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CaptiveAire D76, Инструкция по установке, эксплуатации и обслуживанию

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Table of Contents

WARRANTY  ............................................................................................................................................................................. 4

INSTALLATION  ........................................................................................................................................................................ 5

Mechanical  ........................................................................................................................................................................... 5

Curb and Ductwork ............................................................................................................................................................... 7

Roof Mount Installation ......................................................................................................................................................... 8

Gas ....................................................................................................................................................................................... 9

ELECTRICAL .......................................................................................................................................................................... 11

Fan to Building Wiring Connection  ..................................................................................................................................... 12

Motorized Intake Damper ............................................................................................................................................... 13

Permanent Split Capacitor (PSC) Motor Speed Control  .................................................................................................... 13

EVO™/ECM-VCU .......................................................................................................................................................... 13

Electronically Commutated Motor (ECM) Speed Control  ................................................................................................... 14

External PWM Signal ..................................................................................................................................................... 14

Unit Mount Controller  ......................................................................................................................................................... 14

Motor Speed Controller (MSC) Installation ......................................................................................................................... 15

MSC Controls Overview  ..................................................................................................................................................... 16

MSC Menu ..................................................................................................................................................................... 16

Input Threshold .............................................................................................................................................................. 18

MSC Menu Tree ............................................................................................................................................................. 19

Remote Control Panel  ........................................................................................................................................................ 20

Motorized Intake Damper  ................................................................................................................................................... 20

Electric Cabinet Heater  ...................................................................................................................................................... 20

Variable Frequency Drive (VFD)  ........................................................................................................................................ 21

Variable Frequency Drive (VFD) Installation .................................................................................................................. 22

Input AC Power .............................................................................................................................................................. 22

VFD Output Power ......................................................................................................................................................... 22

VFD Programming  ......................................................................................................................................................... 23

ACTECH SMV VFD  ....................................................................................................................................................... 24

OPERATION ........................................................................................................................................................................... 25

Start-up Procedure  ............................................................................................................................................................. 25

Pilot Adjustment  ................................................................................................................................................................. 26

Main Burner Adjustment ..................................................................................................................................................... 27

Final Start-up Procedure ................................................................................................................................................ 28

Pulley Adjustment ............................................................................................................................................................... 29

Pulley Alignment/Proper Belt Tension ................................................................................................................................ 30

Pulley Combination Chart ................................................................................................................................................... 31

Sequence of Operation  ...................................................................................................................................................... 32

Flame Safety Control  ..................................................................................................................................................... 32

Modulating Gas System  ..................................................................................................................................................... 34

High Temperature Limit ...................................................................................................................................................... 34

Optional Remote Panel Circuit  ........................................................................................................................................... 35

Remote Panel Option  .................................................................................................................................................... 36

Troubleshooting .................................................................................................................................................................. 37

Burner Troubleshooting  ..................................................................................................................................................... 38

Remote Panel Troubleshooting Chart ............................................................................................................................ 39

MSC Troubleshooting  .................................................................................................................................................... 40

MAINTENANCE ...................................................................................................................................................................... 41

General Maintenance  ......................................................................................................................................................... 41

2 Weeks After Start-up  ....................................................................................................................................................... 41

Every 3 Months  .................................................................................................................................................................. 41

Yearly  ................................................................................................................................................................................. 41

Burner Maintenance  ...................................................................................................................................................... 42

Re-Setting of the Unit  .................................................................................................................................................... 42

Emergency Shutdown of Unit  ........................................................................................................................................ 42

Prolonged Shutdown of the Unit  .................................................................................................................................... 42

Start-Up and Maintenance Documentation  ........................................................................................................................ 44

Содержание D76

Страница 1: ...amage If damage is found report it immediately to the carrier Check that all accessory items are accounted for and are not damaged WARNING Improper installation adjustment alteration service or mainte...

Страница 2: ...2...

Страница 3: ...ive VFD Installation 22 Input AC Power 22 VFD Output Power 22 VFD Programming 23 ACTECH SMV VFD 24 OPERATION 25 Start up Procedure 25 Pilot Adjustment 26 Main Burner Adjustment 27 Final Start up Proce...

Страница 4: ...erated within the limitations set forth in this manual 5 The invoice is not paid within the terms of the sales agreement The MANUFACTURER shall not be liable for incidental and consequential losses an...

Страница 5: ...ort equipment Refer to manufacturer s estimated weights 2 Locate unit close to the space it will serve to reduce long twisted duct runs 3 Consider general service and installation space when locating...

Страница 6: ...silicone or weather proof gasket on the backside of the flanges of the intake hood or V bank intake 2 Secure the flanges of the intake hood to the unit with the supplied sheet metal screws 3 Use caulk...

Страница 7: ...steners are secure Figure 3 and Figure 4 show different mechanical installations Adequate building relief shall be provided so as not to over pressurize the building when the heating system is operati...

Страница 8: ...Opening 2 Curb Outer Wall 3 Flex Conduit for Field Wiring 4 Screened Intake 5 Filter Access Door 6 Service Disconnect Switch 7 1 2 NPT Pipe 8 Blower Motor Access Door 9 Control Drop 10 Motor Drop 1 Se...

Страница 9: ...manual shut off valve external to the unit casing Install shut off valve adjacent to the unit for emergency shut off and easy servicing of controls Refer to Figure 5 5 Provide a sediment trap as shown...

Страница 10: ...14 Inches WC Maximum NOTICE Refer to the heater s rating plate for determining gas supply pressures and requirements 1 1 2 3 4 5 A 1 Gas Supply Line Connection 2 Manual Gas Shut off Valve 3 Ground Jo...

Страница 11: ...uld supply the motor circuit with short circuit protection according to the National Electric Code This dedicated branch should be run to the junction box 4 Verify that the power source is compatible...

Страница 12: ...itch 2 Galflex Conduit In Unit 3 Factory Wiring 4 Field Supplied Wiring From building power or pre wired control panel WH BK GR 120V 1 PH RD BK GR 208 240V 1 PH BK BK BK GR 208 240 460 600V 3 PH 1 2 3...

Страница 13: ...ensures the motor runs with sufficient torque to prevent stalling To adjust this 1 Motor must be in actual operating conditions to achieve proper speed adjustment Motor will not slow down unless prop...

Страница 14: ...ex has a range of 0 100 and is typically linear with motor RPM If the remote function re is enabled the speed is controlled through a 0 10V input 0V 0 and 10V 100 unless overridden by the low speed an...

Страница 15: ...nance must be carried out by qualified skilled personnel who are familiar with the installation assembly commissioning and operation of the electronic board and the application for which it is being u...

Страница 16: ...ts how the fan will be controlled Local The fan will be controlled by the MSC Remote Modbus The fan will be controlled by another master board through the MSC A connection between the 0 10V Out to 0 1...

Страница 17: ...Settings This will reset all values back to factory settings T B Settings This will reset all values back to last saved test balance settings Change Password Users may update the password setting to t...

Страница 18: ...threshold set to 0V LOW SPEED DEVICE OUTPUT HIGH SPEED 0 1 4 2 3 6 7 8 5 9 10 OPERATING BAND INPUT VOLTS 0 10V OR PWM OUTPUT SIGNAL DEPENDANT ON SETTINGS 0 10V INPUT DEVICE OUTPUT LOW SPEED Zero opera...

Страница 19: ...TS DAY HOUR MINUTE SECONDS DISPLAYS BOARD REBOOT FAULT HISTORY FAULT TOTALS FEEDBACK MODBUS REBOOT VARIABLE DEVICE and TOTAL FAULT COUNTS ARE SHOWN 2 SPEED ANALOG SPEED RANGE 20 100 or 0 10V DEFAULT V...

Страница 20: ...e where the heater is located and the thermostat set to 0 Degrees Fahrenheit WH 1 2 9 8 N 70 GY BR BK OR 60 50 YW 17 10 18 T1 T3 BK RD PK RD 80 40 Temperature Control Off Auto Manual Heat Vent Flame F...

Страница 21: ...e installation environment conforms to the VFD manual The drive is mounted securely Space around the drive meets the drive s specification for cooling The motor and driven equipment are ready to start...

Страница 22: ...spective motor Do not run different fan output power cables in the same conduit VFD mounted in ECP A load reactor should be used and sized accordingly when the distance between the VFD and motor is gr...

Страница 23: ...cates that the PROGRAM mode has been accessed at the beginning of the parameter menu 3 Use the Up and Down buttons to scroll to the desired parameter number 4 Once the desired parameter is found press...

Страница 24: ...X 48 42 80 20 ESV153N02TXB 240V X 59 54 90 1 ESV751N04TXB 480V X 2 5 2 1 15 1 5 ESV112N04TXB 480V X 3 6 3 15 2 ESV152N04TXB 480V X 4 1 3 5 15 3 ESV222N04TXB 480V X 5 4 4 8 15 5 ESV402N04TXB 480V X 9 3...

Страница 25: ...tation will result in poor air performance motor overloading and possible burnout For units equipped with a single phase motor check the motor wiring diagram to change rotation For 3 phase motors any...

Страница 26: ...uired disconnect the pilot line at the outlet of the pilot valve 5 Check the pilot flame voltage at the Flame Safety Control interface test jacks A weak pilot flame can be caused by low gas pressure o...

Страница 27: ...screw to adjust the high fire manifold pressure to design temperature rise 5 inches wc maximum for natural gas and 2 5 inches wc maximum for propane gas High fire should be set to generate the design...

Страница 28: ...loading or bearing failure Do not set fan RPM higher than specified in the maximum RPM chart See the troubleshooting guide for more information 3 Measure and record the voltage and amperage to the mot...

Страница 29: ...ease in speed represents a substantial increase in horsepower required by the unit Motor amperage should always be checked to avoid serious damage to the motor when the speed is varied Always torque s...

Страница 30: ...e a sharp reduction in belt life and produce squeaky noises Over tightening will cause excessive belt and bearing wear as well as noise Too little tension will cause slippage at startup and uneven wea...

Страница 31: ...Open TURNS ON MOTOR PULLEY Closed 5 4 1 2 4 3 1 2 3 2 1 2 2 11 2 1 1 2 0 AK32H 3 3 2 1617 1671 1725 1779 1833 1887 1941 1995 2048 2102 2156 1 3 to 2 HP MOTOR PULLEY Dd1 Dd2 Pd1 Pd2 AX BELTS 1VL40 2 4...

Страница 32: ...dant solenoid gas valves and the operation of the spark igniter to initiate a pilot flame upon start up Upon a call for heat there is a 15 second Pilot Trial For Ignition PTFI During PTFI the FSC open...

Страница 33: ...not allowing the low airflow switch to close The high airflow switch protects against profile plate failures that cause excessive airflow through the burner In the event that the pressure drop across...

Страница 34: ...s valve controls the amount of gas flow to the burner based on the temperature rise needed When the modulating gas valve is all the way open and achieving the maximum BTUs and temperature rise of the...

Страница 35: ...tion Heat Circuit is Energized Burner On Light Illuminates with proper flame Flame Failure Light illuminates if proper flame is not established Blower Operates Cooling Circuit is Energized Cool Positi...

Страница 36: ...definitions are as follows POWER Illuminated when there is power to the remote panel BLOWER ON Illuminated when the blower motor is powered BURNER ON Illuminates after pilot flame has established and...

Страница 37: ...rmine if HP is sufficient for job Duct static pressure lower than design Reduce fan RPM Insufficient Airflow Incorrect fan rotation Verify that the fan is rotating in the direction shown on rotation l...

Страница 38: ...eplace combination valve Loose valve wiring Check wiring to valve Defective flame rod Replace flame rod Shut off valve closed Open shut off valve Defective flame safety controller Replace flame safety...

Страница 39: ...temperature thermostat timed out optional Power Light and Blower On Light Proper ventilation operation No correction required No power to flame safety controller Manual Off Auto switch in Off positio...

Страница 40: ...g Secure connections to fan If faulty wiring is found repair or replace as required No feedback for 30 seconds Check parameters Less than 70 of RPM Check duct fan for obstructions Modbus Modbus fault...

Страница 41: ...rotated as they are lubricated to evenly distribute the grease either by hand or via extended grease lines Do not attempt to grease bearings from inside the enclosure while the motor is energized Cau...

Страница 42: ...to the unit 2 Turn power to the unit back ON Emergency Shutdown of Unit To shutdown the unit in the event of an emergency do the following 1 Turn power OFF to the unit from main building disconnect 2...

Страница 43: ...43 Notes...

Страница 44: ...ate and Unit Information Field Measure Information Model Number Motor Voltage Serial Number Motor Amperage Hardware Rev RPM Software Rev Burner Differential Pressure Inches WC Motor Volts Pilot Flame...

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