most of the motors supplied on the unit heaters have either ball bearings or sleeve bearings and should not require lubrication for long periods of time. It is however advisable that motor maintenance and lubrication recommended by the motor manufacturer be followed.

Check motors for dirt and dust accumulation, and remove any accumulation as often as necessary. Open type motors may overheat if the dirt or dust is not removed from ventilation openings.

MOTOR LUBRICATION

Motors with oilers or oil holes are lubricated before when necessary, with the motor at a stand-still, until oil reaches the proper level.

Use SAE 20W non detergent oil for motors operating in ambient temperatures of 32°F to 100°F (0°C to 38°C). Below 32°F (0°C), SAE 10W non detergent oil will be required.

The frequency of oiling will depend upon operating conditions and length of running time. Inspect the oilers or oil holes when cleaning the unit. If the unit has a fractional horse-power motor, lubricate at least once a year. Under high ambient conditions or constant fan operation, fractional horse-power motors should be lubricated every 90 days. On those motors without oilers or oil holes, follow the instructions given on the motor nameplate.

Ball bearing motors are pre-lubricated and normally are equipped with removable grease plugs to allow lubrication of ball bearing motors.

the following procedure: With the motor at a stand-still, remove the vent and grease plugs. Install grease fitting and add grease sparingly. Remove the old grease from the vent relief chamber. Operate the motor a few minutes before reinstalling the vent plug to allow excess grease to escape. If there is evidence of grease working out around the motor shaft, less grease should be added and the greasing periods lengthened.

If grease continues to appear, take the motor to the repair.

Should maintenance be required, perform the following inspection and service routine:

CLEANING THE UNIT

The unit casing, fan, diffuser and coil should be cleaned thoroughly once a year. Coil heat transfer efficiency depends on cleanliness. The following recommended procedures may be performed when lubricating the motor and cleaning the coil.

1. Wipe all excess lubricant from the motor, fan and casing. Clean the motor thoroughly. A dirty motor will run hot and eventually cause internal damage.

2. Clean the coil:

a) Loosen the dirt with a brush on the fan side of the coil. Operate the motor allowing the fan to blow the loosened dirt through the unit.

b) Use high pressure air or steam on the side of the coil away from the fan.

3. Clean the casing, fan blades, fan guard and diffuser using a damp cloth. Any rust spots on the casing should be cleaned and repainted.

4. Tighten the fan guard, motor frame and fan bolts.

free rotation.

REPLACEMENT PARTS

10 - Fan (1) 11 - Junction Box (1) 12 - Junction Box Cover (1) 13 - Connector (1) 14 - Conduit, Flex (1) 15 - Anti-Short (2) 16 - Screw (4) 17 - Nut Retainer (4) 18 - Bolt (3) Models 24 & 36,

(4) Models 48/204 19 - Flange Screw 20 - Threaded Inserts

1 - Element (1) 2 - Bottom Jacket Panel (1) 3 - Venturi Jacket Panel (1) 4 - Top Jacket Panel (1) 5 - Motor Mount & Fan Guard*

[Std. Unit Shown] 6 - Motor Mounting Bracket [3 Phase and/or Explosion Proof]* 7 - Motor Mounting Angle [3 Phase and/or Explosion Proof]* (1) 8 - Motor [Std. Units]* 9 - Motor [3 Phase and/or Explosion Proof]*

HORIZONTAL STEAM UNIT HEATER PARTS

Unit Heaters

TO MOTOR

TO FAN

D-6061

D-6061

21 - Grommet (4) 22 - Washer, Flat (4) 23 - Nut (4) 24 - Bolt (4) 25 - Washer, Spring Lock (8) 26 - Nut (8) 27 - Screw (2) 28 - Louvers (Horiz) 29 - Cone Spring 30 - Grommet, Stem (4) 31 - Screw (18)

1. Frozen coil.

2. Defective coil.

3. Corrosion.

1. Check for air in coil.

1. No circulation of water through coil.

2. Short cycling of motor.

3. Backward rotating motor.

1. Damaged fan blade.

2. Dirty fan blade.

A. Leaking coil.

B. Poor output on steam.

C. Poor output on steam or hot water.

D. Noisy or vibrating unit.

1. Replace.

2. Replace.

3. Replace leak has occurred.

1. Repair or replace thermostatic air vent.

1. Check circulation pump. Check for blocked tubes.

2. Check voltage and correct. Check for linted coil and clean. Check for defective overload and repair or replace motor.

3. On single phase motor replace motor.

On three phase motor, reverse two leads to change rotation.

1. Change fan blade.

2. Clean fan blade.

SYMPTOMS POSSIBLE CAUSE(S) CORRECTIVE ACTION

HOW TO ORDER REPLACEMENT PARTS

Please send the following information to your local representative; If further assistance is needed, contact the

• Model number

• Serial Number (if any)

• Part description and Number as shown in the Replacement Parts Catalog.

LIMITED WARRANTY

The Manufacturer warrants to the original owner at the original installation site that the Horizontal Steam and Hot Water Unit Heaters (the “Product”) will be free from defects in material and workmanship for a period not to exceed one (1) year from startup or eighteen (18) months from date of shipment from the factory, whichever workmanship during the warranty period, the Manufacturer will repair or replace, at its option, that part of the Product which is shown to be defective.

This limited warranty does not apply:

has not been installed, maintained or operated in accordance with the furnished written instructions, or

(b) to any expenses, including labor or material, incurred during removal or reinstallation of the defective Product or parts thereof.

(c) to any workmanship of the installer of the Product.

This limited warranty is conditional upon:

(a) shipment, to the Manufacturer, of that part of the Product thought to be defective. Goods can only be returned with prior written approval from the Manufacturer. All returns must be freight prepaid.

(b) determination, in the reasonable opinion of the Manufacturer, that there exists a defect in material or workmanship.

Repair or replacement of any part under this Limited Warranty shall not extend the duration of the warranty with respect to such repaired or replaced part beyond the stated warranty period.

THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EITHER EXPRESS OR IMPLIED, AND ALL SUCH OTHER WARRANTIES, INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF

MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED AND

EXCLUDED FROM THIS LIMITED WARRANTY. IN NO EVENT SHALL THE MANUFACTURER BE LIABLE

IN ANY WAY FOR ANY CONSEQUENTIAL, SPECIAL, OR INCIDENTAL DAMAGES OF ANY NATURE

WHATSOEVER, OR FOR ANY AMOUNTS IN EXCESS OF THE SELLING PRICE OF THE PRODUCT OR ANY PARTS THEREOF FOUND TO BE DEFECTIVE. THIS LIMITED WARRANTY GIVES THE ORIGINAL OWNER OF THE PRODUCT SPECIFIC LEGAL RIGHTS. YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY

BY EACH JURISDICTION.

Type of Equipment: Unit Heater

Serial Number _________________________ Model Number __________________________

Name Plate Voltage: _____________ Name Plate Amperage: _____________

Steam Hot Water Rating: _ _____ BTU @ ____ °F _ _____ kw @ ____ °C

Are all panels in place?

Has the unit suffered any external damage? Damage ______________________________

Does the piping and electric wiring appear to be installed in a professional manner?

Is the supply properly sized for the equipment?

Were the installation instructions followed when the equipment was installed?

Do you understand all the controls on this equipment?

EQUIPMENT

FAN

❐ Check voltage. L1_____ L2_____ L3_____

❐ Check fan rotation.

❐ Check motor amps. L1_____ L2_____ L3_____

Remarks: _____________________________________________ slotted holes in each of the mounting brackets.

Mounting brackets are designed to provide both lateral and vertical adjustments.

connections (units are shipped with left hand connections). NOTE: If coil connections are reversed, fan speed control must also be reversed. Coils should be level and adjustment in mounting hardware is provided. Coils for steam service may be pitched for condensate removal using the coil mounting hardware.

using good practice and in accordance with appli-cable codes.

applicable codes. All models are furnished as standard with a solid state variable speed fan control. The fan control, with connection box, is factory mounted on the right side of the unit unless otherwise specified. NOTE: If coil connections are reversed, fan speed control must also be reversed. If speed control is to be wall mounted, junction box must be furnished by others.

be test run. If operational difficulties are experi-enced, recheck all wiring connections and power source.

FIELD INSTALLED OPTIONS

NOTES:

1. An "installation envelope" is packed with every unit and in it you will find installation instructions and various hardware items, including those listed below.

2. On orders for multiple units, various options may be packed in a separate carton(s) due to quan-tity. The notes below generally apply to single units of a given model/size.

Option 114 – Duct Collars: Packed in carton with unit. Hardware in "installation envelope". Installs over existing louver. These options are included when ordering models C-1150, RC-1190 and RC-1210. The required cutout (no louver) is provided on these three models.

Option 116 – Leveling Legs: Placed in cloth bag in installation envelope.

Options 118 & 119 – Manual and Motorized Outside Air Damper Kits: Shipped in separate box.

Options 125 and 127 – Aquastat & Line Voltage Thermostat: If either one of the two is ordered, its carton will be taped to the mounting bracket. If both are ordered, they will be shipped in a separate carton.

Options 126A & B – Wall Seals: Packed in carton with unit. Hardware in cloth bag inside installation envelope. Wall seals are included with models RC, RW and RWI, but must be ordered for all other models.

WALL SEAL SCHEDULE

Fully 21⁄4" Partial

Model Recessed Recess F F-1020, F-1030 F-1000, F-1010

FI FI-1050 FI-1040

W, RW RW-1120 W-1060, W-1070

WI, RWI RWI-1130 WI-1090, WI-1100

C, RC C-1170, RC-1200 C-1140, C-1150

C-1160, C-1180

RC-1190, RC-1210

Option 129 – Extra Filter: Packed inside unit carton with standard filter.

Option 140 – 24VAC - 40VA transformer: shipped in separate box.

MAINTENANCE INSTRUCTIONS

NOTE: Due to the reliability of our cabinet unit heaters, we do not recommend the stocking of any components or subassemblies.

MOTORS

Motors permanent split capacitor (PSC) type and are fitted with permanently lubricated sleeve bearings.

COILS

Coils should be kept clean to insure proper heat transfer. Frequency of cleaning is dependent upon operating environment. Coils may be vacuumed or the following method may be used: Brush the fins on the side where the air enters the unit and then operate the fan after placing a bag or dampened cloth over the discharge of the unit to catch the dirt.

High pressure air may be used to blow dirt out from the air leaving side.

BLOWERS

Blowers may also be cleaned out using high pres-sure air.

FILTERS

Filters should be cleaning using compressed air or washed with a mild detergent solution at intervals of three (3) months or sooner depending on job conditions.

CABINET UNIT HEATER LIMITED WARRANTY

Mestek, hereinafter referred to as the Company, warrants all material manufactured by it and to be delivered hereunder, to be free from defects in material, workmanship and title and to be as ordered. If within one (1) year from the date of any shipment by the Company, the Company is notified that the merchandise delivered hereunder does not meet the foregoing specific warranty, the Company's sole liability shall be, at its option, to refund the purchase price of the equipment or to correct any defect (the results of ordinary wear and tear, neglect, misuse or accident not to be deemed a defect) including non-conformity with specifications, by repairing any defective parts or, at its option, by furnishing replacement parts F.O.B. the factory where same are manufactured with all freight costs paid by the customer. The company is not liable for any damages to plant, personnel, equipment or products resulting from the use or misuse of any of its products and its sole liability shall be as set forth and as limited herein.

THE WARRANTIES SET FORTH ABOVE ARE IN LIEU OF ALL OTHER

WARRANTIES, GUARANTEES OR REPRESENTATIONS WHETHER ORAL,

WRITTEN OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY

OR FITNESS FOR PURPOSE. THE COMPANY SHALL NOT BE LIABLE FOR

CONSEQUENTIAL DAMAGES.

260 North Elm Street - Westfield, MA 01085 Tel: (413) 568-9571 Fax: (413) 562-8437 www.mestek.com

WATER STEAM

LP-723 Revision Date 2.23.22

Part 14 - Maintenance

DANGER!

The boiler must be inspected and serviced annually, preferably at the start of the heating season, by a qualified service technician. In addition, the maintenance and care of the boiler as outlined in this manual must be performed by the user/owner to assure maximum efficiency and reliability. Follow the maintenance procedures given throughout this manual. Failure to perform the service and maintenance or follow the directions in this manual could damage the boiler or system components, resulting in substantial property damage, severe personal injury, or death.

A. Procedures Periodic maintenance should be performed once a year by a qualified service technician to ensure that all the equipment is operating safely and efficiently. The owner should make necessary arrangements with a qualified heating contractor for periodic maintenance of the boiler.

The installer must also inform the owner that a lack of proper care and maintenance of the boiler may result in a hazardous condition.

Check the Surrounding Area

DANGER!

To prevent the potential of substantial property damage, severe personal injury, or death, eliminate all the materials listed in Table 6 from the area surrounding the boiler and the vicinity of the combustion air intake. If contaminants are found:

• Remove products immediately from area.

• If contaminants have been there for an extended period, call a qualified service technician to inspect the boiler for possible damage from acid corrosion.

If products cannot be removed, immediately call a qualified service technician to re-pipe the combustion air intake piping away from the contaminated areas.

Ensure the Cabinet is Closed When the Boiler is Operating

The boiler cabinet must be closed when the boiler is operating.

Combustible/Flammable Materials

Do not store combustible materials, gasoline, or other flammable vapors or liquids near the boiler. If found, remove these materials immediately.

Air Contaminants

If allowed to contaminate combustion air, products containing chlorine or fluorine will produce acidic condensate that will cause significant damage to the boiler. Read the list of potential contaminants and areas likely to have these contaminants in Table

6. If any of these contaminants are in the room where the boiler is located, or combustion air is taken from one of the areas listed, the contaminants must be removed immediately or the intake pipe must be relocated to another area.

Check the Power Source

Make sure the power cord and the main power line are properly connected to the manual switch box inside the boiler.

Check the Status of the Control Panel

Observe the Control Panel to ensure the boiler is powered on and to check for any error codes. Clear any debris from the panel.

Check CH Pressure Gauge

Ensure the pressure reading on the CH gauge does not exceed 30 psig. Higher pressure readings may indicate a problem with the expansion tank. Immediately contact a qualified service technician to inspect the boiler and system.

Check Exhaust Vent and Intake Pipe Terminations

Verify that the boiler exhaust vent and intake pipe terminations are clean and free of obstructions. Remove any debris from the exhaust vent or intake pipe openings. If removing the debris does not

B. Maintenance That May be Performed by the User allow the boiler to operate correctly, contact your qualified service technician to inspect the boiler and the vent system.

Check Exhaust Vent and Intake Piping

Visually inspect the exhaust vent for any signs of blockage, leakage, or deterioration of the piping. Inspect the exhaust vent bracing.

Ensure bracing is undamaged and in good condition. Notify a qualified service technician immediately if any problems are found.

WARNING!

Failure to inspect the venting system and have it repaired by a qualified service technician can result in vent system failure, causing severe personal injury or death.

Check Pressure Relief Valve

1. Visually inspect the primary pressure relief valve and discharge pipe for signs of weeping or leakage.

2. If the pressure relief valve often weeps, the expansion tank may not be operating properly. Immediately contact a qualified service technician to inspect the boiler and system.

Operate Pressure Relief Valve

1. Before proceeding, verify that the relief valve outlet has been piped to a safe place of discharge, avoiding any possibility of scalding from hot water.

2. Shut power off to the boiler. To avoid scalding, wait for boiler to cool before operating the relief valve.

WARNING!

To avoid water damage or scalding due to relief valve operation, a discharge line must be connected to the valve outlet and directed to a safe place of disposal. This discharge line must be installed by a qualified service technician in accordance with the boiler installation manual. The discharge line must be terminated so as to eliminate possibility of severe burns or property damage should the valve discharge.

3. Lift the relief valve lever. If water flows freely, release the lever and allow the valve to seat. Watch the end of the relief valve discharge pipe to ensure that the valve does not weep after the line has had time to drain. If the valve weeps, lift the lever again to attempt to clean the valve seat. If the valve does not properly seat and continues to weep, contact a qualified service technician to inspect the valve and system.

4. If water does not flow from the valve when you completely lift the lever, the valve or discharge line may be blocked.

Immediately shut the boiler down per instructions on page 2 and call a qualified service technician to inspect the valve and system.

5. If relief valve seats properly, restore power to the boiler. Observe operation for five minutes and ensure it operates properly.

Check the Condensate Drain System

1. While the boiler is running, check the discharge end of the condensate drain tubing. Ensure no flue gas is leaking from the condensate drain tubing by holding your fingers near the opening.

2. If you notice flue gas leaking from the opening, this indicates a dry condensate drain trap. If problem persists, contact a qualified service technician to inspect the boiler, condensate line and condensate trap.

3. If applicable, check the condensate neutralizer and ensure it is full of condensate neutralizing marble chips.

DANGER!

Ensure power and gas to the appliance are shut off before performing the following operations. Failure to do so will result in substantial property damage, severe personal injury, or death.

C. Maintenance Only to be Performed by a Qualified

Service Technician

Removing the Cabinet Cover and Inspecting the Boiler

Before carrying out any work on the boiler, switch off the power supply at the external power switch and circuit breaker. Close the external gas shutoff.

See Figure 80 to access the interior of the boiler:

1. Release the four (4) latches from the front cover (two [2] each side). Lift and remove the front cover from the cabinet (a).

2. Remove the screw securing the control panel to the cross-member

(b).

3. Push in the tabs and pull the control panel housing forward (c).

Figure 80 - Removing the Cover and Control Panel Housing

WARNING!

Have leaks fixed at once by a qualified service technician. Failure to comply could result in substantial property damage, severe personal injury, or death.

Before Starting Maintenance:

1. Ensure the power and gas remain off.

2. Close the valves of heating and hot water circuit.

3. Remove the front panel as shown in Figure 80.

4. If necessary, empty the appliance on the water side.

Draining Procedure

To drain the heating system:

1. Ensure the boiler power and gas remain off.

2. Open the manual purge valve.

3. Open the system drain valve and collect the escaping water in a container.

4. Drain the water from the lowest points of the system (where applicable).

If the system is to be inactive in areas where the room temperature may fall below 0°C during winter, it is recommended that anti-freeze liquid be added to the heating system in order to avoid the need for repeated draining. Ensure the antifreeze used is compatible with the stainless steel boiler heat exchanger.

WARNING!

NEVER use any toxic chemical, including automotive, standard glycol antifreeze, or ethylene glycol made for hydronic (non-potable) systems. These chemicals can attack gaskets and seals in water systems, are poisonous if consumed, and can cause personal injury or death.

Check Water and Gas Piping

1. Remove the boiler cover and perform a gas leak inspection following Operating Instructions on page 2 of this manual. If gas odor or leak is detected, follow procedures on page 2. Call a qualified service technician.

It is recommended to use antifreeze which contains PROPYLENE GLYCOLS as these inhibit corrosion. Use the quantities and formulation suggested by the antifreeze manufacturer to protect against freezing in your region and prevent scaling and corrosion.

Regularly check the pH level of the water/anti-freeze mix in the boiler circuit and replace it when the value measured is lower than the limit prescribed by the manufacturer.

DO NOT MIX DIFFERENT TYPES OF ANTI-FREEZE.

The manufacturer will not be held liable for any damage caused by the appliance or the system due to the use of inappropriate antifreeze substances or additives.

Draining the DHW System and Indirect Water Heater

Every time there is a danger of freezing, the domestic hot water system must be drained as follows:

1. Shut off the main water inlet valve.

2. Open all the hot and cold water taps.

3. Drain the water from the lowest points of the system.

WARNING!

Water drained from the boiler could be scalding hot. Wait for the boiler to cool before draining water, and take precautions when draining water. Failure to do so could result in property damage, personal injury, or death.

(b)

(a)

(c)

2. Visually inspect for leaks around the boiler water connections and around the heat exchanger. Visually inspect the external system piping, circulators, and system components and fittings. Immediately call a qualified service technician to repair any leaks.

WARNING!

Allowing the boiler to operate with a dirty combustion chamber will hurt operation. Failure to clean the heat exchanger as needed by the installation location could result in boiler failure, property damage, personal injury, or death. Such product failures ARE NOT covered under warranty.

The combustion chamber insulation in this product contains ceramic fiber material. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, “Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1).”

• Avoid breathing dust and contact with skin and eyes.

• Use a NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written. Other types of respirators may be needed depending on job site conditions. Current NIOSH recommendations can be found on the NIOSH website:

http://www.cdc.gov/niosh/homepage.html. NIOSH approved respirators, manufacturers, and phone numbers are also listed on this website.

• Wear long-sleeved, loose fitting clothing, gloves, and eye protection.

• Apply enough water to the combustion chamber lining to prevent dust.

• Wash potentially contaminated…