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Installation
Required Clearances
Clearance to Combustibles Floor Top Sides Ends
Clearance to combustibles is defined as the minimum
Insulated/Units 0 0 0 0
distance required between the unit and adjacent
combustible surfaces to ensure the adjacent surface Non Insulated Units 0 6 (16) 6 (16) 6 (16)
temperature does not exceed 90ºF above the ambient
temperature. All measurements are shown in inches (cm).
Required Clearances
Service Clearances Recommended Minimum Service Clearances
Service clearances are factory recommendations for Model Housing A inches (cm)
ease of servicing. All deviations must still adhere to H05 36 (92)
clearance to combustibles requirements. All deviations H10 36 (92)
XDG
from the service clearance recommendations are at H20 37 (94)*
the discretion of the end-user as this may impede H30 48 (122)
component removal. H12 33 (84)
Reference the Start-Up: Optional Features, Other, H22 44 (112)**
PDX Cooling Module section in this Installation, H32 52 (132)
XDGX
Operation and Maintenance Manual for further H35 78 (198)
clearance requirements, if applicable. H38 96 (244)
Not all models listed will incorporate access on both H42 101 (255)
sides; this will vary based on supply fan type and * 67 in. (170 cm) when equipped with evaporative cooling module
options selected. ** 61 in. (155 cm) when equipped with evaporative cooling module over
4800 cfm
Note: If XDG-H05 is equipped with an evaporative
cooling module, access to the filters, media, sump,
and water connections
is accomplished through
the roof of the evaporative 36 inches (91.4 cm)
cooling module. A
minimum service clearance OPTIONAL DG ACCESS
36 inches (91.4 cm)
of 24 inches (61cm) is
DAMPER SECTION
OPTIONAL OPTIONAL
OPTIONAL SUPPLY
WEATHERHOOD COOLING DIRECT GAS
module. EVAPORATIVE COOLING
FILTER
SECTION
COIL SECTION
FAN
SECTION
SECTION SECTION
CONTROL CENTER
Plenum Fans
Down Discharge End Discharge Side Discharge
Installation Inta
ke
It is highly recomm
and attached after
on application, building design, code requirements, and locate the unit in place.
unit size, and unit weight. The following information is The use of all lifting lugs
provided as a guideline; it is not intended to replace and a set of spreader bars
job specific structural design provided by a structural is mandatory when lifting
engineer. the unit.
1. Install Field-Supplied Hangers It is recommended that any shipped loose modules be
Install hangers from ceiling supports. Ensure hangers installed after the base unit. The shipped loose modules
are located to avoid interference with access doors and must be fastened together. Fasten the cover seams
allows for component removal. and vertical panels on each module using sheet metal
screws. Some shipped loose modules will require field-
2. Install Unit provided shims for proper alignment with the base unit.
Using sheet metal screws, assemble optional shipped
loose modules. Ensure that all cover seams and vertical Fasten the unit using appropriate methods. The installer
panels on each module are fastened securely. Raise the is responsible for determining appropriate support
assembled unit into place. and fastening methods to ensure compliance with all
applicable codes.
Appropriate field-supplied unit supports, such as
C-channel or angle iron, are to be placed under the unit. 2. Attach Ductwork
Fasten the unit supports to the hangers and to the unit Refer to the unit submittal for the duct size and location.
using appropriate methods. An appropriate sealant should be used around the
discharge opening of the unit to create a weathertight
To prevent the unit from swinging and to provide a safe seal.
environment for service and maintenance, additional
measures must be taken to secure the unit in all Follow good duct practices for all ductwork. Install
directions. ductwork in accordance with SMACNA and AMCA
guidelines, NFPA 96 and local codes. Reference
The installer is responsible for determining appropriate Installation, Duct
support and fastening methods to ensure compliance Sizes section in
with all applicable codes. this Installation,
3. Attach Ductwork Operation, and
Using appropriate methods, attach ductwork to unit. Maintenance
Follow good duct practices for all ductwork. Install Manual for proper
ductwork in accordance with SMACNA and AMCA duct sizes.
guidelines, NFPA 96 and any further local codes. Note for both Hanging and Floor Mounted
Reference Installation, Duct Sizes section in this Installations: The manufacturer recommends units
Installation, Operation, and Maintenance Manual for equipped with evaporative cooling be installed
proper duct sizes. outdoors. If an evaporative cooling module must be
Ceiling installed indoors, it is recommended a field-supplied
Supports
Ductwork
secondary drain pan be installed under the evaporative
Hangers cooling section. This will help mitigate damage to
building materials in the event the evaporative cooling
module sump tank overflows.
Unit Supports
Equipment
Support
Setting Unit
Equipment Exhaust
Support Ductwork
by Others
Supply
Ductwork
Curb and Equipment Support by Others
Ductwork
4. Apply Sealant
Apply an appropriate sealant around the perimeter of
the curb and duct to isolate unit vibration and prevent
water penetration.
Leg Supports
Exhaust Duct Installed
Sealant
Unit Profile and Leg Support
Supply
Combination Extension
all lifting lugs and a set of Lifting Lugs (4) and position the unit on the
spreader bars is mandatory field-supplied rail supports.
when lifting the unit. It is The use of all lifting lugs and
recommended that any a set of spreader bars is
shipped loose modules be mandatory when lifting the Lifting Lifting
installed after the base unit. unit. It is recommended that Lugs (4)Lugs (4)
The shipped loose modules must be fastened together. any shipped loose modules be
Fasten the cover seams and vertical panels on each installed after the base unit.
Sans text used in the TSU IOM
module using sheet metal screws. Using an appropriate The shipped loose modules must be fastened together.
sealant, seal the seam(s) between each shipped loose Fasten the cover seams and vertical panels on each
module and the weatherhood. module using the appropriate methods. Fasten the unit to
Some shipped loose modules will require field-provided the rails using appropriate methods.
shims for proper alignment with the base unit. If an optional evaporative cooling module is included,
If an optional evaporative cooling module is included, reference Installation, Optional Component Mounting,
reference Installation, Optional Component Mounting, Evaporative Cooling Module section in this Installation,
Evaporative Cooling Module section in this Installation, Operation and Maintenance Manual for more
Operation and Maintenance Manual for more information.
information. The installer is responsible for determining appropriate
Fasten the unit to the slab using appropriate methods. fastening methods to ensure compliance with all
The installer is responsible for determining appropriate applicable codes.
fastening methods to ensure compliance with all 3. Attach Ductwork
applicable codes. Use an appropriate sealant around the discharge opening
3. Attach Ductwork of the unit to create a weathertight seal.
Use an appropriate sealant around the discharge opening Follow good duct practices for all ductwork. Install
of the unit to create a weathertight seal. ductwork in accordance with SMACNA and AMCA
Follow good duct practices for all ductwork. Install guidelines, NFPA 96 and local codes. Reference
ductwork in accordance with SMACNA and AMCA Installation, Duct Sizes section in this Installation,
guidelines, NFPA 96 and local codes. Reference Operation, and Maintenance Manual for proper duct
Installation, Duct sizes.
Sizes section in
this Installation,
Operation, and
Maintenance
Manual for proper
duct sizes.
Room Thermostat
Requires wiring to be run in separate
conduit or run with shielded cable.
From
WARNING Gas
Supply
All components of this or any other gas-fired heating 1/8 in. Plugged Tap
unit must be leak tested prior to placing the unit into 6 in. Trap
Type
Maximum
of gas
gas
pressure
Sump Overflow
VALVE A
Field-Supplied
Sump Drain Supply Solenoid
Field-Supplied Supply Line Valve
(normally closed)
Drain Line Valve
Drain Line
Overflow
VALVE B Trap
Trap Supply Line Drain Solenoid
(normally open) Drain Line
461264 8210G35
Sump
Open
3/4 inch
1 Provisions must be taken to prevent damage to the
Drain (19.mm) evaporative cooling section during freezing conditions.
Part numbers subject to change. The sump, drain lines and supply lines must be
drained prior to freezing conditions or an alternate
method must be used to protect the lines and media.
high quality materials and an inert gas purge (such as Remote Sensing Bulb Straps
Suction Connection
nitrogen) to reduce oxidation of the internal surface of
General Installation
the coil.
All field-piping must be self-supporting and flexible 5. Mount the TXV Sensing Bulb (by others)
enough to allow for the thermal expansion of the coil Mount the TXV sensing bulb to the horizontal run of the
and piping. suction line at the TXV manufacturer’s recommended
position and insulate it.
1. Locate the Distributor(s)
A field-provided opening must be 6. Check System for Leaks
created for the liquid line(s). The Pressurize the coil to 100 psig with dry nitrogen. Leave
distributor(s) are located behind the the system pressurized for a minimum of 10 minutes.
distributor access panel. If the system holds the pressure, the hook-up can be
considered leak free. If the pressure drops by 5 psig or
2. Verify Nozzle Placement less, re-pressurize the system and wait another
Inspect the refrigerant distributor 10 minutes. If the pressure drops again, there is likely
and verify that the nozzle is in place. one or more small leaks which must be located and
The nozzle is generally held in place Distributor repaired. Pressure losses greater than 5 psig indicate a
by a retaining ring or is an integral Access Panel large leak that must be isolated and repaired.
part of the distributor itself.
The nozzle is not a metering 7. Evacuate and Charge the System
device. A thermostatic Use a vacuum pump to evacuate the system. Measure
expansion valve (TXV) must the vacuum in the system using a micron gauge
be field-supplied. located as far from the pump as possible. Evacuate the
Retainer
Ring Nozzle Distributor system to 500 microns or less, and then close the valve
3. Install Suction Line between the pump and the system. If the vacuum holds
Install suction line(s) from the compressor(s) to the to 500 microns or less for one minute, the system is
suction connection(s) which are stubbed through the ready to be charged.
side of the cabinet.
A steady rise in vacuum pressure indicates that moisture
4. Install the Liquid Line and Thermostatic is still present and that the system must be further
Expansion Valve (TXV) (by others) vacuumed until the moisture has been removed.
Liquid line openings vary by coil size and circuiting and Failure to obtain a vacuum of 500 microns or less
are field-supplied. Follow the TXV recommendations indicates a great deal of moisture or a leak. Break the
for installation to avoid damaging the valve. If the valve vacuum with a charge of dry nitrogen and recheck for
is externally equalized, use a tubing cutter to cut off leaks. If no leaks are found, continue vacuuming the coil
the plugged end of the factory installed equalizer line. until the desired vacuum is reached.
Use a de-burring tool to remove any loose metal from
the equalizer line and attach it to the TXV. If the valve is 8. Install the Drain Line
internally equalized, the factory-installed equalizer line Connect an unobstructed drain line to the drain pan. A
can be left as is. trap must be provided for proper unit drainage.
All traps must be
installed below
the roof line or be 6 in./min. (0.254 cm/sec)
otherwise protected
from freezing. Drain 6 in./min. (0.254 cm/sec)
Trap
Factory Wiring
Gap
Check the alignment by using a Inlet Cone
straight edge across both sheaves.
Differences in sheave width must
be accounted for.
Mixed Flow Alignment
Drive Alignment
to Burner
Gas Connection
Airflow
Burner Gas
Safety Shut-Off Valves Regulator
Pressure Test Port
Airflow
Burner Gas
Safety Shut-Off Valves
Pressure Test Port
Maxitrol 44 Series
Set the discharge temperature Optional shipped loose accessories include a remote
Typical 65°F (18°C) temperature sensor, Selectrastat and remote selector
Minimum: Typical: 55°F (13°C) dial. The room temperature sensor and selector can be
Maximum: Typical: 90°F (32°C)
combined as one with the selector dial on the face or
Maxitrol Series 14 this system can be provided with the sensor body and
the dial as separate components.
Optional shipped loose accessories include a remote
temperature dial or a room override thermostat.
Manual reset
2-10 VDC or 4-20 mA signal in
[terminals 5 (-) and 6 (+)]
J1 jumper = No jumper (required)
J2 jumper = 1-2 (suggested position)
J3 jumper = 2-3 (required)
Typical Gas Pressure Switch
Maxitrol SC Series
UV Scanner
The optional UV scanner is a flame sensing
device that can be used in lieu of a flame rod.
The UV eye senses the flame by detecting
the ultraviolet light produced by the flame.
A special spark generator and rectification
amplifier card are required with the use of this
option.
Minimum
firing rate
adjustment
Minimum
firing rate
adjustment
Minimum
firing rate
adjustment
Pilot gas pressure
adjustment
Combination Valve Regulator and Modulating Valve
Maxitrol SC Series
2. Set-Up Optional Components
Adjust the settings on the optional components.
Set the discharge temperature Reference the Reference, Control Center Layout
Typical 65°F (18°C) section in this Installation, Operation and Maintenance
Minimum: Typical: 55°F (13°C)
Manual for location of optional components.
Maximum: Typical: 90°F (32°C)
Fig. A • Heating Inlet Air Sensor
Maxitrol Series 14
Typical setting: 60-70ºF (15.56-21.11ºC)
• Cooling Inlet Air Sensor
Maxitrol Series 44
Typical setting: 75ºF (23.89ºC)
The Maxitrol Series 44 temperature selector must be
set to the desired room temperature. The stand-alone • Building Freeze Protection
dial may be mounted remotely. Keep low fire start time Typical setting: 5 minutes; 35ºF (7.22ºC)
(LFST) DIP switch in the “up” position at all times for • Dirty Filter Switch
10 second delay. Typical setting: Settings vary greatly for each unit.
Set the space temperature Reference Start-Up: Optional Features, Other,
Typical: 70ºF (21°C) Dirty Filter Switch section in this Installation,
Operation and Maintenance Manual.
(OPTIONAL)
HEAT
turn the potentiometer to the two proper operation of variable volume units. It functions
extremes. Make sure the fan goes to maintain proper combustion by providing a constant
to maximum and minimum speed. airflow over the burner when outside air volumes are
When the potentiometer is at changed. It is located adjacent to the burner.
minimum, the fan speed will be at its Potentiometer
minimum. When the potentiometer Control
is at maximum, the fan will be at its
maximum speed.
Building Pressure Control EXHAUST
BLOWER
to maximum speed. Set both knobs and approximately 50% of the total airflow will pass
at the lowest setting and the VAV PHOTOHELIC
through the damper. The remaining air will pass over
system should go to minimum speed. the burner. As the supply airflow is reduced, the bypass
Reset the correct pressure limits damper will begin to close. This reduces the amount
before starting the unit. Building Pressure of air passing through the damper and maintains a
Control constant volume of air passing over the burner. At
Typical settings are 0.0 in. wg (0 kPa) for the lower and
80
65
(OPTIONAL)
60
85
55
90
air damper adjusts accordingly. The 0.10 in. wg (0.02 kPa) for the upper pressure setting.
damper actuator may take a few 2-Position The needle in this photo indicates a negative building
minutes to open or close. Damper Control
pressure. During correct operation, the indicating needle
Modulating Options will remain between or near the setting needles.
Potentiometer Control External Signal
A modulating spring return actuator is used to control A modulating spring return actuator is used to control
the return air amounts. The return air damper modulates the return air amounts. Return air damper modulates
from fully open to fully closed from fully open to fully closed based on an external
2-10 VDC or 4-20 mA signal (by others).
BLOWERS
(OPTIONAL)
SUPPLY
potentiometer. HEAT
MAIN VALVES
85
75
90
70
65
60
55
(OPTIONAL)
minutes to open or close.
fully opens and fully closes. When
the potentiometer is at minmum, the
return air damper will open. When
the potentiometer is at maximum,
the return air damper will close. The Potentiometer
damper actuator may take a few Control
minutes to open or close.
Building Pressure Control
A floating point spring return actuator BLOWER
HEAT
85
75
90
70
65
55
60
(OPTIONAL)
3. Fill the Sump and Adjust the Float • T1 timer setting set to 10 and timer scale set to
Turn on the water supply and allow the sump tank to 1d for 1 day of operation
fill. Adjust the float valve to shut-off the water supply • T2 timer setting set to 10 and the timer scale set
when the sump is filled to within 1 inch (2.54 cm) of the to 10m for 10 minutes of drain time
bottom of the overflow.
4. Break-In the Media
Open the ball valve completely and saturate the media
with the fan(s) off for no less than 20 minutes.
Timer
A jumper will need to be installed in the control center Scale T1
to power the evaporative pumps or single pass valves Settings
with the fan(s) off. Reference the unit’s ladder diagram Timer
to determine proper terminals. Settings
T2
5. Put the Unit into Service Settings
Timer
Remove the jumper and energize the fan(s). Verify
Scale
proper operation.
6. Check the Flow Rate
The pumps or water supply should provide enough
water to saturate the media in 45 to 60 seconds with the
fan running. Consult the factory if
Auto Drain and Fill Timer
adequate flow is not achieved.
If too much water is flowing to the Bleed-Off Pump Supply Float
media, the flow can be adjusted Valve Filter Connection Valve
115 VAC between Yes High limit (HLC1) tripped. Reset/replace high limit (HLC1).
No
terminals 104 and 101? Investigate cause of high limit trip.
(Optional) high/low gas pressure switch(es) (PS3 and PS4)
115 VAC between Yes
No tripped. Correct gas pressure and reset. Reference Pre-Start: Direct
terminals 106 and 101?
Gas-Fired Heating, All Units.
Record the flash code from the alarm light. Reference the flame
Is alarm light blinking on the flame No safeguard literature or contact the factory for details about the alarm
Yes flash codes. Investigate the cause of the code.
safeguard (FSG)?
Push the reset button to reset the fault.
Is test/run switch (located on top of Yes
No Move switch to 'Run'.
flame safeguard) in 'Run' mode?
Check wiring in flame safeguard subbase. Correct any wiring
115 VAC between Yes issues.
No
terminals 107 and 101?
Flame safeguard (FSG) faulty. Replace flame safeguard.
Airflow switch (PS2) holding for proper airflow.
115 VAC between Yes
No Correct airflow across burner. Reference Start-Up: Direct Gas-Fired
terminals 108 and 101?
Heating, All Units.
Check wiring in flame safeguard subbase. Correct any wiring
Is the pilot light on the flame safeguard Yes Issues.
No
(FSG) illuminated?
Flame safeguard (FSG) faulty. Replace flame safeguard.
Check wiring in flame safeguard subbase. Correct any wiring
115 VAC between Yes issues.
No
terminals 109 and 101?
Flame safeguard (FSG) faulty. Replace flame safeguard
24 25 10
13 22
11 12
27
26 28
14 19 20
3
18 4
15 1 7 8 6
2 9
21
23
17
16
5
1. Supply Motor Starter — 24 volt magnetic contacts 15. Remote Temperature Selector (optional) —
for starting supply motor. allows for remote temperature set point.
2. Supply Overload — provides electronic overload 16. Heat Relay — allows power to pass to heating
protection to supply motor. controls.
3. Low Voltage Transformer — provides low voltage 17. Heating Terminal Block — provides wiring access
to fan/heat/cooling enable controls. to heating controls.
4. Control Terminal Block — provides wiring access 18. Flame Safeguard/Spark Generator — monitors
to controls. flame, shuts down unit when unsafe conditions are
5. Fan Relay — allows power to pass to energize detected.
motor starter. 19. High Limit — prevents unit from discharging air
6. Exhaust Auxiliary Contact (optional) — provides above a set point.
one normally closed and one normally open 20. Low Voltage Transformer — reduces voltage to
contact for other equipment. Maxitrol system.
7. Supply Auxiliary Contact (optional) — provides 21. Amplifier — controls modulating valve, assures the
one normally closed and one normally open desired temperature is delivered.
contact for other equipment. 22. Transformer (optional) — provides voltage to
8. Exhaust Motor Starter (optional) — 24 volt optional evaporative cooling pump.
magnetic contacts for starting exhaust motor. 23. Cooling Relay (optional) — allows power to pass
9. Exhaust Overload (optional) — provides to cooling controls.
electronic overload protection to exhaust motor. 24. Cooling Terminal Block (optional) — provides
10. Transformer Fuse (optional) — provides proper wiring access to cooling controls.
fusing for cooling transformer. 25. Low Voltage Transformer (optional) — reduces
11. Terminal Block — provides wiring access to high voltage to cooling controls.
voltage circuits. 26. Reset Timer (optional) — resets cooling system to
12. Exhaust Fuses (optional) — provides proper run a time interval.
fusing for exhaust fan motor(s). 27. Auto Drain Relay (optional) — assures supply
13. Dirty Filter Switch (optional) — monitors filter pump does not operate during drain interval. Allows
pressure drop, turns on indicating light when pump to operate in cooling mode.
pressure drop is above field-adjustable set point. 28. Cooling Timer (optional) — allows for automatic
14. Inlet Air Sensor (optional) — outdoor air stat that draining of the evaporative cooling system based
automatically controls the heating and/or cooling on time schedule.
based on outdoor air temperature.
Our Commitment
As a result of our commitment to continuous improvement, Accurex reserves the right to change specifications
without notice.
Specific Accurex product warranties are located on accurex.com within the product area tabs and in the Library
under Warranties.
64 482886 • Direct Gas Make-Up Air, Rev. 1, November 2017 Copyright 2017 © Accurex, LLC