DH Operation and Installation Manual

Transcription

Concepts and Designs Inc.
DH Series - SSCR Rotor
Installation, Operation and Maintenance Manual
Desiccant Dehumidifier Series
Installation, Operation And
Maintenance Manual
PO Box 288 / Owatonna MN 55060
Phone: (507) 451-2198 / Fax: (507) 451-1177
EMail: [email protected]
Web Site:www.cdihvac.com
After Hour Technical Support: (507) 451-2198
1
January 29 2010 Rev8 SGA
2
C o n c e p t s a n d D e s i g n s I n c.
Hazards
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read the
installation, operating and maintenance instructions thoroughly
before installing or servicing this equipment.
FOR YOUR SAFETY
The use and storage of gasoline or other flammable vapors and
liquids in open containers in the vicinity of this appliance is hazardous.
FOR YOUR SAFETY
If you smell gas:
1. Open Windows
2. Don’t touch electrical switches
3. Extinguish any open flames
4. Immediately call your gas supplier
3
This manual shall be placed in a specific location and maintained in legible condition,
with directions on unit as to the location
where the manual is to be stored.
Owners Name:__________________________________________
Address:____________________________________________ Street______________________________________________
City ___________________________________
State ___________________ Zip code _______________
Country __________________
Telephone # : (______)_______________________________
Fax # : (_______)____________________________
Unit Model #________________________________________
Unit Serial # _______________________
4
The Installing Contractor Must Identify all of the emergency shut-off devices.
All wiring will be done in accordance with the National Electrical Code.
A manual shut-off shall be installed on the outside of the unit’s gas vestibule to be used as the
main shut-off of the unit’s gas supply, when local codes require the installation of such a valve.
A minimum 1/8 inch NPT plugged tapping, accessible for test gauge connection, must be
installed immediately upstream of the gas supply connection to the unit.
In Case of Emergency:
1.
Close main manual gas supply valve.
2. Shut off main disconnect.
When shutting down unit for extended periods of time we recommend that the following be done:
1. Shut off main disconnect.
2. Close main manual gas supply valve to prevent the leaking of gas into the combustion chamber.
3. Cover reactivation air outlet.
When restarting the unit after long periods of shut down the following should be
done:
1. Check the unit for general cleanliness; any debris small or large has been removed
and the unit is clean.
2. Make sure all wire terminals and connections been checked for tightness.
3. Check the supply air outlet, and the blower inlets have been checked and are free
from any obstructions.
4. Remove cover from reactivation air outlet.
5. Check blowers to make sure the shaft rotates freely, sheaves are aligned, sheaves,
blowers, and motor bolts or set screws checked for tightness.
6. Make sure all damper linkages are free to move, no binding will occur.
7. Open main manual gas supply valve and check for leaks.
8. Turn on main disconnect.
5
Table of Contents
Hazards.....................................................3
18. Heating Applications......................... 21
Contractor Information............................4-5
19. Electrical Parts and Options.......21-23
Generic Unit Drawing................................ 8
Carel Controller Information
Installation
1.0 Locating The Unit ............................. 9
Start Up
2.0 Clearance...........................................9
20. Special Tools Required..................... 30
3.0 Curbs................................................10
21. P
recautions Before Attempting Startup
Of The Desiccant DH..................30-31
4.0 Handling The Equipment.................. 11
peration of the basic pCO3
O
Carel Controller...........................24-29
22. Start Up.......................................31-33
5.0 Preparing Unit For Installation.......... 12
MR212 Modulation Adjustment..33-34
6.0 Assembling The Unit........................ 12
M611 Modulation Adjustment.......... 34
7.0 Check For Tightness........................ 12
23. Typical Sequence Of Operation..34-40
8.0 Location Of Accessories................... 12
Reactivation Rate Control (RCC).... 35
9.0 Electrical Connections...................... 13
Reactivation Rate Control with Face
& Bypass..........................................36
10. Gas Piping . ..................................... 13
11. Coil Piping...................................13-17
Heating Cooling And Face & Bypass
Control (HCFB)................................. 37
12. Coil Maintenance............................. 17
Make Up Air Control (MDH).............. 38
13. Condensate Drain.......................17-18
Make Up Air Control (MDH-CTR)..... 39
14. Duct Connections............................. 19
24. S
hutting Down Unit For Extended
Periods Of Time............................... 40
Control Overview
15. Make-Up Air Applications................. 19
25.
26.
16. Return Air Applications................19-20
17. Unit Shut Down Results From:......... 20
6
estarting Unit After Extended Shut
R
Down................................................40
hutting Down The Burner In An
S
Emergency....................................... 40
Table of Contents Cont.
Rotor and Cassette Technical Infor- 42. Safety
mation
Handling SGA Rotor And
Cassettes.........................................55
27. General Rotor Do’s And Don’ts........ 42
Maintenance Schedule
28. C
haracteristics of Silica Gel Desiccant
Media...............................................43
43. Maintenance Schedule................56-58
29. C
haracteristics of SSCR Desiccant
Media...............................................44
44. Door Gasket Replacement..........59-60
30. C
hemical Compounds That May Dam-.
age SSCR Silica Gel Honeycomb
Rotor................................................44
Warranty and Parts Information
31. Principle Of Operation...................... 45
General Warranty............................. 61
32. DH Rotors & Cassettes
Warranty Claims............................... 62
Replacement Parts........................... 62
Specifications..............................45-46
33. Operation
Troubleshooting Section
Rotor Section................................... 63
Drive System Operation................... 47
eneral Unit Shut Down
G
Problems.....................................64-65
Reactivation Section...................66-71
Process - Supply Section............72-73
Fault Lights..................................74-79
Measurement Of Performance......... 47
Maintenance Of The Rotor
34. Rotor Cleaning................................. 48
35. R
otor Core Samples......................... 49
36. Desiccant Rotor Repair.................... 50
Maintenance Log & Notes
37. Rotor Removal & Replacement...51-52
38. Seal Replacement............................ 52
39. Drive System Parts Replacement.... 52
40. Rotor Alignment Inspection.........52-54
41. Limited Rotor Warranty...............54-55
7
Maintenance Log.........................80-81
Notes...........................................82-83
Unit above showing top view with some available options installed
Unit below is a side view of a unit with some available options installed
8
Installation
are to be supported around the perimeter and
The following recommendations are not across any shipping split. Be sure to verify that
intended to supplant any requirements of support structure dimensions coincide with the
federal, state, or local codes having juris- unit dimensions.
diction.
Be sure to locate the unit so that any unit air
This equipment shall be installed and wired in intakes are remote from any building exhaust
accordance with regulations of the National fan outlets, gasoline storage facilities, or any
Boards of Fire Underwriters, National Electric other contaminants that could potentially
Code, and any other local governing bodies. cause dangerous situations. The use and
In Canada, equipment should be installed storage of gasoline or other flammable vapors
in accordance with the applicable provincial and liquids in the vicinity of this unit is very
regulations. Furthermore, this document does hazardous.
not exempt the installer, designer, or user of
this equipment from its correct application, On the direct fired gas reactivation DH series
nor from the safe and correct operation of this dehumidifier the gas is burning directly into the
unit(s) and any required ancillary systems; reactivation air stream being heated, thereincluding but not limited to, precooling, pre- fore anything passing across the burner may
heating, steam, post cooling and post-heating be combusted. If this type DH series unit is
equipment, duct distribution, vapor barriers, used in a hazardous environment, insure that
contaminants cannot enter the unit intake(s).
controls, etc.
1.0 LOCATING THE UNIT
2.0 CLEARANCE
Prior to locating the unit, authorities that have
jurisdiction should be consulted before installations are made.
For horizontally vented units the distances
from adjacent public walkways, adjacent
buildings, windows that can be opened, and
building openings, shall conform with the local codes.
Except where required for service access or
venting, DH series units may be installed on
top of combustibles with 0” of clearance. A
minimum of 6” clearance on other sides and
top is to be provided.
The Concepts and Designs Inc. DH unit must
be installed LEVEL and located so that there
is enough clearance for opening the access
doors or service clearances (See unit drawing
for clearances). In addition to allowing room
for access door swing and service clearances,
NEC or other governing agencies may require
a minimum 42” or more of clearance in front
of the electrical panel or vestibule. Refer to
the submittal documents for proper air flow
direction through the unit so that it may be
positioned to accommodate necessary ductwork. Also note from the submittal where approximate electrical and gas hookup points are
located so that the proper connections can be
made. Remember to verify position and ability of support beams, pad, or curb to properly
support the unit. At a minimum all DH units
When located on a roof, the unit intakes need
to be a minimum of 14” above the roof to
prevent the intake of snow or splashed rain.
The unit should be located if at all possible so
that the prevailing winds do not blow into the
unit inlet. The optional fresh air inlet hood (if
supplied) is not designed for extreme weather
conditions. If the application is critical, other
provisions must be made to protect the unit
inlet from driving winds.
9
3.0 CURBS
Under structure beam spacing should also
be checked to preclude any interference with
air ducts.
When units are installed on rooftop curbs,
there must be a gasket between the top of
the curb and the base surface of the unit to
prevent moisture from leaking into the building from either driving rains or melting snow.
When Concepts and Designs provides curbs,
gasketing will also be provided and shipped
with the unit.
Curb Dimensions
A=Length of unit minus 1 1/2”
B=Width of unit minus 1 1/2”
B
UNDER
STRUCTURE
BEAM
A
WOOD NAILER
5/8" TYP CLEARANCE
UNIT BASE
BEAD OF CAULK
WOOD NAILER BY CDI
WEATHERSTRIPING
INSULATION AND
CANT BY OTHERS
10
4.0 HANDLING THE EQUIPMENT
The CDI unit is designed for handling by two
methods. In both cases it is lifted from the
bottom base in a fashion that holds it level
and keeps it from tipping, falling or twisting.
If the unit is severely twisted during handling,
permanent damage may occur. The unit is not
to be lifted from the top unless the optional
top lifting or suspension package has been
provided. It is the installer’s responsibility
to verify the handling equipment’s ability to
safely handle the equipment.
The preferred method of handling is from the
unit’s channel base frame where special lifting
lug brackets are installed on the unit, see the
Figure to the bottom right of this page for an
example of units with only four lifting lugs; see
the Figure to the top left of this page for an
example of units with six lifting lugs and see
the Figure at the bottom left of this page for
an example of units with eight lifting lugs. All
lifting operations must be accomplished with
a load spreader of sufficient width to insure
that the lifting cables clear the side of the
unit to prevent any damage to the unit. If this
type of spreader is not available, wood strips
should be inserted between the cables and
unit where necessary.
The alternative method of lifting would be
by forklift (but not recommended unless
necessary), provided that the forks extend
completely underneath the unit and reach
the unit base frame on the opposite side.
Forks which do not reach to the other side
of the unit could cause it to tip resulting in
unsafe conditions or damage to the unit.
All lifting points must be used and will be
marked “LIFT HERE” on the unit.
11
5.0 PREPARING UNIT FOR INSTAL- 7.0 CHECK FOR TIGHTNESS
LATION
During transit, unloading, and setting of the
When inspecting the unit before installation be unit, some of the bolts, nuts and screws may
sure to look for any shipping brackets or other have become loosened. Particularly in pillow
packaging that should be removed prior to block ball bearing assemblies on blower secassembling the unit. It is the installers respon- tions. It is required that all bolts, nuts and set
sibility to remove any protective coverings and screws be checked and tightened as required.
shipping supports. All such items should be Be sure to turn all blower fan shafts by hand
to make certain that no interference or rubbing
removed prior to unit startup.
occurs. Also, insure that bearing lock rings and
or set screws are tight.
6.0 ASSEMBLING THE UNIT
All sections or parts that are not shipped attached to the basic unit must be installed at
the job site, using the assembly hardware
provided with the unit. The determination of
the general arrangement of the assembly can
be made by referencing the unit-specific drawings. For the location of the mounting hardware, caulk, foam tape, etc. see the packing
list (the packing list sheet is usually located
attached to the door with the following tag attached on the out side in the upper corner).
Open the door/cover on the electrical control
box of the unit. This box can be opened by
turning the main fused
disconnect switch to the
“off’ position (disconnect
switch is optional on
some units). Be sure to
inspect all of the wire
terminals and wiring
terminations to ensure
that connections are
tight prior to startup of
the unit.
8.0 LOCATION OF ACCESSORIES
All field assembled sections must be sealed
with water proof gasketing at the assembly
joint. This gasketing must be placed directly
onto the face of the joint to be bolted together
in order to form a tightly sealed joint. Some
of this gasketing material may squeeze out of
the joint as it is pulled together. This excess
should be trimmed off. The assembly joint
should then be trimmed with regular silicone
caulk to improve appearance of the unit and
to prevent any water leakage into the unit.
CDI provides the required gasketing with the
unit. Caulk will also be supplied, if required,
to provide proper sealing or if specifically requested for cosmetic purposes. See packing
list for location of caulk and gasketing.
Optional remote control panel and/or room
stat(s) as required can be found by checking
the Ship Loose Packing list as to where they
are located in the unit at the time of shipment
and these items must be removed and installed by the electrical contractor. (Refer to
unit electrical drawings for terminations) The
following is a basic recommendation as to how
to install the remote components.
A) Align the box with a spirit level.
B) Examine wiring box and control panel for
clearance before providing any conduit
hole(s).
C) All wiring must comply with applicable
electric codes.
12
9.0 ELECTRICAL CONNECTIONS
separate conduit form power or line voltage—
See electrical schematic located on electrical
A complete wiring diagram of the equipment panel door or in the O&M manual.
is included on the electrical panel door and in
the O&M manual.
10. GAS PIPING
All wiring will be done in accordance with the
National Electrical Code.
The unit must be electrically grounded in accordance with local codes.
All wiring must comply with all applicable local,
provincial, and national electric codes. Visually inspect all nameplates, control voltage
wiring, control transformer, and main fused
disconnect switch on the unit prior to running
power to the unit. Cross check voltage with
unit drawing to insure that the voltage option
ordered is the voltage received.
A manual shut-off (supplied by others) shall
be installed on the outside of the unit’s gas
vestibule to be used as the main shut-off of
the unit’s gas supply, or as how local codes
require the installation of such a valve.
A minimum 1/8 inch NPT plugged tapping,
accessible for test gauge connection, must
be installed immediately upstream of the gas
supply connection to the unit.
All the different gas piping configurations are
not shown in this manual because of the many
manifold arrangements that are available for
various building code and insurance company
requirements, and types of gas modulation.
Complete all wiring to any optional acces- Gas piping must comply with “Standards of
sories as shown on electrical wiring diagram National Board of Fire Underwriters” and all
before applying voltage to the unit. An optional applicable local codes and insurance comwiring junction box may be provided at the pany requirements. Contact the CDI factory
shipping split if the unit is large enough to be for exact gas piping dimensions, if required.
shipped in pieces. All wiring not attached at Gas pipes are taped off at the factory before
the time of shipment will be numbered to aid shipment. Be sure to run correctly sized gas
in the reattachment of the wires.
line to unit (same size or larger than that used
on the unit). Install a manual shut off valve and
Be sure to reconnect the numbered a reducing regulator if required. A 1/4 inch NPT
wires to the numbered terminals in pressure tap upstream of the unit regulator is
recommended.
electrical cabinet.
Comply with the unit nameplate data when
sizing fusing and the main power wiring to
the unit.
Check the supply voltage to the unit before energizing or turning on the main disconnect for
the unit. Maximum variation in voltage should
not exceed +/-10%. Phase voltage imbalance
must not exceed 2%. Use proper wire sizing
practices when running wires for the remote
control panel and controls.
NOTE: Gas line pressure must be
as shown on unit name plate
when unit is operating at full
Input.
On Indoor Units be sure to vent the pressure
regulators, any vent valves and vent lines to
outside of building. With vent pipe outside,
install a proper vent cap and/or screen to
prevent entrance of foreign material to prevent
plugging.
Some controls may require shielded cable and
13
solutions or brines are the only freeze-safe
media for operation of water coils for low
entering air conditions.
11. COIL PIPING
When optional coils are provided, insure that
distribution piping is of adequate size, and that
required specialties if required, such as three- 5. Two position control valves, modulating
valves, three way valves or a combination
way valves, vent and drain valves and traps
of these controls can accomplish control
are correctly installed, and that actuators and
of water coils. Follow the recommendavalves (if provided) are mounted and wired.
tions of the control manufacturer regarding
types, sizing and locations.
Note: Always use a back up wrench on the
coil connections when attaching the
piping to the coil if pipe thread con- Note: Vent and Drain connections are provided on water coils when specified.
nections are utilized.
This allows the coils to be drained.
Keep in mind that when draining the
coils, all water may not drain from the
coil. In order to completely drain the
coil to prevent the possibility of freezing
during cold ambient temperatures, air
or nitrogen pressure must be utilized to
blow any remaining water from the coil.
Water Coil Installation Recommendations: Steam Coil Installation Recommendations:
1. Piping should be in accordance with ac- A. General
cepted industry standards. Always use a
back up wrench on the coil connections 1. Always use a back up wrench on coil connections when attaching piping to the coil.
when attaching the piping to the coil if pipe
thread connections are utilized.
2. Be certain that adequate piping flexibility
is provided. Stresses resulting from ex2. Connect the water supply to the bottom
pansion of closely coupled piping and coil
connection on the air leaving side and the
arrangement can cause serious damage.
water return to the top connection on the
air entering side.
3. Do not reduce pipe size at the coil return
connection. Carry the return connection
3. When four connections are provided the
size through the dirt pocket, making the
extra bottom connection can be used for
reduction at the branch leading to the trap.
an auxiliary manual drain connection, and
the extra top connection can be used for
an automatic air vent or the extra con- 4. Vacuum breakers and air vents must be installed on all applications to prevent retainnections can be capped. Connecting the
ing condensate or air in the coil. Generally
supply and/or return in any other manner
the vacuum breaker is to be connected
will result in very poor performance.
between the coil inlet and the trap. For
a system with a flooded return main, the
4. Water coils without glycol added are not
vacuum breaker should be open to the
normally recommended for use with enteratmosphere and the trap design should
ing air temperatures below 40°F. Glycol
allow venting of large quantities of air.
14
5. Do not drip steam mains through coils.
minimum. General recommendations for
component selection and line sizing follow. Nitrogen charged and capped piping
is recommended.
6. Insure steam pressure and condensate
line pressure differential is sufficient to allow efficient condensate removal from the
steam coil, especially when using modu- A. Liquid Line Sizing
lating steam control valves to control the
leaving air temperature of the coil.
1. All compressors have a Refrigerant
Charge Limit [RCL] that must not be ex7. Do not attempt to lift condensate without
ceeded. Since the RCL and pressure drop
the assistance of a condensate pump. The
are in direct conflict with each other, CDI
pressure required to lift condensate must
recommends that the liquid line be sized
also be considered for sufficient pressure
as small as possible, while maintaining a
differential.
low enough pressure drop to ensure 5°F of
sub-cooling at the expansion valve.
Check valves are also required to prevent reverse flow of condensate back into the coil. B. Liquid Line Components
8. Entering air temperatures should not be 1. CDI recommends the use of a properly
sized liquid line filter-drier, installed upbelow 40° F to insure freezing doesn’t ocstream from the expansion valve and as
cur unless steam is always applied to the
close to the evaporator coil as possible. coil to prevent freezing.
Filter-drier selection should be based on
a maximum pressure drop of 2 psi at the
B. Traps
design condition.
1. Size traps in accordance with the manufacturer’s recommendations. Be certain 2. A moisture indicator / sight glass should be
installed between the expansion valve and
that the required pressure differential will
filter-drier. The moisture indicator / sight
always be available. Do not undersize.
glass must be sized to match the size of the
liquid line at the thermal expansion valve.
DX Coil Installation Recommendations:
1. DX coils sold in units built by CDI are 3. A liquid line shut-off valve with an access
port should be sized with the selected
shipped with a small nitrogen holding
liquid line OD, and installed close to the
charge. Care should be taken when opencondenser,
ing these coils for installation. DX coil
distributors have caps installed with soft
silver solder. Once the cap is removed 4. The use of other valves, tube bends and
reducers should be minimized, since these
and if the TEV is to be installed using anyitems tend to increase pressure drop and to
thing other than soft solder, the distributor
reduce sub-cooling at the expansion valve.
connection should be sufficiently cleaned
with emery cloth to remove the soft solder.
Follow accepted refrigeration piping prac- 5. The Thermal Expansion Valve [TEV] must
be selected for proper size, capacity and
tices and safety precautions per ASHRAE
refrigerant being used. A slightly oversized
Standards. If bends or 90’s are necessary,
valve will allow the unit to operate satisfaclong radius fittings must be used to keep
torily at low-load conditions. An undersized
the pressure drop through the piping at a
15
valve should not be used at any time as D. Suction Line Components:
this will starve the evaporator of refrigerant
causing insufficient air temperatures. The 1. A suction line pressure tap should be inuse of a hot gas bypass valve should also
stalled on the leaving side of the evaporabe considered when sizing the TEV. Select
tor coil near the TEV sensing bulb location.
expansion valves with external equalizer
Accurate superheat measurement and
connections, and those designed to operTEV adjustment demands that suction
ate against a backpressure of 20 pounds
pressure and temperature be measured
per square inch higher than actual evaponear the evaporator coil outlet.
rator pressure.
2. Suction line filter-driers are usually only nec6. The TEV must be installed directly on the
essary on systems that have experienced a
evaporator coil liquid line connection prosevere compressor motor burn out or other
vided. The liquid distributor must be in a
failure that results in extremely high refrigvertical position. Insure that the distribuerant temperature. This filter-drier should
tor nozzle is installed in the distributor if
not be left in the suction line permanently.
required and that the correct nozzle for
the refrigerant being used is installed. 3. Suction lines should be insulated completely
Sensing bulbs must be mounted on a
with sufficient wall thickness insulation for
clean horizontal suction line close to the
the application temperature range being
evaporator outlet and insulated properly.
utilized.
The bulb must be tight against the suction
line at a 10 or 2 o’clock position, but take Installation Checklist:
care not to over tighten and cause damage to the sensing bulb. The bulb should Use the following checklist to verify that all
not be mounted directly on top or bottom necessary installation procedures have been
of the suction line.
completed. CAUTION: Disassemble the thermal expan- 1. Coils are installed with airflow in same dision valve before completing the brazing conrection as indicated on the coil nameplate
nections. If necessary, wrap the valve in a cool
or casing.
wet cloth while brazing. Failure to protect the
valve from high temperatures may result in 2. Suction connection is at the bottom of
damage to the internal components.
the suction header on the evaporator coil,
suction line is pitched towards compressor
C. Suction Line Sizing:
and traps are installed in suction risers.
Suction line is insulated with correct wall
1. Suction line tubes must be sized to mainthickness insulation for the temperature
tain refrigerant vapor velocities that are
application utilized.
high enough to ensure good oil return to
the compressor under all operating condi- 3. Condensate drain pans and piping is intions. It is necessary to pitch horizontal
stalled with a trap in the condensate line
suction lines toward the compressor to inand piping insulated and heated if installed
sure sufficient oil return to the compressor.
in applications that are below freezing.
Traps should be provided at the bottom of
suction line risers and at 15 foot intervals 4. Clean filters are installed upstream of the
for sufficient oil return.
condenser coil when applicable.
16
5. A liquid line filter-drier is installed upstream
of the expansion valve.
2. Remove large debris from the coils and
straighten fins before cleaning.
6. A moisture indicator/sight glass is installed between the expansion valve and
filter-drier.
3. Clean refrigerant coils with cold water and
detergent or with one of the commercially
available chemical coil cleaners. Rinse
coils thoroughly after cleaning.
7. A liquid line shut off valve with access port
is installed close to the condenser.
CAUTION: Do not clean the coil with hot water
or steam. The use of hot water or steam as a
8. A schrader valve is installed in the suction refrigerant coil-cleaning agent will cause high
line close to the evaporator coil outlet.
pressure inside the coil tubing and subsequent
damage to the coil.
9. The TEV, with external equalizer connections, is installed directly on the evaporator CAUTION: Do not use acidic chemical coil
liquid connection, sensing bulb mounted in cleaners. Do not use alkaline chemical coil
the horizontal position on the suction line cleaners that, after mixing, have a ph value
and insulated. The liquid distributor must greater than 8.5 without also using an aluminum corrosion inhibitor in the cleaning
be in a vertical position.
solution. Failure to follow these guidelines
10. Piping system is leak-tested with dry or the manufacturer’s instructions for use
nitrogen, evacuated to 500 microns, and of cleaning chemicals could result in damcharged with correct refrigerant type and age to the unit.
amount.
Fin Straightening:
11. Superheat and sub cooling measurements
are taken. Thermal expansion valve is ad- 1. Coil fins may have been bent during shipping or servicing, should be straightened
justed to obtain desired superheat. Desired
to maintain maximum heat transfer. Reducsuperheat on most applications is 8° to 12°
tion of the effective coil surface will corat the outlet of the evaporator.
respondingly reduce coil capacity. Always
check fin appearance after any handling
12. COIL MAINTENANCE:
of the coil and after any servicing is done
near the coils.
Coil Cleaning:
1. Coils should be kept clean to maintain 2. Fin combs are sized according to number
of fins per inch of the coil. For relatively
maximum performance. For operation
small bends that require only minor repair,
at it’s highest efficiency, the coil should
other tools may be used to evenly space
be cleaned often during periods of high
the fins. Be careful not to damage the coils.
cooling demand or when dirty conditions
prevail. Power should be disconnected and
locked out and motors should be covered 13. CONDENSATE DRAIN CONNECTION
to insure that no moisture penetrates into
the windings causing motor failure if apAll unit drains require pressure traps in order
plicable.
to prevent tramp air from entering or exiting
the unit. Minimum vertical dimension of each
trap must be calculated from the submittal
17
documents. Traps associated with latent (wet)
coils should be filled with water prior to unit
startup. Traps associated with sensible only
(dry) coils may be filled with mineral oil to
prevent evaporation, and maintain the seal.
If then unit has a condensate pan, such as
under a cooling coil, the unit will be provided
with a male NPT condensate drain connection. Refer to unit drawings for the exact location. The unit and drain pan must be level
side to side and a P-trap must be installed for
proper drainage.
CDI units may have positive or negative pressure sections. It is recommended that the
traps be used in both cases with care given to
the negative pressure sections. Dimension A
should be a minimum of 8”. As a conservative
measure to prevent the cabinet static pressure
from blowing or drawing the water out of the
trap and causing air leakage, dimension A
should be two times the maximum static pressure encountered in the coil section in inches
of W.C. Drainage of condensate directly onto the roof
may be acceptable; refer to local codes. It is
recommended that a small drip pad of either
stone, mortar, wood or metal be provided to
protect the roof against possible damage.
If condensate is to be piped into the building
drainage system, the drain line should be
pitched away from the unit at a minimum of
1/8” per foot. The drain line must penetrate
the roof external to the unit. Refer to local
codes for additional requirements. Sealed
drain lines require venting to assure proper
condensate flow.
Where the coils have intermediate condensate
pans on the face of the evaporator coil, PVC
tubes on the end of the intermediate pan provides drainage into the main drain pan.
Because drain pans in any air conditioning
unit will have some moisture in them, algae,
etc. will grow. Periodic cleaning is necessary
to prevent this buildup from plugging the drain
and causing the drain pan to overflow. Also,
the drain pans should be kept clean to prevent
the spread of disease. Only qualified personnel should perform cleaning.
18
14 . DUCT CONNECTION(S)
or outlets. Caulk the mating surfaces
to make the connection water tight.
Connect supply and return ducts as
specified in the submittal documents.
Insure that duct opening(s) to building
is adequately flashed and sealed to
prevent moisture leakage.
A) Indoor Units
1) Lifting lugs may serve as suspension
points on all indoor style units. (Customer should provide service platforms
for suspended units unless unit was
ordered with optional service platform.)
12) The optional snow proof inlet hood
(See Figure below) may require additional support in certain wind loading
conditions or hood designs. Provide adequate support from building structure
taking care not to reduce the weather
integrity of the building or intake hood.
2) Make required fresh air opening(s)
in wall and line with an angle frame.
Inside should be completed before outside is started to avoid any crumbling
of penetrated wall.
3) Utilize an insulated fresh air collar
through the opening with flanges
turned out to provide rigidity.
4) Anchor intake hood with bird screen (if
supplied) to outside of wall.
5) Caulk perimeter of opening to make
connection water tight.
6) Reactivation ducts require external
insulation because of the potential for
condensation.
7) Pitch reactivation discharge duct down
away from the DH unit, and toward the
building exterior.
Control Overview
15. MAKEUP AIR APPLICATIONS
8) Avoid traps in reactivation discharge
duct! Provide low point drains if necessary.
Refer to submittal documents for specific information about any preconditioning equipment,
such as enthalpy recovery devices, precooling
coils, mixing boxes, etc.
9) Avoid locating reactivation discharge
near fresh air intakes.
16. RETURN AIR APPLICATIONS
10) Seal all ductwork to prevent moisture
infiltration.
B) Outdoor Units
Standard DH equipment runs in response to
a space humidistat only. Limited outside air
quantities may be introduced through optional
fresh air damper when unit is running in response to room humidistat.
11) Fasten weather-hoods to any air inlets
19
With power applied, and the main disconnect
switch closed;
tem. This is a microprocessor based electronic
system providing rapid response to rotor inlet
air temperature and discharge air temperature.
On call for dehumidification (Humidistat, or It is intended to protect the desiccant rotor
unit “manual” switch): process and reactiva- from excessively high temperatures, provide
tion fan motor starters are energized through full dehumidification capacity, even on cool
(optional) normally closed return air smoke days, and allow for economical operation durdetector contacts.
ing moderately humid days.
Units with optional Modulating Face and Bypass humidity control dampers are energized
via an end switch on the damper actuator.
Process fan operates continuously when
enabled by remote panel switch. Humidity is
controlled through variable desiccant rotor and
bypass air flows.
The system consists of a microprocessor controller, an electronic modulating valve, signal
conditioner, rotor inlet temperature sensor
and discharge temperature sensor. Gas flow
is modulated by the modulating valve based
on a signal from the controller, through the
signal conditioner. Rotor inlet temperature is
maintained at a pre-programmed value until
Desiccant rotor drive starts.
the discharge sensor, via a rising discharge
temperature, indicates a reduced humidity
Roller switch, LS-08 (on rotor perimeter), re- load. During part-load situations, the inlet temsets time delay relay RE-04 on every rotation, perature is reset down in order to economize
in order to verify desiccant rotor rotation. If on energy use.
rotation is not detected, unit shut down occurs. Reset by pressing the reset button on When the humidity control (humidistat) is satiselectrical control door.
fied, unit process fan and reactivation burner
cycle off. The reactivation fan, and desiccant
Reactivation air proving switch and reactiva- drive continue to operate for two minutes in
tion fan motor starter auxiliary contacts prove order to cool the desiccant rotor and related
airflow and energize reactivation burner con- components.
troller.
Burner initiates pilot trial for ignition after
7-second purge period.
The flame safety relay senses pilot flame and
energizes main gas valve and modulation
circuit.
17. UNIT SHUT DOWN CAN RESULT
FROM:
A) Burner flame failure/failure to ignite.
B) High reactivation air temperature.
C) Loss of supply air flow.
Burner fires to maintain specified reactivation
inlet and discharge air temperatures pro- D) Process or reactivation motor overload.
grammed into the reactivation temperature
controller. Burner high temperature limit in hot E) Loss of desiccant rotor rotation.
plenum de-energizes burner in the event of an
overheat condition.
F) Smoke in the process air stream. (Optional smoke alarm)
Reactivation firing rate is continuously controlled by a dedicated firing rate control sys- G) Humidistat satisfied.
20
18. HEATING APPLICATIONS
Refer to submittal documents for specific information about post-heating devices, such as
direct, or indirect heating equipment, steam or
hot water coils, etc.
19. ELECTRICAL PARTS AND
OPTIONS
FREEZE PROTECTION
A vacuum switch sets to de-energize the
reactivation burner when the filters become
dirty. Operating the unit in this condition would
result in improper combustion. The design of
the clogged filter switch incorporates a sensitive diaphragm, single pole double throw snap
action electrical switch, visible on-off indicator in a compact die-cast aluminum housing.
Spring adjustable switches have dual scales
calibrated in millimeters and inches of water
column mounted in front and easily visible. AIRFLOW SWITCH
There are many circumstances which could
prevent the burner from lighting. Should a
malfunction or trip of a safety or operating
control prevent burner operation, intemperate air may be discharged into the heated
area. Freeze protection consists of a freeze
thermostat with a startup bypass timer and
will prevent intemperate air to be discharged
into the area being heated. Freeze protection
is actually for building protection only and is
recommended whenever a makeup air unit
will be operating unattended for any period of
time. All Concepts and Designs Make‑Up Air
Units are provided, as standard, with a flame
failure lockout relay. This relay de‑energizes
the unit whenever a flame failure occurs that
can be detected by the flame rod or optional
UV detector.
A vacuum
switch
sets to de-energize the burner whenever the
airflow across the burner falls below the set
point of the airflow switch. The airflow switch
is also used as a proving switch that will let a
system controller know when there is enough
airflow to begin any other operation required
by the unit or just to prove that there is airflow
in the unit.
HIGH/LOW GAS PRESSURE SWITCHES
CLOGGED FILTER SWITCH
The gas pressure switches monitors gas pressure and shuts the unit off when the pressure
drops below or rises above the desired preset
point. The position of the yellow ring, on the
reset button, shows whether the reset button
is on or off. If the yellow ring on the button is
below the cover, the unit is on. If the yellow ring
21
is above the cover, the unit is off. The yellow
ring must be below the cover after latching to
be properly set.
any comfort or control level. The humidistat
controls the unit through an ON/OFF contact.
REMOTE TEMPERATURE /
HUMIDITY TRANSMITTER
SMOKE DETECTOR
Duct Smoke Detectors provide early detection of smoke and products of combustion
present in air moving through an HVAC
duct. These devices are designed for prevention of smoke recirculation in areas by
the air handling systems. Fans, blowers,
and complete systems may be shut down in
the event of smoke detection. The detector
offers a universal voltage input compatibility
on any one of four input voltages. Air sampling is accomplished by two tubes which
protrude into the duct.
The remote temperature humidity transmitter
lets you enjoy the comfort that comes with a
more precise regulation of your indoor environment. The transmitter lets you monitor and
control both the temperature and the humidity
levels in your facility. With a versatile operating
range to control the % of humidity and the temperature, the unit accommodates any comfort
or control level. This transmitter comes in both
a wall mount and a duct mount model.
DELUXE REMOTE CONTROL BOX
REMOTE ON/OFF HUMIDISTAT
The remote humidistat lets you enjoy the
comfort that comes with precise regulation of
your indoor environment. The humidistat lets
you monitor and control humidity levels in your
facility. With a versatile operating range to control the % of humidity, the unit accommodates
The Deluxe remote unit features a backlit
graphic display that is designed for the user
friendliness of controlling the unit from a remote location. The Deluxe remote also has a
Manual/OFF/AUTO switch with display lights
for faults and correct operation of the unit. This
22
remote unit allows the customer to easily see
what the unit is doing and they are also able
to see and change what the set points are
for the unit’s temperature and humidity levels
from this remote display rather than having
to go up to the unit to make any changes.
REMOTE CONTROL BOX
and they are able to see and change what
the set points are for the unit from this remote
display rather than having to go up to the unit
to make any changes.
ANNUNCIATOR PANEL
(See Picture Below)
The annunciator panel is a series of lights and
a bar graph mounted onto the unit or remote
panel which enables a service man to both
monitor the operation of the unit and assist in
tracing down a component failure.
The remote unit features a 120 x 32 backlit
graphic display and 6 backlit buttons that is
designed for the user friendliness of controlling
the unit from a remote location. It is available
in a wall or panel mounting version, which
promotes a consistent look and feel for multiple applications. This remote unit allows the
customer to easily see what the unit is doing
23
Operation of the Basic pCO3 Carel Controller
This is the program on a basic DH unit; Your program may be similar to this one or may be a custom
program that will have some different screens and features.
1. When you first power up the controller
you will first see this on the screen.
3. After the unit has completed the self-test, it
will change to the following screen.
Supply Fan:On
DH Status:Drying
******HH:MM:SS******
Concepts and Designs
Loading....
2. Then it will change over to this self-test 4. The Above screen shows the status of the
mode.
Supply fan (if it is ON of OFF), what the DH
Status is (Off or Drying mode) and the time
of day read in Military time (24hr clock).
##################
selftest
please wait
##################
5. The Escape button on the controller will take you back to the beginning
screen if you push it.
24
6. By using the up
and down
arrow buttons you can scroll through the
menu screens on the controller.
9. If you arrow down
once again it will
take you to the screen below showing what
the humidity transmitter is reading only if
using a transmitter input.
Humidity:000.0
once it will
take you to the screen below showing
what the controller is seeing for the Reactivation Heated to temperature is trying
to achieve, the actual RIT (reactivation
inlet temperature) reading. The actual
ROT (reactivation outlet temperature)
reading, and the percent of output to the
modulating controller for heating the rotor
(example; 10%=1VDC, 50%=5VDC and
once again it will
100%=10VDC).
take you to the screen below showing what
the Analog Humidity setpoint is for internal
Reac SetPt: 285.0º
and also if there is an external source. This
one is active on Internal Setpoint value
RIT: 284.0º
(runs on an on off signal)
Valid Only if Using
Transmitter Input
ROT: 125.0º
Reac Ht Rate: 050.0%
Analog Humidity SP
Internal SP: 050.0
External SP: 000.0
Active SP: Internal
once again it
will take you to the screen below showing
what type of input the controller is looking
for to Call for Dehumidification.
Dehumidification
On Command:
once again it will
take you to the screen below showing if the
Unit Run switch is turned on and if the unit
is calling for DH mode.
Unit Run Enable:ON
Call For DH:ON
On/Off Via ID2 Stat
25
once again it will 15. If you arrow down
once again it will
take you to the screen below showing; If
take you to the screen below displaying the
the reactivation fan is On or Off. If the ReRotor and Supply Fan run time for this unit.
activation Energy (voltage to the Heater) is
activated. If the Rotation Switch has been
energized (this will come on once every
rotation of the rotor as it passes the cam
or magnetic sensor. And if the DH Rotor
Purge is enabled.
Rotor Run Time
000000 Hours
Supply Fan Run Time
000000 Hours
React Fan Status:ON
React Energy:ON
Rotation Switch:OFF
DH Rotor Purge:OFF
once again it will
take you to the screen below displaying the
program and rev information and a number
to call if you need help.
once again it will
take you to the screen below showing What
the output the Face and Bypass Damper
is if the unit has one installed.
Concepts and Designs
10800244 Rev1
For Help Call:
507-451-2198
Optional
Face/Bypass
Rotor Face Damper
000% open
once again it
once again it will 17. If you arrow down
will
take
you
to
back
to
the
first screen
take you to the screen below displaying
(see #3).
the information that is used for a steam
unit only.
Steam Units only
18. The Alarm button
when the unit is in alarm.
ROT: 140.0º
Stm Ht Rate: 000.0%
26
will light up red
19. To view the alarms;
a. Push the Alarm Bell button
****************************
External Fault
****************************
and
then scroll using the up
and
down arrow buttons to view all
the alarms before resetting.
21. Press the down
arrow again to
see if there are any more faults, if there
is, you will see what that fault is and can
****** Alarms ******
Press Enter to
Reset All Alarms
Arrow to View Alarms
arrow down
are any more.
again to see if there
Below are a few more of the faults that you
may see:
b. Next, press the Enter button
if you want to reset all of the alarms
before viewing them.
c. If you press the Enter button before pushing the up
****************************
External Fault
****************************
and down
This alarm tells you something connected to
arrow buttons to scroll through the customer fault input had shut down the
the alarms you will not know if the unit unit.
was down on more than one alarm.
20. To view what Alarms the unit is down on
****************************
React High Temp Alm
****************************
press the up
or down
arrow
to see what alarm that has caused the unit
to shut down. In this example we will press
the down
to view what some of the
alarms could be (they may not show up in This alarm tells you that you will need to reset
this order).
the High limit mounted on the reactivation tunnel first before this alarm can be reset.
27
****************************
Supply Fan Fail
****************************
****************************
React Flame Fail
****************************
This alarm tells you the flame safety for the
This alarm tells you that the Supply airflow
gas reactivation alarmed and will need to be
switch did not close due to the fan relay not
reset before you can reset the controller alarm.
closing or the supply fan is not running or
tripped out or something else within that circuit.
22. To view Alarm History, push the alarm bell
button twice
play the Alarm Log.
****************************
Rotation Fault
****************************
and this will dis-
a. The alarm log will show the most recent
alarm the unit went down on first; If you
want to view the rest of the alarms you
This alarm tells you the DH rotor was not rotating or has not been hitting the rotation switch
to prove rotation of the rotor.
will need to push the up
button.
arrow
08:35:27 10/25/09
001:React High Temp
RIT:
325.5
ROT:
135.2
****************************
React Low Temp Alm
****************************
This alarm does not shut the unit down, but
tells you that the reactivation outlet temperature was below the 95º set point for 15
minutes. You cannot reset this alarm until the
outlet temperature get above 95º or you power
down the unit.
28
b. The Screen shown above shows that
on this unit the most recent alarm 001:
is as follows:
i. The unit went down on Reactivation High Limit on October 25, 2007
at 8:35AM, the reactivation inlet
temperature was 325.5ºF and that
the reactivation outlet temperature
was 135.2ºF.
c. To see the next alarm 002: in the history press the up
tion inlet temperature was 125.5ºF
and that the reactivation outlet temperature was 90.5ºF which is below
the minimum outlet temperature for
a period of 15 minutes.
arrow.
10:15:27 09/21/09
002:Rotor Rot Fault
RIT:
265.5
ROT:
145.5
g. Use the Up
arrow button to scroll
to see what other alarms the unit went
down on or press the Down
arrow button to scroll back to the most
recent alarm in the history and then
d. The Screen shown above shows that
on this unit alarm 002: is as follows:
i. The unit went down on Rotor
Rotation on September 15, 2007
at 10:15AM, the reactivation inlet
temperature was 265.5ºF and that
the reactivation outlet temperature
was 145.5ºF. This fault was possibly caused from the unit not proving
rotation of the rotor in a 10 minute
cycle.
press the escape
button to exit
and go back to the original screen.
h. If you want to clear the alarm history
in the controller you will need to press
Up and Down arrows
at
the same time and hold for several
seconds.
23. If you have the Service Password, you
e. To see the next alarm 003: in the history press the up
can use the Program button
to
enter other parts of the program, like the
Service Menu. (This is not recommended
for the basic user, only for a qualified service technician)
arrow.
10:15:27 09/21/09
002:React Low Temp
RIT:
125.5
ROT:
90.5
If you have any further questions or
need help with going through the
menus please contact the Customer
Service Department @ 507-451-2198.
f. The Screen shown above shows that
on this unit alarm 003: is as follows:
i. The unit went down on Low Reactivation Temperature on September
11, 2007 at 09:20PM, the reactiva-
29
Start Up
The unit must be isolated from the gas supply
piping system by closing the manual shut-off
valve located in the gas vestibule during any
pressure testing of the gas supply piping system at test pressures equal to or less than ½
psi.
20. SPECIAL TOOLS REQUIRED
The following specialty tools are required at
the time of startup. (The complexity of the unit
will dictate how many of the following are actually required in order to complete the startup)
A) Locate and have ready the “Field Startup“ form, one copy is included in a plastic
sleeve hanging in the electrical control
panel enclosure.
Ammeter, Amprobe or Equal.
Ohm Meter / Volt Meter
NOTE: This form must be completed and
returned directly to Concepts and
Designs, Inc. In order for the
WARRANTY on the unit to be valid.
Complete the form as the startup
is performed using but not limited
to the following Instructions.
Gas Pressure Gauge 0 to 30” W.C.
Gas Pressure Gauge 0 to 10 PSIG.
U‑Tube Manometer 0 to 6” W.C. or suitable
differential pressure gage.
B) Perform the Pre‑Start Inspection, Including
but not necessarily limited to:
Temperature Gauge (450º F maximum
needed).
1) Remove any shipping blocks from
units.
Temperature/Relative Humidity Meter (Hygrometer).
Rotating Vane Anemometer or Equal.
2) Measure supply voltage and make sure
it agrees with the unit nameplate.
21. PRECAUTIONS BEFORE ATTEMPTING STARTUP OF THE
DESICCANT DEHUMIDIFIER
3) Check all electrical connections in the
main control panel and remote control
panel (if supplied) for tightness.
All the information below pertains to a gas
fired reactivation unit. All others (electric,
steam, etc.) will be somewhat similar to this is
one form or another. (Please refer to the unit
specific sequence of operation for the proper
operation of your unit)
4) Check to see that all fuses are installed,
and are of the correct value.
The unit and its manual shut-off valve must
be disconnected from the gas supply piping
system during any pressure testing of that
system at test pressures in excess of ½ psi
or greater than the inlet pressure that is noted
on the unit name plate.
6) Verify that supply gas line to the dehumidifier was blown clean prior to connection to the dehumidifier Purge gas
lines of air. Close Manual gas valves
before supplying main gas pressure.
5) Make sure all fuel connections are tight
and that all joints have been properly
sealed. Use soap test for assurance.
30
7) Measure the supply gas pressure and
make sure it agrees with the unit nameplate. (Gas pressure over that specified
in the nameplate can result in damage
to components.)
8) Check unit return or outside air inlets to
insure that they are free of any obstructions.
22. STARTUP
All safety and operating controls have been
checked during the factory test period, however, it is advisable to complete a similar
check when first operating the unit.
A) Check and reset all manual safeties.
9) Check unit supply air outlet, and supply
blower inlets for obstructions.
1) The High limit switch is mounted on the reactivation tunnel in downstream side
of desiccant wheel in supply air stream
may have to be reset.
10)Check supply air blower assembly to
insure freedom of shaft rotation and
proper belt tension.
11)Check supply air blower assembly to
insure that pulleys are aligned and
secure.
12)Check reactivation air blower assembly
to insure freedom of shaft rotation and
proper belt tension.
13)Check filters for cleanliness, replace if
dirty or damaged.
14)Make certain that all damper linkage
(If provided) is free to move and that
no binding will occur. Air dampers that
operate in normally open position are
shipped in closed position in order to
minimize shipping contamination.
15)Check inside unit for general cleanliness, close and secure access doors.
16)Main gas and pilot manual gas valves
must be in the “off’ or “closed” position.
17)Check reactivation High Limit switch
setting; it should be set at or slightly
below 350º F. (Unless unit is designed
for a higher reactivation inlet temperature)
18)Inspect the desiccant rotor and seals
for damage and or binding.
2) Gas pressure switch(es) (if supplied)
may have to be reset. (The upstream
manual valve must be open to reset
the low pressure switch.)
B) Open pilot line gas valve and purge air
from gas line through the plugged test port
in pilot line.
C) Close main disconnect switch.
D) All three phase motors were properly
phased during factory testing. If rotation is
reversed, interrupt main power supply and
interchange any two of the incoming power
leads. Reestablish power and recheck the
blower direction and desiccant rotor drive
operation.
E) On three phase units, the starter contacts
should pull in and hold quietly without
“chatter” (relays serve as starters on single
phase units). If they do not operate quietly,
check immediately for proper line voltage
or foreign material in the starter contactor.
Low voltage noted at startup will cause
persistent operating trouble and must be
corrected before the unit is placed into
service.
F) Recheck all set screws or bolts on motor sheave, blower sheave, and blower
wheel(s). Spin the blower wheel on direct
drive fans to insure there will be no rub-
31
bing during operation. Check alignment
of belts and pulleys. Run blower for a few
minutes and readjust the belt tension, if
necessary. Do not over tighten belts since
excessive tension will reduce belt life and
cause excessive loads on bearings. After
initial startup has been made, give the
belts a few days running time to become
seated into pulley grooves, then readjust
as necessary. Run the unit and adjust belt
tension until only a slight bow appears in
the slack side of the belts.
NOTE: DO NOT roll belts over grooves or
sheaves, as this results in permanent belt damage.
G) Move “Manual/Off/Auto” switch to “Manual” position to start the unit. (If the unit has
optional face and bypass dampers they
may require control signal to open.) The
blowers and desiccant rotor will start. Using a manometer, (unless magnehelic are
installed on unit) verify correct differential
pressure across process and reactivation
test ports. After a seven second purge,
the pilot will ignite. If pilot does not light,
the flame safety relay will alarm. The
alarm is reset by pushing the reset button
on the Flame Safety Device. Ensure that
the supply gas line has been purged. If it
becomes necessary to adjust pilot flame,
connect a manometer to the pilot gas test
port. Connect a voltmeter to the test points
on the Flame Safety Device. With the pilot
established adjust the pilot regulator to
a reading greater than 1.5 volts. (This is
accomplished by using the optional Keyboard Display Module or by measuring the
voltage at the flame current test jacks on
the Flame Safety Device) The manometer
should indicate a pilot gas pressure of approximately 3-5” W.C. for natural gas (usually 2.5 to 3”), and 5-9” W.C. for propane
gas (usually 6 to 8”) is enough or what
ever it takes to get the best DC voltage
Keyboard Display Module
Flame Safety Device
output from the flame safety (make sure
the signal is over 2 VDC). Make sure all
manual gas valves are open and (optional)
gas pressure switch(s) are reset for burner
operation.
H) With pilot established, main gas valve(s)
open to burner.
I) 120-140º F reactivation discharge temperature is desired. Because the desiccant
has been collecting moisture during shipment, the reactivation discharge may be
lower than 120º F until the moisture load
32
stabilizes, normally after about one hour
or so of operation. Measure reactivation
air discharge temperature after one hour
of continuous operation. Maximum and
minimum firing rate settings are factory
set for proper operation with the specified
inlet gas pressure. If field reactivation firing rate adjustments are necessary, be
sure to keep continuous flame across the
full length of burner on low fire and do not
exceed maximum unit capacity on high
fire.
2) Remove the seal cap (A) and turn regulator pressure adjusting screw to obtain
desired manifold pressure. (Clockwise
rotation increases pressure) (See Figure 20.2).
J) Unit manifold pressure is factory preset to
provide the required capacity as stated on
the unit nameplate for the burner at high
fire. Before making any regulator adjustments, be sure there is adequate supply
pressure and the output to the modulating
valve is at 15 to 20 volts.
K) Modulation systems adjustments for different modulating valves are as follows:
MR212 VALVE HIGH FIRE
MANIFOLD ADJUSTMENTS
1) Apply either a 10 volt or 20mA signal
(depending on what you have the input
signal set for on the dip switches) to
terminals #5 & 6 on the Maxitrol SC11
amplifier (See Figure 20.1). This will
cause the valve to call for continuous
high fire.
Figure 20.2
MR212 VALVE LOW FIRE OR BY PASS
ADJUSTMENT
1) Disconnect wires from terminal #1 on
the Maxitrol SC11 amplifier (See Figure
20.1). This causes the valve to call for
continuous low fire.
Figure 20.1
33
2) Remove seal cap (B) and loosen lock
screw (C). Turn (D) to desired low fire
adjustment. (Clockwise rotation reduces minimum flow rate) (See Figure
20.2)
3) Tighten set screw (C), replace cap (B)
and reconnect wire to terminal #1.
M611 VALVE HIGH FIRE
MANIFOLD ADJUSTMENT.
1) Apply either a 10 volt or 20mA signal
(depending on what you have the input
signal set for on the dip switches) to
terminals #5 & 6 on the Maxitrol SC11
amplifier (See Figure 20.1). This will
cause the valve to call for continuous
high fire.
M) Check all of the safety devices to make sure that the unit will respond properly to
2) Adjust the pressure regulator to obtain
each device and shut down if required.
the manifold pressure stated on the
unit name plate (4.5 W.C. max.)
O) Move “Manual/Off/Auto” switch to
“Auto” position to start the unit. The unit
M611 VALVE LOW FIRE OR BY
will now automatically run and maintain
PASS ADJUSTMENT.
the discharge temperature that is programmed into the controller.
1) Disconnect wire from terminal #1 on
the amplifier (See Figure 20.1). This 23. TYPICAL SEQUENCE OF
causes the valve to call for continuous
OPERATION
low fire.
2)Remove cap (A) and turn adjusting
screw (B) to desired low fire adjustment (See Figure 20.3 ).
3)Replace cap (A) and reconnect wire to
Terminal #1.
On the Following, five pages are some of the
typical sequence of operation procedures for
the different types of control procedures used
in controlling the operation of the unit depending on the complexity of the unit.
L) Test for gas leaks in the gas train,
then spray the gas train with WD-40 or
equivalent, to help aid in the prevention
of any rust forming on the piping in the
future.
34
Field Wiring
RRC Microprocessor
Dehumidifier Controller
RRC
Optional Remote Control Station
(Mounting and Wiring by Contractor)
Unit Control Panel
with Terminal Strip Connections
Desiccant Inlet
Outdoor Air
Sensor
Desiccant Outlet
Sensor
Wet Air Out
Reactivation Air
Filter
Reactivation Burner, Electric
Resistance Heater, or Steam Coil
Fresh Air
Optional Outside Air
Manual or Automatic Damper
Return Air
Filters
Desiccant Rotor
Supply Air Field Wiring
Fan
Return Air From Space
or from Optional MDH Section
Supply Air to Space
(Or to Post Heating and
Post-Cooling Section)
Optional
Room Humidistat or Humidity Controller
Sequence of Operation
With unit disconnect switch closed, Microprocessor and
ancillary components are energized. The "Power On"
indicator light on unit annunciator will energize.
Reactivation burner or electric heater firing rate is
controlled via microprocessor controller as
follows:
With selector switch in “Manual” or “Auto” position, and
safety circuits normal, supply fan operates
continuously, and (optional) motorized outdoor air
damper drives open. On a call for dehumidification,
reactivation fan, desiccant rotor drive and reactivation
burner are energized as required to maintain space
humidity (adjustable setpoint) via room humidistat.
"Call for Dehumidification" light on unit annunciator will
energize.
15 seconds after opening of main gas valve, the
"Burner On" light on unit annunciator will
energize. The firing rate is modulated as follows:
On units supplied without optional remote control panel,
unit cycles in response to call for dehumidification from
room humidistat exclusively.
Reactivation burner ignition and flame management on
gas fired units are controlled via a dedicated flame
safeguard system and proven via flame rectification.
Pre-ignition interlocks include reactivation airflow
differential pressure proving switch, and manual reset
high temperature limit switch.
(1) Desiccant reactivation inlet temperature is
maintained at optimum temperature for maximum
dehumidification performance irrespective of
outdoor temperature or filter loading.
(2) As moisture load decreases, reactivation
outlet temperature rises, and microprocessor
controller resets reactivation inlet temperature
down as required to limit reactivation outlet
temperature.
(Optional) Steam reactivation units use
reactivation air volume rate modulation.
Reactivation outlet temperature modulates
reactivation airflow via variable frequency drive or
(optional) modulating damper. Reactivation Inlet
temperature is available for diagnostic
information.
Fail-Safe Mode: In order to preserve limited
performance, in the event of a sensor failure, the
microprocessor controller will deliver burner rate
signal as follows:
(1) With failed desiccant reactivation inlet sensor,
burner output signal is 50%.
(2) With failed reactivation outlet sensor,
desiccant reactivation inlet is maintained at 260
degrees F.
(3) With diminished reactivation airflow (I.e. dirty
filters) desiccant reactivation inlet temperature is
limited in order to prevent rotor overheat.
(4) With overheat caused by an abnormal
condition, a manual reset high temperature limit
in desiccant reactivation inlet air stream cycles
burner off.
Dehumidification Reactivation
Rate Control (RRC)
G:\Engineering\Templates\Sequence of operations\DH,MDH,RRC,HCFB Controllers\RRC-Carel Control Sequence 8x11 11-9-05.vsd
35
Unit shutdown occurs via the following:
Desiccant rotor rotation is proven via
roller switch input to the RRC
controller. If rotation is not detected
within programmed time, unit shutdown occurs. The "Rotation Fault" light
on unit annunciator will energize.
Adequate reactivation energy is proven
via reactivation outlet temperature. If
adequate leaving temperature is not
sensed within the programmed time.
The “Low Reactivation Temp” light on
unit annunciator will energize. Unit will
continue to run.
Other customer or factory furnished
devices may be installed to initiate unit
shutdown via “External Faults” input.
Unit shut-down occurs upon closing of
customer contacts, or installed factory
contacts, or loss of supply airflow. The
“Other Faults” light on unit annunciator
will energize.
Flame failure via flame safeguard relay
causes unit shut-down in the event of
failure to ignite or maintain pilot flame.
The “Flame Failure light on unit
annunciator will energize.
DH Series
Field Wiring
RRC Microprocessor
Dehumidifier Controller
RRC
Unit Control Panel
Desiccant Inlet
Outdoor Air
Sensor
Desiccant Outlet
Sensor
Wet Air Out
Reactivation Air
Filter
Reactivation Burner, Electric
Resistance Heater, or Steam Coil
Fresh Air
Optional Outside Air
Manual or Automatic Damper
Return Air
Filters
Desiccant RotorOptional
or from Optional MDH Section
Face & Bypass
Dampers
Supply Air to Space
(Or to Post Heating and
Post-Cooling Section)
Supply Air Field Wiring
Fan
Optional
Room Humidistat or Humidity Controller
With unit disconnect switch closed, Microprocessor and
ancillary components are energized. The "Power On"
indicator light on unit annunciator will energize.
Reactivation burner or electric heater firing rate is
controlled via microprocessor controller as
follows:
With selector switch in “Manual” or “Auto” position, and
safety circuits normal, supply fan operates
continuously, and (optional) motorized outdoor air
damper drives open. On a call for dehumidification,
reactivation fan, desiccant rotor drive and reactivation
burner are energized as required to maintain space
humidity. The humidity set-point may be set internally
via the RRC key pad or extenally via room humidistat.
(The RRC must be confugured for internal or external
set-point.”
"Call for Dehumidification" light on unit
15 seconds after opening of main gas valve, the
"Burner On" light on unit annunciator will
energize. The firing rate is modulated as follows:
(Optional) On units with modulating face and bypass
rotor dampers, a modulating signal from a
dehumidification controller signal modulates face and
bypass dampers and energizes reactivation energy as
required to satisfy the load.
On units supplied without optional remote control panel,
unit cycles in response to call for dehumidification from
room humidistat exclusively.
Reactivation burner ignition and flame management on
gas fired units are controlled via a dedicated flame
safeguard system and proven via flame rectification.
Pre-ignition interlocks include reactivation airflow
differential pressure proving switch, and manual reset
high temperature limit switch.
(1) Desiccant reactivation inlet temperature is
maintained at optimum temperature for maximum
dehumidification performance irrespective of
outdoor temperature or filter loading.
(2) As moisture load decreases, reactivation
outlet temperature rises, and microprocessor
controller resets reactivation inlet temperature
down as required to limit reactivation outlet
temperature.
(Optional) Steam reactivation units use
reactivation air volume rate modulation.
Reactivation outlet temperature modulates
reactivation airflow via variable frequency drive or
(optional) modulating damper. Reactivation Inlet
temperature is available for diagnostic
information.
Fail-Safe Mode: In order to preserve limited
performance, in the event of a sensor failure, the
microprocessor controller will deliver burner rate
signal as follows:
(1) With failed desiccant reactivation inlet sensor,
burner output signal is 50%.
(2) With failed reactivation outlet sensor,
desiccant reactivation inlet is maintained at 260
degrees F.
(3) With diminished reactivation airflow (I.e. dirty
filters) desiccant reactivation inlet temperature is
limited in order to prevent rotor overheat.
(4) With overheat caused by an abnormal
condition, a manual reset high temperature limit
in desiccant reactivation inlet air stream cycles
burner off.
Dehumidification Reactivation
Rate Control (RRC)
G:\Engineering\Templates\Sequence of operations\DH,MDH,RRC,HCFB Controllers\ RRC-Face_bypass Carel Control Sequence 8x11 11-9-05.vsd
36
Unit shutdown occurs via the following:
Desiccant rotor rotation is proven via
roller switch input to the RRC
controller. If rotation is not detected
within programmed time, unit shutdown occurs. The "Rotation Fault" light
on unit annunciator will energize.
Adequate reactivation energy is proven
via reactivation outlet temperature. If
adequate leaving temperature is not
sensed within the programmed time.
The “Low Reactivation Temp” light on
unit annunciator will energize. Unit will
continue to run.
Other customer or factory furnished
devices may be installed to initiate unit
shutdown via “External Faults” input.
Unit shut-down occurs upon closing of
customer contacts, or installed factory
contacts, or loss of supply airflow. The
“Other Faults” light on unit annunciator
will energize.
Flame failure via flame safeguard relay
causes unit shut-down in the event of
failure to ignite or maintain pilot flame.
The “Flame Failure light on unit
DH Series
Field Wiring
Unit Control Panel
RRC
HCFB Microprocessor
Heating/Cooling
Face & Bypass Controller
Room Temperature
and Humidity Transmitter
MDH
HCFB
Post-Cooling Coil may be Chilled Water with Modulating
Three-Way Mixing Valve or Dual-Circuit DX
Heating-Cooling-Face & Bypass ("HCFB")
Controller functions in concert with Reactivation
Rate Controller (RRC) and (Optional) MDH
controller to manage post- cooling and postheating modes of operation.
With
unit
disconnect
switch
closed,
Microprocessor and ancillary components are
energized. (optional) "Power On" indicator light
on (optional) remote control panel lights. With run
command input and fault status normal, controller
is enabled.
Dehumidification:
Humidity setpoint is adjusted via setpoint control
knob on (optional) remote control panel, or as
customer analog input.
Space humidity is input via a room temperature
and humidity transmitter or via customer
furnished analog input. On projects requiring two
controlled spaces, a second transmitter (optional)
or customer input is required.
When space humidity rises above setpoint via
adjustment knob on (optional) remote control
panel, analog output signal is sent to
Reactivation Rate Control ("RRC"). When output
signal achieves preset value, and safety circuits
normal; supply fan, reactivation fan and
reactivation burner are energized (See RRC
sequence). (Optional) "Call for Dehumidification"
light on (optional) remote control panel is
energized. Unit furnished with (optional) Face
and
Bypass
dehumidification
modulation
dampers receive output to modulate dampers as
required to satisfy humidity setpoint.
Units utilizing two space temperature and
humidity signals operate until dehumidification of
both spaces are satisfied.
Post-Heat may be Indirect Fired (Atmospheric for 640
MBH and Below, and Power Burner style for above
640 MBH) or Hot Water Coil or Steam Coil with Face
and Bypass Modulating Dampers
Cooling:
Heating:
Temperature setpoint is adjusted via
setpoint control knob on (optional) remote
control panel, or as customer analog
input.
Temperature setpoint is adjusted via setpoint
control knob on (optional) remote control panel, or
as customer analog input.
Space temperature is input via a room
temperature and humidity transmitter or
via customer furnished analog input. On
projects requiring two controlled spaces, a
second transmitter (optional) or customer
input is required.
When space temperature rises above
setpoint, supply fan is energized. When
dehumidification is energized, two stages
of cooling are sequentially energized for
customer use or for staged control of
(optional)
factory
furnished
DX
condensing unit. A concurrent analog
output signal is available for customer use
or for modulating control of (optional)
factory furnished modulating chilled water
valve.
When dehumidification is not energized,
cooling is limited to first stage, and 50% of
analog output.
Units utilizing two space temperature and
humidity signals operate until both spaces
are satisfied. In the event of a conflict (one
space calling for heating and one space
calling for cooling) supply fan is energized
and cooling and heating are disabled until
both spaces are satisfied or a concurrent
call for either heating or cooling exists in
both spaces.
Space temperature is input via a room temperature
and humidity transmitter or via customer furnished
analog input. On projects requiring two controlled
spaces, a second transmitter (optional) or customer
input is required.
When space temperature falls below setpoint,
supply fan is energized. When dehumidification is
energized, one stage of heating is energized for
customer use or for staged control of (optional)
factory furnished heating unit.
When dehumidification is not energized, second
stage heating is available and a concurrent analog
output signal is available for customer use or for
modulating control of (optional) factory furnished
heating unit.
Units utilizing two space temperature and humidity
signals operate until both spaces are satisfied.
Units utilizing two space temperature and humidity
signals operate until both spaces are satisfied. In
the event of a conflict (one space calling for heating
and one space calling for cooling) supply fan is
energized and cooling and heating are disabled
until both spaces are satisfied or a concurrent call
for either heating or cooling exists in both spaces.
Heating Cooling and Face & Bypass
Management HCFB Control
January 26, 2006
37
DH Series
MDH Series
MDH-CTR Series
CDH Series
CDH-F Series
RRC
MDH
HCFB
Unit Control Panel
with Terminal Strip
Connections
Outdoor Air
Automatic Damper
MDH Microprocessor
Ventilation Controller
Outdoor Air
To Desiccant
Rotor Section
Field Wiring
Exhaust Fans
Exhaust Air
Recirculation
Automatic Damper
Enthalpy
Recovery Rotor
"MDH" Controller functions in concert with
Reactivation Rate Controller (RRC) and (Optional)
Heating-Cooling-Face & Bypass (HCFB) controller
to manage ventilation modes of operation.
With
unit
disconnect
switch
closed,
Microprocessor and ancillary components are
energized. (optional) "Power On" indicator light on
(optional) remote control panel lights. With run
command input and fault status normal, controller
is enabled.
Airflow modes may include any or all of the
following:
With ventilation mode selector switch on (optional)
remote control panel in the "unoccupied"
position, and safety circuits normal; supply fan,
reactivation fan and reactivation burner are
energized as required to maintain space humidity
(adjustable setpoint) via room humidistat (See
RRC
sequence).
(Optional)
"Call
for
Dehumidification" light on (optional) remote control
panel is energized. Outdoor air damper is fully
closed, and recirculation damper is fully open.
With ventilation mode selector switch on (optional)
remote control panel in the "low occupancy"
position, and safety circuits normal; supply fan
operates continuously, outdoor air damper drives
20% open and recirculation damper drives to 80%
open. On a call for dehumidification, reactivation
fan, desiccant rotor drive and reactivation burner
are energized as required to maintain space
humidity (adjustable setpoint) via room humidistat
(See RRC sequence). (Optional) "Call for
Dehumidification" light on (optional) remote control
panel is energized.
With ventilation mode selector switch on
(optional) remote control panel in the "Full
Occupancy" position, and safety circuits
normal; supply fan operates continuously,
outdoor air damper drives 50% open and
recirculation damper drives to 50% open.
Enthalpy rotor and exhaust fan 1 starts. On a
call for dehumidification, reactivation fan,
desiccant rotor drive and reactivation burner are
energized as required to maintain space
humidity (adjustable setpoint) via room
humidistat (See RRC sequence). (Optional)
"Call for Dehumidification" light on (optional)
remote control panel is energized.
(optional) remote control panel in the "Event"
position, and safety circuits normal; supply fan
operates continuously, outdoor air damper
drives 100% open and recirculation damper
drives fully closed. Enthalpy rotor and exhaust
fans 1 and 2 start. On a call for
dehumidification, reactivation fan, desiccant
rotor drive and reactivation burner are
energized as required to maintain space
humidity (adjustable setpoint) via room
humidistat (See RRC sequence). (Optional)
"Call for Dehumidification" light on (optional)
Make Up Air
Management
MDH Control
September 10 2002
38
(optional) remote control panel in the any
position, and safety circuits normal,
closure of an "Indoor Air Quality"
contact from customer furnished or
(optional) factory furnished air quality
monitoring system; supply fan operates
continuously, outdoor air damper drives
100% open and recirculation damper
drives fully closed. Enthalpy rotor and
exhaust fans 1 and 2 start. Units with
(optional) supply fan variable frequency
drive are commanded to maximum
speed. On a call for dehumidification,
reactivation fan, desiccant rotor drive and
reactivation burner are energized as
required to maintain space humidity
(adjustable setpoint) via room humidistat
(See RRC sequence). (Optional) "Call for
Dehumidification" light on (optional)
On units supplied without optional remote
control panel, unit airflow modes require
customer furnished dry contacts for each
mode.
MDH-Series
Unit Control Panel
RRC
MDH-CTR
Outdoor Air
Automatic Damper
MDH-CTR Microprocessor
Ventilation Controller
Outdoor Air
Field Wiring
To Desiccant
Rotor Section
With ventilation mode selector switch on (optional) remote
control panel is in any position, and safety circuits normal,
closure of an "Indoor Air Quality" contact from customer
furnished or (optional) factory furnished air quality monitoring
system; supply fan will operate continuously, outdoor air damper
drives 100% open and recirculation damper drives fully closed.
Units with (optional) supply fan variable frequency drive are
commanded to maximum speed. On a call for dehumidification,
reactivation fan, desiccant rotor drive and reactivation burner are
energized as required to maintain space humidity (See RRC
sequence). The "Call for Dehumidification" light on unit
annunciator is energized. When the indoor air quality has been
corrected and the Indoor Air Quality contact opens the unit
returns to normal operation in unoccupied or low occupancy
mode. The unit may also have a manual switch to place the unit
into the IAQ mode.
"MDH-CTR" option is integral to the RRC and functions in concert
with Reactivation Rate Controller (RRC) to manage the
ventilation option.
With unit disconnect switch closed, Microprocessor and ancillary
components are energized. The "Power On" indicator light on
the unit annunciator will energize. With run command input and
fault status normal, controller is enabled.
Airflow modes may include any or all of the following:
With ventilation mode selector switch on (optional) remote control
panel in the "unoccupied" position, and safety circuits normal;
supply fan, reactivation fan and reactivation burner are energized
as required to maintain space humidity (See RRC sequence).
The "Call for Dehumidification" light on unit annunciator will
energize. Outdoor air damper is fully closed, and recirculation
damper is fully open.
On units supplied without optional remote control panel, unit
airflow modes require customer furnished dry contacts for each
mode.
With ventilation mode selector switch on (optional) remote control
panel in the "low occupancy" position, and safety circuits
normal; supply fan operates continuously, outdoor air damper
drives 20% open and recirculation damper drives to 80% open.
On a call for dehumidification, reactivation fan, desiccant rotor
drive and reactivation burner are energized as required to
maintain space humidity (See RRC sequence). The "Call for
Dehumidification" light on unit annunciator will energize.
MDH-CTR Series
Make Up Air Management
MDH-CTR Control
G:\Engineering\Templates\Sequence of operations\DH,MDH,RRC,HCFB Controllers\MDH CTR Carel sequence 8xll 11-9-05.vsd
39
24. SHUTTING DOWN UNIT FOR
EXTENDED PERIODS OF
TIME
F) Check blowers to make sure the shaft rotates freely, sheaves are aligned, sheaves,
blowers, and motor bolts or set screws
checked for tightness.
When shutting down unit for extended periods of time we recommend that the following be done:
G) Make sure all damper linkages are free to
move, no binding will occur.
A) Shut off main disconnect.
H) Open main manual gas supply valve and
check for leaks.
B) Close main manual gas supply valve to
prevent the leaking of gas into the combustion chamber.
C) Cover reactivation air outlet.
D) If the Unit electrical is subject to humidity
you should remove the Flame Safety device and Carel controller to store them in a
drier environment to prevent moisture from
entering the devices and causing then to
trip or fail on faults.
25. RESTARTING UNIT AFTER EXTENDED SHUT DOWN
I) Turn on main disconnect.
26. SHUTTING DOWN THE BURNER IN AN EMERGENCY
In Case of Emergency:
A) Shut off the main power disconnect for
the unit.
B) Close main manual gas supply valve to
the unit.
When restarting the unit after long periods of
shut down the following should be done:
A) Check the unit for general cleanliness. Any
debris small or large has been removed
and the unit is clean.
B) Reinstall the Flame Safety and Carel Controller into the unit.
C) Make sure all wire terminals and connections have been checked for tightness.
D) Check the supply air outlet and the blower
inlets to insure they are free from any obstructions.
E) Remove reactivation air outlet cover.
40
Rotor and Cassette Technical Information
41
27. GENERAL ROTOR DO’S AND
DON’TS
When handling the rotor, please observe the
following guidelines:
A) DO NOT drop the rotor. Dropping the rotor
may cause damage to the shell and the
fluted desiccant media.
B) DO NOT strike the surface of the rotor or
allow any objects to strike the surface.
C) DO NOT allow the surface of the rotor to
become scratched. Use caution around
the rotor when working with any tools that
could cause scratches to the surface.
D) DO NOT stand or place objects on the face
of the rotor or rotor segments.
E) DO NOT roll the rotor once it is outside the
cassette or unit.
F) DO NOT drag the rotor.
G) DO NOT store the rotors on an inclined
surface as this may cause them to tip over
and damage the rotor or media.
H) DO NOT allow dirt, dust, or debris to settle
into the rotor element. Follow rotor washing
instructions if the rotor has been subjected
to long periods of storage in extreme conditions.
I) DO NOT subject the rotor to vibration.
J) DO NOT allow the rotor to come in contact
with paint, oil, acids, etc.
K) DO install the side with “F” printed on it
toward the reactivation air in or “Hot” side,
if so marked.
L) DO secure the rotor using a method to
prevent it from falling over or rolling.
42
difficult if not impossible to remove. This type
of contamination can lead to a rapid deterioration of adsorption capacity. Filtration of both process and reactivation air
steams is necessary to ensure longevity of
performance. Experience has shown that the
most dirt accumulation and resulting loss of
performance are from poor filter maintenance.
This is especially true on the reactivation side
of the rotor as most attention is normally on
the process air stream. The following list is representative of contaminants, which can adversely affect performance:
28. CHARACTERISTICS OF SILICA
GEL DESICCANT MEDIA SGA desiccant media will retain 90% of it’s
original capacity over a 10 year period (87,600
hrs) when operated in clean air. This reduction in capacity is due to natural aging of the
desiccant and does not account for any contaminants, which are passed through the rotor
during its lifetime. Dirt/dust
Flour/sugar/powdery substances
Greases/oils
Hydrocarbons
Alkaline detergents/cleaning compounds,
etc.
Acidic gases
Chlorine
Any high PH (8.0+) air stream
Typically a 1000 ppm concentration is the
upper threshold of exposure for gases. Any
oils, greases, or high PH contaminants will
immediately begin to affect performance. Deterioration of the desiccant media can occur from repeated exposure to water droplets,
Accumulated dust and dirt simply covers and such as from condensate carryover. The mesometimes fills the pores of the desiccant. In dia tends to soften when soaked with water
some cases this type contamination cases and structural integrity can be compromised.
be blown out and/or washed from the media. Over time, water carryover can break down
This normally results in a gradual, long-term the bond between the substrate and desiccant,
decrease in performance. literally washing the desiccant from the media. Oils or greases in the air stream can rapidly
deteriorate performance by masking the pores
of the desiccant. Chemical contaminants tend to attack the
structure of the desiccant and most times are
The desiccant media can be washed 4-5 times
before breakdown of the desiccant/substrate
bond occurs. Acceptable PH range for washing of media is 1.5 to 7.5 PH. 43
29. CHARACTERISTICS OF SSCR
DESICCANT MEDIA 5. SSCR is not good at alkali environment.
Please do not use under ammonia atmosphere.
1. In order to prevent any mist or dust intake,
all air inlets should have mist separator 6. SSCR is not good at hot and wet condition. There will be possibility to loose its
and dust filter.
performance if exposed to hot water or
hot steam.
2. SSCR is basically incombustible. However, it may cause of deterioration if SSCR
is exposed to high temperature such like
180 C or higher.
7. Please do not keep SSCR in water or wet
condition. It may cause deterioration.
3. Please be noted that strength of SSCR will 30. CHEMICAL COMPOUNDS
get bad impact if water drops physically
THAT MAY DAMAGE SSCR
touches to element when it is dry. Please
SILICA GEL HONEYCOMB
maintain any water splash should be shut
ROTOR
off when pre-cooler coil is installed.
As the following chemical compounds damage
4. SSCR is basically washable. However, the media of silica gel desiccant honeycomb
please blow ambient air for more than rotor, the performance of the rotor is deterio30 minute until SSCR absorbed enough rated by them.
moisture before rinsing. Otherwise, SSCR
will get physical and chemical damages.
Chemical
Chemical Compounds
Formula Cause of Damage (Deterioration)
Oil Mist
N/A Clog the micropore’s of the silica gel.
Ammonia
NH3 Though silica gel is strong against acid,
Amine
RNH2 ammonia or amine may crack the silica
gel.
Hydrogen Fluoride
HF
Corode Silica gel.
Sodium Hydroxide (High Concentrate)
NaOH Corode Silica gel.
Potassium Hydroxide (High Concentrate) KOH Corode Silica gel.
Lithium Chloride
LiCI Decrease Adsorption capacity of silica gel.
Sodium Chloride
NaCI Decrease Adsorption capacity of silica gel.
Potassium Chloride
KCI Decrease Adsorption capacity of silica gel.
Calcium Chloride
CaCI Decrease Adsorption capacity of silica gel.
Magnesium Chloride
MgCi Decrease Adsorption capacity of silica gel.
Aluminum Chloride
AICI3 Decrease Adsorption capacity of silica gel.
Sea Water N/A Decrease Adsorption capacity of silica gel.
Strong Acid (pH = 3 or lower)
N/A Deteriorate the physical property of ceramic substrate.
Plasticizer
N/A Clog the micropore of silica gel.
High Temperature Steam
N/A Corrode silica gel if content of alkali exists.
44
31. PRINCIPLE OF OPERATION
32. DH ROTORS & CASSETTES
The function of the Dehumidification Rotor
and Cassette is to remove moisture (in the
vapor state) from an air stream. This is accomplished by exposing the air to an adsorbing media (desiccant) in a sealed air stream
(process). After the desiccant has absorbed
moisture, it is exposed to a second air stream
at an elevated temperature (reactivation). This
causes the moisture to be driven out of the
desiccant preparing it for more moisture adsorption. This process is done on a continuous
basis, providing a constant drying process.
SPECIFICATIONS
The two air streams (process and reactivation)
are separated by seals, which contact the
desiccant media. The figure below illustrates
the airflow relationship of the seals and airflow
pattern.
The Dehumidification Rotor and Cassette is
designed with the two air streams flowing
in opposite directions (counter flow) thereby
maximizing the energy efficiency of the equipment.
Desiccant Rotor shall be provided by Concepts and Designs Inc. and shall conform to
the following specifications:
Media shall be uniform in nature, comprised
of corrugated fiberglass with an “in situation”
formed silica gel desiccant. Corrugations
shall be 0.059” tall by 0.118” wide, with a
wall thickness of 0.007” + 0.001”. Media shall
be nominally 16 lbs per cubic foot with “dry”
(reactivated) desiccant concentration of not
less than 80% of the total media mass. Not
more than 4% of the media, including face
coat, shall be of an organic material. Rotor
media must withstand temperatures to 2000
FDB without mechanical failure. Rotor media
shall be independently tested in accordance
with ASHRAE guidelines for performance
and independently tested in accordance with
ASTM E-84 for flame resistance and smoke
production. ASTM E-84 result must be 0/0
for both flame and smoke rounded indexes.
45
Independent test results must be furnished by
Concepts and Designs Inc. at the factory.
the manufacturer upon request.
Rotor Frame shall be comprised of thick wall
“DOM” carbon steel tubing, with welded 10
gage spokes and welded internal 10 gage
media retention strips. Spoke ends shall terminate with welded heavy duty coupling nuts
for bolt attachment of outer rim. Outer rim
shall be manufactured from not less than 14
gage 304 stainless steel. When applicable, 14
gage minimum 304 SS flanges shall be stitch
welded to the outer rim on 4” centers. Flanges
shall be additionally sealed to the outer rim
using 400 FDB rated silicone sealant. Rotor
Frame shall include 200,000 hour rated, no
maintenance, sealed bearings. (Optional full
stainless steel construction).
Rotor Drive shall include a parallel shaft gear
reducer with hardened steel gears and drive
motor suitable for both 50 and 60 Hz operation. Cast aluminum motor gear case shall be
permanently lubricated. Gear Reducer drive
shall be equipped with a #40 chain hardened
carbon steel ANSI drive sprocket, nickel plated
corrosion resistant drive chain and spring type
automatic chain tensioner.
Desiccant Rotor Cassette shall be provided
by Concepts and Designs, MS. and shall conform to the following specifications:
Cassette Frame shall be manufactured from
welded 304 stainless steel tubing. All welds
shall be reasonably ground and dressed for
appearance. Structural welds shall be continuous and non-structural welds shall be on
4” centers. Cassette face panels shall be 304
stainless steel and welded in place. Cassette
seal guides shall be of 304 stainless steel and
shall be welded in place. Cassette motor drive
base plate shall be of 304 stainless steel and
shall be welded in place with welded threaded
nuts on the base underside to allow for ease
of drive motor removal and installation. Rotor
shaft shall be manufactured from 4140 Cold
Rolled steel and shall be bolted to the cassette
via oversized allen head socket type shoulder
screws. Rotor movement on the drive shaft
shall be prevented by the use of two (2) square
collar blocks with stops.
Rotor Seals shall be of an Extruded rubber
silicone on both circumferential and divider
portions. Rotor seals shall be self-adjustable.
Rotor seals shall be readily available from
46
33. OPERATION
Drive System Operation
In the picture on the previous page, the drive
system operates as follows: With 115v power
applied to the drive motor, the drive sprocket
rotates and pulls on the drive chain. The drive
chain engages the perimeter rotor sprocket
(seen more clearly on page 29 of this manual),
which in turn, rotates the SGA rotor. The Drive
motor and sprocket are mounted on a metal
hinged plate with tension springs that are held
in place with a welded rod. The purpose of the
tensioner is to remove slack from the drive
system, so as to prevent unnecessary wear
on drive parts to reduce wear and improve
system reliability.
Measurement of Performance
Refer to the schematic in Figure 33.2 for
location of readings. At each of the following
locations, perform measurement of Dry Bulb
Temperature, Dew point and air volume flow:
1. Entering Process Inlet, Leaving Process
Outlet
2. Entering Reactivation Inlet, Leaving Reactivation Outlet
Additionally, measure dry bulb temperature at
the reactivation heater outlet, and time rotor
speed of rotation. Lastly, measure process
and reactivation air pressure drop and drive
motor amperage.
Compare all measurements against the performance graphs. Results should agree within
a few percent (likely measurement error) of
graph and software performance readings.
In the event of substantial (>5%) difference
between measured and predicted results, reperform measurements. Note that common
measurement and calculation errors are:
Figure 33.2
A) Process Leaving dew point is inaccurately
determined by measuring wet bulb (or RH)
and calculating dew point. In many cases,
the leaving process air is so dry that even
slight measurement errors in dew point (or
RH) will have significant results. If possible
use a chilled mirror dew point sensor for
all dew point readings
B) Turbulence in air streams causes variance
in all readings. Take an average reading
in a transverse across the face of the rotor in order to minimize variance due to
turbulence.
C) Heat and mass transferred do not balance.
The amount of heat gain in BTUH on the
process side must match the heat loss
in BTUH on the reactivation side. Also,
the amount of moisture removed on the
process side must match the amount of
moisture gained on the reactivation side.
If mass and heat transfer do balance, it is likely
that the readings obtained are correct. Refer
to the troubleshooting section of this manual
for additional actions.
47
MAINTENANCE OF THE ROTOR
in the unit (as per the picture below) while
holding the nozzle about 1” from the face
of the rotor and having other personnel
simultaneously vacuum the opposite side
of the rotor to catch dust and debris. A
standard shop vacuum, equipped with a
rubber hose adapter is typical (be sure
not to scratch or damage the face of the
rotor). Remember that the air nozzle that
is admitting the 100 PSI air should never
come closer than 1” to the face of the rotor.
Be careful not to damage the rotor face
with extreme air pressure or with the metal
body of the air nozzle. Clean a small area
of the rotor at a time (generally a 6” x 6”
area) for best results. Be sure to adhere
to the appropriate confined space entry
requirements (as applicable) when entering the air handler.
34. ROTOR CLEANING
Periodically, the rotor may need cleaning
from accumulated dust and debris or if the efficiency of the rotor decreases. Generally, air
handlers are equipped with air pressure drop
monitoring devices, which indicate pressure
drop through the rotor. If the air pressure drop
exceeds 125% of the “new” pressure drop,
the rotor should be cleaned by the following
method:
A) With the air handler shut down and the
power locked out, clean & dry 100 psi air
should be directed into the rotor in the
opposite direction of the process air flow
48
35. ROTOR CORE SAMPLES
Rotor Core Sample procedure is as follows:
Under most conditions the dehumidification
rotor and cassette is rated for 87,600 hours of
continuous operation. The operating lifetime
of the unit is determined at the percentage of
moisture removal performance at a given time
versus the original, new, moisture removal
performance. When the performance drops to
90% +0% -5% of original, the rotor is generally
considered at the end of its use. If the rotor
performs at this reduced level substantially
in advance of the rated lifetime, a standard
procedure is to perform a rotor core sample.
At an estimated cost to you Concepts and
Designs, Inc. will have the sample evaluated
and provide results of the evaluation. The
evaluation is to determine if the moisture adsorption effectiveness in the desiccant material has been affected during use. Common
factors that can reduce the effectiveness of
the desiccant media are:
A) Grind the edge of a 12” long by approximate 2” Inside diameter thin wall copper
tube or conventional hard conduit as per
the sketch below.
B) After securing the air handler, and observing applicable safety requirements, gently
tap and turn the sharpened edge through
the desiccant media.
A) Exposure to acidic air streams, gases or
solutions
B) Exposure to petroleum products such as
oil mists
C) Exposure to organic dusts such as sugar,
flour, etc.
D) High concentrations of other hydrocarbon
based airborne pollutants
If the core sample test determines that the
surface of the rotor has been contaminated,
the factory may recommend either solvent
cleaning or rotor replacement.
C) Firmly turn the tube and withdraw from
media. A plug of media should be retained
within the tube.
D) Mark the sampling tube with the Return
Air Inlet and Process Air Outlet end of the
sample taken.
E) Ship the tube, with the sample inside, to
the factory at: 2100 Park Drive, Owatonna,
MN 55060 with a letter regarding details,
Serial number, etc.
F) Fill the hole with a plug with 400°F rated
silicone sealant. Allow sufficient time for
the sealant to cure. (A plug can be purchased from Concepts and Designs, Inc.)
G) The surface of the media plug silicone filler
should be flush with the media surface.
Trim away excess as necessary.
H) Return the air handler to service.
I) Normal lead time for sample results are
six (6) to ten (10) weeks.
Concepts and Designs, Inc. will contact the
address information/ personnel submitted with
the sample and will provide a written report.
49
36. DESICCANT ROTOR REPAIR
Minor repairs, such as rotor cracks, separations
or dents can be preformed by service
technicians when required.
Materials needed include:
Masking tape
Small piece of stiff cardboard with flat edge
100% silicone RTV with a minimum
temperature rating of 350-450°F
Caulking gun
A) Position the rotor so you have unobstructed
access to the cracked or damaged portion
of the rotor.
B)Turn the unit OFF and disconnect the
power. Remove the service panels to the
unit.
C)Apply masking tape to the face of the rotor
on the right and left sides of the crack.
Allow for about two “corrugations” on each
side of the crack.
D)Apply 100% silicone with a minimum
temperature rating of 350-450°F to the
crack, keeping the angled cut of the
silicone tube parallel and very close to
the surface of the rotor to ensure good
penetration. For best results, apply the
silicone in an upward motion to push the
silicone into the crack.
E)After applying the silicone, take the piece
of cardboard, and at a 45° angle, drag
the cardboard over the bead to press
the silicone into the crack and make the
surface of the silicone smooth and flush
with the face of the rotor. This will further
enhance the penetration of the silicone
and will ensure that the silicone does not
protrude above the surface of the rotor.
F)Immediately after pressing the silicone into
the crack with the cardboard, remove the
masking tape. This must be done before
the silicone starts to cure, or “skin over”.
G)Allow the silicone to fully cure prior to
running the unit. Should any questions
or problems arise, contact Concepts &
Designs (507) 451-2198.
50
37. ROTOR REMOVAL AND
REPLACEMENT
In the event that the rotor needs to be removed
for maintenance, cleaning or replacement,
follow the steps and photographs on the following pages. Exercise care when removing
the rotor so as not to damage rotor, shaft,
cassette or seals. Observe applicable safety
practices regarding heavy material handling
when following the removal or reinstallation
procedure.
A) Secure the air handler and observe applicable safety precautions regarding
confined space entry and electrical tag out.
B) Determine if the rotor will be removed from
the drive side of the cassette (requires
drive system removal) or the opposite side
of the cassette. If the rotor is to be removed
from the drive side of the cassette, disassemble the drive system as follows:
1) Unbolt the tensioner bolts. Exercise
caution as the tensioner is under tension at the time of removal.
2) Remove the locking clips from the
chain drive master link. Separate chain
and remove chain
3) Electrically disconnect drive motor and
remove the four (4) bolts which secure
the drive motor to the cassette. The
motor and bracket should be removed.
C) Once the drive system is disassembled
and removed, or if removing the rotor from
the side of the cassette opposite the drive,
support the rotor with a ratchet strap of appropriate capacity per the picture below.
Do not over tighten the strap at this time
as it is just being used to gently support
the Rotor.
D) At the center shaft of the rotor (per the
photo below) loosen the shaft locking collar on both sides of the rotor. Next, loosen
and remove both shaft end bolts. Be sure
that the ratchet strap is tightened as necessary to support the rotor when removing
the shaft end bolts.
E) After removing both shaft end bolts, carefully loosen the ratchet strap and allow the
rotor to gently slide to the bottom of the
cassette. Slide the shaft and shaft lock-
51
C) Using pliers, grab seal and pull firmly. The
seal is adhered in place using Degree
Fahrenheit dry bulb rated silicone sealant. This adhesive will allow the seal to be
removed with moderate hand pressure.
Remove all seals which require replacement.
D) Clean all silicone residue from the cassette
using acetone or other approved solvent
cleaner. You could also use a wire brush
attached to a drill motor. It is essential
to remove all residue and debris prior to
installing new seals.
E) New seal should be cleaned with acetone
prior to installation and handled with clean
hands.
ing collars out of the rotor. Disconnect the
ratchet strap from around the cassette, and
reroute the top of the strap over the rotor,
but below the cassette top.
F) Using the strap by holding both ends,
gently pull the rotor out of the cassette.
G) Replace the rotor using the reverse procedure.
38. SEAL REPLACEMENT
During the lifetime of the rotor, seal replacement may be required as outlined in the
troubleshooting section.
If the seal surface is damaged, or it is determined that the seals should be replaced,
replace the seals (refer to photograph on the
previous page) as follows:
A) Secure and lock out the air handler per
approved safety procedures.
B) Follow the steps for rotor removal on Previous page.
F) Allow seals to dry overnight.
G) Carefully install rotor using the reverse
procedure to remove the rotor.
39. DRIVE SYSTEM PARTS
REPLACEMENT
Under normal conditions, all drive system
parts should last the lifetime of the cassette.
Under extreme conditions, drive system parts
may require replacement. Replace drive system.
40. ROTOR ALIGNMENT
INSPECTION
Desiccant dehumidification cassettes are
shipped fully assembled from Supplier,
including dehumidification rotor, seals and
drive system. The rotor and drive system
should be carefully aligned within the cassette
frame. The rotor is supported by a central
shaft and shaft bolts which pass through a
clearance hole in the vertical center support
member of the cassette frame. Alignment
of the rotor is maintained by the rotor shaft
52
position (vertical and horizontal) within the
cassette. This position may be adjusted by
loosening the shaft bolts, aligning the rotor to
its desired position within the cassette frame,
and retightening the shaft bolts. Small wooden
wedges, inserted between the rotor perimeter
and rotor seal are sufficient to align the rotor
to the desired position.
may also use a wood block and a length of
2 x 4 to leverage the rotor up on one side
or the other from the bottom. Position the
rotor such that equal gaps exist between
the rotor flange and cassette panel wall.
After adjustments have been made and
center shaft bolts have been retightened,
operate the drive to ensure that the gap is
consistent during rotation.
Should rotor or sprocket miss-alignment be
evident the following procedures apply to
troubleshooting and correcting the alignment.
Please note that this rotor alignment must be
correct prior to attempting any adjustment
to the factory location of the perimeter
sprocket mounted on the outer band of the
dehumidification rotor.
4. If run out is evident (change of gap spacing
during rotation) verify if the rotor band or
flange is causing the variation. The band
position would indicate the amount of run
out, the flange position can be adjusted
perpendicular to the band manually with
a slotted tool, at the thickness and width
of the flange.
1. Check to verify whether or not the rotor is
improperly aligned within the framework
of the cassette by checking the gap inbetween the rotor flange and cassette
panel walls where the perimeter seals are
attached. Misalignment of the rotor will be
evident by a smaller gap at one point on
the rim of the rotor from the other on the
opposite end. This may be witnessed in a
vertical or horizontal plane.
If an adjustment is made in the position
of the rotor within the frame, the location/
alignment of the perimeter sprocket must
be checked in relationship to the cassette
panels and drive sprocket. If adjustment is
necessary, the following procedures apply:
1. Operate the drive system and check
the position of the perimeter sprocket in
relationship to the drive sprocket at a fixed
spot on the cassette frame. The perimeter
sprocket should track with a consistent
gap between the frame. To adjust position,
it will be necessary to loosen or possibly
remove the attachment screws holding the
sprocket to the rotor band.
2. Connect the correct voltage to the motor
(refer to nameplate on the rotor drive
motor) and operate the drive system to
verify that the gap is consistent and stays in
the same location during rotation. If the gap
is consistent, misalignment is the cause.
If the gap changes during rotation, it may
be run out of the rotor around the central
axis or a run out of the perimeter flange of
the rotor.
2. Move the perimeter sprocket left or
right as required to establish the proper
gap and re-secure with the attachment
screws. Repeat this process as required to
establish a consistent gap and alignment
with the drive sprocket. A minimum of two
to four attachment screws per bracket are
required to properly secure the sprocket.
3. If the misalignment is to be corrected:
Correct the misalignment by loosening the
center shaft bolts and adjusting the rotor
position within the cassette. Small wooden
wedges, inserted between the rotor
perimeter and rotor seal are sufficient to
align the rotor to the desired position. You
Upon completion of the perimeter sprocket
alignment, the drive chain and sprocket
53
engagements should be smooth with consistent
vertical chain alignment. Some vibration of the
A) Material will not fail due to exposure of
rotor may be evident from friction generated by
saturated (100% relative humidity) air
the perimeter seals. This should be mild and
streams.
will not affect the operation of the drive system.
The dividing seals separating the reactivation
B) If installed and operated in accordance
area should also be checked to ensure proper
with the manufacturer’s instructions,
contact with the face of the rotor. Normally the
media shall perform as per data pubgap between the rotor face and seal mounting
lished by the manufacturer.
angle should be approximately three quarters
of an inch.
Additional Components such as rotor bearings, seals, belts, chains, sprockets, drive
motors and controls (as applicable) are war41. LIMITED ROTOR WARRANTY
ranted for a period of Eighteen (18) months
Concepts and Designs, Inc. (hereafter referred from the date of shipment, and are specifically
to as CDI) warrants to the original Purchaser warranted, in addition to being free of defects
of its Desiccant Dehumidification & Energy in material and workmanship, for the following:
Recovery Rotors and Cassettes (“Products”),
A) Equipment shall not fail due to insufsubject to the enclosed exclusions and conficient torque and or duty for selected
ditions, that the Products will be free from
application.
defects in materials and workmanship as
described herein.
B) Material shall not wear to the point of
failure, within the period, from normal
Rotor and Cassette metallic structure, includoperating stresses.
ing hub, shaft, spokes, perimeter band, cassette sheet metal and tubing structures (as applicable) are warranted for a period of eighteen CDI’s sole obligation under this Limited War(18) months from the date of shipment, and ranty, is to repair or replace, at its option, free
are specifically warranted, in addition to being of charge to the original purchaser (except
free of defects in material and workmanship, as noted), F.O.B. CDI’s factory, any Product
determined by CDI (in its sole discretion) to
for the following:
be defective.
A) Structures including welds and base
materials shall not fail due to corro- CDI’s Limited Warranty excludes defects, failsion from normal ambient sources ures and reduced performance caused, either
(corrosive industrial environments are directly or indirectly, by improper installation,
abuse, misuse, misapplication, improper mainexcluded).
tenance, lack of maintenance, negligence,
B) Structures shall not fail due to normal accident or normal deterioration, including
operating pressures and subsequent wear and tear.
developed stresses.
This Limited Warranty additionally shall not
Media and Substrate are warranted for a pe- apply to failures, defects or reduced perforriod of eighteen (18) months from the date of mance, resulting either directly or indirectly,
shipment, and are specifically warranted, in from any use or purpose other than desiccant
addition to being free of defects in material dehumidification and or energy recovery (as
applicable), or from exposure to corrosive enand workmanship, for the following:
54
vironments (liquid or gaseous) or liquid water,
in the form of impingement from a moving
air stream. This limited Warranty additionally
excludes damages due to natural disasters
and Force Majure. This Limited Warranty does
not include costs for transportation (including
without limitation, freight and return freight
charges, costs and insurance), cost from removal or reinstallation of parts or equipment,
Premiums for overtime, or labor for performing repairs or replacement to equipment in
the field. CDI is not responsible for damages
during transport of any product to or from CDI.
42. SAFETY
HANDLING SGA ROTORS & CASSETTES
THE OBLIGATION AND LIABILITY OF THE
CDI UNDER THIS LIMITED WARRANTY
DOES NOT INCLUDE LOSSES, DIRECT
OR INDIRECT, FOR INCIDENTAL, SPECULATIVE, INDIRECT, OR CONSEQUENTIAL
DAMAGES, RESPECTIVE OF THE FORESEEABILITY OF ANY SUCH DAMAGES.
THIS LIMITED WARRANTY IS PROVIDED
EXCLUSIVELY TO THE ORIGINAL PURCHASER OF PRODUCTS AND MAY NOT BE
TRANSFERRED OR ASSIGNED WITHOUT
THE EXPRESS WRITTEN CONSENT OF CDI
THIS LIMITED WARRANTY IS IN LIEU OF,
AND CDI HEREBY EXPRESSLY DISCLAIMS,
ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING WITHOUT LIMITATION, ANY WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, AND THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE
DESCRIPTION ON THE FACE HEREOF. In no event shall CDI liability to Purchaser
hereunder, or in any respect of the transactions contemplated hereby, whether direct or
indirect, exceed the amount paid by the Purchaser in respect of the products from which
any such liability is said to arise.
Concepts and Designs inc. Rotors and cassettes are shipped in plywood containers.
Upon receipt, carefully unpack the rotor (and
or cassette) and inspect for damage. (If the
is visible damage seen on the outside of the
shipping container, please make sure to note
that on the truck driver’s waybill. If you find any
interior damage after opening the container,
please notify the Customer Service department at Concepts and Designs Inc. 507-4512198). The rotor should remain in the packing
crate as much as possible until ready to install,
after removing from the crate the rotor should
be keep in the upright position as much as
possible. Rotors should not be handled by
rolling (except for short distances only) or by
placing sling around the entire perimeter of
the rotor and hauling with lift truck or crane.
If possible, a customer supplied shaft (rotor
only) placed through the bearings on the rotor
should be used to support the rotor. As always,
follow all applicable safety precautions when
handling rotors and cassettes.
Concepts and Designs Inc. Cassettes may be
lifted by any part of the perimeter structural
framework, and are designed to support the
weight of their own structure, the desiccant
rotor and drive. When installed in air handlers,
cassettes should not be used to support other
structure within the air handler.
Exercise caution when handling rotors and
cassettes to prevent damage to the face of
the rotor media, seals and drive systems.
Also refer to the section on the “General Rotor
do’s and don’ts” of handling the rotor.
55
Maintenance
43. MAINTENANCE SCHEDULE
Preventive maintenance is the best way to avoid unnecessary expense and inconvenience.
Have this system inspected at regular intervals by a qualified service technician. The required
frequency of inspections depends on the total operating time and the indoor and outdoor
environmental conditions. Routine maintenance should cover but not limited to the following
items:
EVERY MONTH
AIR FILTERS: Check for cleanliness and replace if necessary
Directions for the replacing of filters:
Replace only with filters designed for a minimum airflow
of 500 FPM.
Replace only with the quantity and sizes stated on the unit
nameplate or per the unit drawing.
Filters may need to replace more often or less often if the
air quality conditions around the unit dictate so.
BLOWER BEARINGS: CONDENSATE DRAIN
P-TRAP: Lubricate with grease. (Some blowers with direct drive fan
motors may have sealed bearings) When grease is needed a
high grade ball or roller bearing grease should be used. Recommended grease for standard service conditions is Polyrex EM
(Exxon Mobil). Equivalent and compatible greases include: Texaco
Polystar, Rykon Premium #2, Pennzoil Pen 2 Lube and Chevron
SRI. (Do Not Over Lubricate)
(If Applicable) Check the condensate P-trap drain for proper seal
or blockage, clean and add water or oil as necessary. EVERY 3 MONTHS
BLOWER V‑BELTS: (If Applicable) Check for belt wear, belt tension, belt alignment.
ROTOR CHAIN:
Check for chain wear, chain tension, chain alignment (Lubricate
with chain lube if necessary).
ROTOR ROTATION
LIMIT SWITCH: Check control to insure operation (Make sure switch is closing
when it comes in contact with the cam or magnetic sensor).
56
EVERY 6 MONTHS
BLOWER FAN: PILOT ASSEMBLY
(IF APPLICABLE): DESICCANT ROTOR: Check sheave alignment, lubricate bearings (manufacturer’s
grease specifications and lubrication procedure enclosed, Do Not
Over Lubricate)
Inspect and clean pilot assembly if necessary, check spark electrode flame rod and/or UV site glass (Site glass must be cleaned
with soft tissue).
Examine desiccant media and sector seals for physical damage
and cleanliness. (Clean with 100 PSI air if necessary – refer to
Rotor Cleaning Section of Manual).
COILS (IF APPLICABLE): Inspect coil fins for damage. (straighten with coil comb if necessary)
Inspect coil fins and tubes for buildup of debris clean coil if necessary.
CONDENSATE
DRAIN PAN: Check to see if there are any leaks in the coils, repair or replace as necessary.
(If Applicable) Check Condensate drain pan for cleanliness, clean
if necessary.
ONCE A YEAR
ELECTRICAL
COMPONENTS:
BURNER
(IF APPLICABLE):
Turn the Main disconnect switch off and then open the electrical
panel door. Make sure all controls are clean and free from dust
and grease. Inspect for loose wires and terminals (Tighten as
necessary).
Check and clean relay and starter contacts. (Use compressed air
to blow all debris from components and clean up cabinet.
Check for any rust accumulation in burner orifices (Clean as
necessary making sure not to use a tool that will make the holes
larger).
Inspect the burner looking for any cracks or distortion in the burner
baffle plates.
57
BURNER -Continued
(IF APPLICABLE):
Clean the burner with compressed air and follow with a clean rag
to remove any debris.
Check gas supply pressure to insure that the pressure matches
the Name Plate.
Check to make sure you have a good pilot flame.
Check burner operation to make sure it modulates properly.
Inspect the gas train and check for any gas leaks.
ELECTRIC HEATER
(IF APPLICABLE):
Inspect the wiring leading to the electric heaters for cracks, frays
or melted wire coating or shielding. (Replace as necessary)
Inspect the ceramic insulators for cracks (replace as necessary).
Check for any broken heater wires (replace as necessary).
Inspect the electric heater terminals for tightness. (Be sure not to
over tighten them as this may crack the ceramic insulators).
DESICCANT ROTOR:
Measure process and reactivation differential pressure against
the specified values on unit Name Plate. (Clean with 100 PSI
air if necessary – refer to Rotor Cleaning Section of Manual).
FIVE YEAR INTERVAL
DESICCANT ROTOR: Thoroughly examine rotor and inspect for damage. If rotor face is damaged repair or replace rotor. (Refer to “Desiccant
Rotor Repair” under the Maintenance Of The Rotor section)
Examine sector seals for wear, and replace if required.
If pressure drop is > 1.25 x new, clean and or replace rotor.
The above is only a suggested maintenance schedule for the unit.
If you have any questions please contact the Customer Service Department
at Concepts and Designs Inc. by phone at 507-451-2198 or by Email at
“[email protected]”
58
44. BASIC ACCESS DOOR FOAM GASKET REPLACEMENT
When the door gasket on your unit gets damaged or worn out and needs to be replaced,
the following are instructions on how to replace the foam gasket on the door. (You can
purchase this material by calling the Customer
Service Department at Concepts and Designs
Inc. 507-451-2198.)
1. Remove The Old Gasket.
B. Cut away the “barb” on the underside of
the gasket approximately 1/8” back from
the cut end. (Refer to drawing Below)
Using fingers or pliers, grasp the old gasket
at a point near the center of any horizontal or
vertical frame component, and pull straight out
of the frame, working from the center toward
the corners. Repeat on each of the four sides
of the gasket.
Note: In the event that the gasket separates
during removal, any material that tears
C. At a point approximately 6” from either
off and remains in the frame channel
corner on the latch side of the door frame,
must be removed before the new gasstart pressing the new gasket into the
ket is installed. This can be done by
channel in the frame. As you proceed with
lifting one end out of the groove using
the gasket replacement, make sure that
a knife tip or small, flat tip screwdriver,
the gasket is fully seated along its entire
then pulling the material straight out of
length. (Refer to drawing Below)
the groove.
2. Remove Any Sealant.
It is necessary to clean up any excess factoryapplied corner sealant that might prevent the
new gasket from laying flat on the frame. Use
a flat, rigid object such as a putty knife to
scrape the surface of the frame where the new
gasket will rest. Also remove as much sealant
as possible from inside the groove so that the
new gasket will seat properly.
3. Install The New Gasket.
A. If necessary, recut the end of the replacement gasket with a sharp knife or scissors
so that the starting end is clean and cut
to approximately 30o. (Refer to drawing
Above Right)
FOAM GASKET BUTT JOINT
LOCATION
59
D. Stop before you reach each corner (approximately 12” from the corner) and use
a pen to mark, on the top surface of the
gasket, the point where it will make a 90o
bend. At that mark, make a 80o notch
through approximately 2/3 of the width of
the gasket, and then carefully cut away the
“barb” on the underside approximately ½”
(6mm) from each side of the notch. (Refer
to drawing “But Joint Angle and Overlap
Conditions” Below)
E. Continue the installation process around
CORNER CUT FABRICATION
G. Apply a small amount of flexible sealant into the gasket channel at the point where
the two ends will meet, and complete the
installation. (If you did not purchas the
sealant with the door gasket contact the
Customer Service department @ Concepts and Designs Inc. 507-451-2198 for
information as to the proper type of sealant
to use)
BUT JOINT ANGLE AND
4. Seal Under The Gasket Corners.
the corner, and proceed to the 2nd, 3rd, Force a small amount of flexible sealant or
and 4th corners, repeating the process in contact cement under the gasket at each
corner where the barbs were cut back. This
step “C.” on the previous page.
will prevent air leakage under the gasket at
F. As you approach the start point, make those points.
a mark on the top surface of the gasket
where it will meet the starting end. Cut
the gasket with a sharp knife or scissors
so that the end is clean and matches the
angle in step (a), above, and overlaps
slightly. (Refer to “Corner Cut Fabrication” Drawing Below) Cut away the “barb” on
the underside approximately 1/8” back
from the cut end.
5. Readjust The Latches.
Adjust the door handle latches so that the door
bottoms out firmly against the stop-leg of the
door frame.
6. Repeat These steps for any door gasket
that may need repairing.
60
CDI STANDARD WARRANTY
AND
LIMITATION OF REMEDIES FOR BREACH OF WARRANTY
Concepts and Designs, Inc. (hereafter referred to as CDI) warrants all products to be free from defects in workmanship and material under normal usage for a period of twelve (12) months from date of factory documented
startup or eighteen (18) months from the date of original factory shipment, which ever is shorter. CDI shall only be
liable under this warranty if the product is properly installed and used according to the directions furnished by CDI.
The Basic Product Warranty is a “Parts Only” warranty and CDI’s obligation shall be limited to the replacement
of new parts of the products for those returned to CDI’s factory at the purchaser’s expense and found to be
defective by CDI. CDI will then repair or replace, at its option any such part determined to be defective during
this warranty period. Replacement parts will be shipped F.O.B. CDI’s factory. CDI is not responsible for damages during transport of any product to or from CDI. Replacement of parts shall not extend the original warranty
period of the original total product, including any replacement parts supplied.
This Standard warranty does not cover corrosion; normal deterioration; misapplication; labor charges paid for
parts replacement, adjustments, repairs or other work; loss of refrigerant or natural gas, oil, or other fuel; components supplied by others; defects in parts resulting from neglect, negligence, accident, fire, explosion, high or
low voltage, jumpering or jamming controls, shorting out of components; improper or contaminated fuel, excessive or inadequate fuel pressure; frozen heating or cooling coils; or any acts of nature.
This warranty does not cover failure of the purchaser or end user to follow the recommended maintenance
schedule intervals and failure to perform such items as bearing lubrication, adjustments, cleaning or service on
the heating system; or improper repairs or alterations; or misapplication of the equipment.
Any component of the unit found not working at the original startup of the unit (DOA) shall be replaced with no
reasonable labor or freight expenses to the owner or installing contractor. After the initial startup the warranty
shall be limited to the original cost of the component. Expenses shall not be charged at more than what is considered a reasonable negotiated rate between CDI and the installing contractor doing the work. This DOA warranty
does not cover corrosion; normal deterioration; misapplication; loss of refrigerant, natural gas, oil, or other fuel;
components supplied by others; defects in parts resulting from neglect, negligence, accident, fire, explosion,
high or low voltage, jumpering or jamming controls, shorting out of components; improper or contaminated fuel,
excessive or inadequate fuel pressure; frozen steam, heating or cooling coils; or any acts of nature.
It is expressly understood that this warranty is made IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR
IMPLIED, WHETHER ARISING FROM STATUTE, COMMON LAW, CUSTOM, OR OTHERWISE, INCLUDING
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR ANY PARTICULAR PURPOSE, QUALITY, DESIGN,
CONDITION, DURABILITY OR SUITABILITY, and in consideration of the express warranty herein contained,
BUYER EXPRESSLY WAIVES ANY RIGHT TO CLAIM OTHER WARRANTIES, EXPRESSED OR IMPLIED.
It is further understood that CDI’s liability for breach of warranty shall be limited to terms of this warranty and buyer
agrees that CDI SHALL NOT, IN ANY EVENT, BE LIABLE FOR SPECIAL, INDIRECT, OR CONSEQUENTIAL
DAMAGES, OR DELAY. The buyer’s remedies are exclusive, and shall be limited to those provided herein.
CDI neither assumes and does not authorize any person to assume any obligation or warranty other
than those stated herein.
Any suggestion to the contrary not withstanding, CDI shall not, in any event, have any liability under this warranty
unless and until it has been paid in full for the products. The warranty period shall begin as described above,
whether or not payment has been made.
61
WARRANTY CLAIMS
Defective material may be repaired or replaced at our option. If replaced, full credit will be issued in the amount
of the original purchase price if returned within 30 Days of shipment, for the returned material; in the event
the material is found to be not defective, or to be damaged or abused, we reserve the right to return the material
“as is” to the sender and at his freight cost. If CDI agrees to keep such material, credit will be issued minus the
cost of repair and reconditioning, the return and less restocking charges.
Other wise only cost of the part will be covered by our warranty. But if the part(s) CDI has sent are not the problem please reinstall the old part and return within 30 Days of shipment the new unused part back to CDI, we
will then after inspecting the part to insure it is still in good working order will return the new unused part(s) to
inventory and issue credit. Old parts returned to us that are in good working condition or after the 30 Day period
will be charged to you and not covered by warranty. It is important to remember that in order for our warranty to
cover the cost of the new part you must return the faulty part to us within 30 days to receive credit. Then after
CDI receives the part we must confirm that the returned part is actually faulty before issuing credit.
When returning the faulty part, please reference the Return Merchandise Authorization Number (Known as the
RMA number). Also please provide a small description as to what is wrong with the part that is being returned
under warranty:
Reminder: Our warranty only covers the cost of the faulty part and must be returned within 30 days from the
time of shipment from the factory to receive credit. You are responsible for any other expenses you incur, including freight charges, miscellaneous parts and the labor to install the part(s).
Warranty does not cover the following Items:
1. A maintenance item such as fuses, lamps, filters, etc.
2. Normal wear, adjustments, and periodic service.
3. Damage caused by accidents, improper installation or handling, or faulty repairs not performed by an
authorized service representative.
4. Damage caused by operation of the unit at improper voltage loads, conditions, modifications, or installation contrary to published specifications or recommendations.
5. Damage caused by negligent maintenance such as:
a. Failure to keep the air inlet and outlet areas clean.
b. Failure to service the air filters.
c. Breakage due to mishandling or misuse of the product or part.
d. Failure to follow and perform scheduled maintenance as prescribed in supplied manuals. (See
Maintenance Schedule in O&M)
6. Rental of any equipment during the performance of warranty repairs.
7. Parts purchased from sources other than CDI, Replacement of a failed CDI part with a non-CDI part
voids warranty on that part. (Unless prior written authorization has been give by CDI for you to do so.)
8. Warranty Labor.
9. Shop supplies such as adhesives, caulk, cleaning supplies, and rags.
10. Expenses incurred investigating performance complaints unless the problem is caused by defective CDI
materials or workmanship.
11. Electrical parts supplied by customer.
REPLACEMENT PARTS
When writing or calling to Concepts and Designs Inc. for service parts, provide the model number and serial
number of the unit as stamped on the unit plate attached to the electrical door. For questions regarding wiring
diagrams, it will be necessary to provide the number on the specific diagram. If replacement parts are required,
include the date of installation, the date of failure, an explanation of the malfunction, and a description or part
number of the replacement parts required.
62
Troubleshooting Guide
For information on troubleshooting your unit not covered by the following guides, contact the
Customer Service Department at Concepts and Designs Inc. (507) 451-2198
---- Rotor Section ---PROBLEM
Rotor does not
turn
Rotor turns,
but drying
performance is
poor
POSSIBLE CAUSE
Power not on
Turn selector switch to DH
Rotor Stuck or Frozen in
place
Determine cause from other inspection and repair
Drive Motor does not turn
Fuse blown, replace if necessary
Replace Drive Motor if necessary
Seals are sticking Loosen if stuck or frozen to unit
Drive chain is not engaging
sprocket on Rotor
Adjust, straighten and align drive
sprocket with rotor sprocket.
Tensioner not tight
Adjust Tensioner
Poor performance
Determine Cause from other inspection
Seal not engaging with cassette causing bypass of air.
Check seal clearance, adjust or
Replace seals if necessary
Blow out dirt if possible with compressed air, replace if necessary
Dirty or damaged rotor
High Process Outlet Temperature
CORRECTIVE ACTION
Poor seal clearance
Check Rotor Speed
Contact Factory
Low Reactivation
Poor seal clearance
Outlet Temperature
Check Rotor Speed
Contact Factory
Check Heated Temperature
Check heated to temperature adjust to
proper setpoint if necessary
63
--- General Unit shut down problems --PROBLEM
Unit will not
start at all
Unit runs for
1 Minute and
shuts down.
POSSIBLE CAUSE
CORRECTIVE ACTION
Unit selector switch not in the
Vent or DH position
Check to see if unit is calling for DH mode to run.
Make sure the jumper plug
is plugged in or the optional
humidistat or selector switch
is in the proper mode
Phase Monitor (Option, if Installed) ON light not lit up
See (Phase Monitor ON light
not lit up under “Red Faults
Lights On” in Fault Light Section)
Process Airflow switch is not
closing
Check to make sure the
process fan is running, if
not check to make sure that
the fuse are not blown or if
equipped with an overload
that it is not tripped, reset or
replace if necessary
If supply motor is running
make sure the tubes attached
to the airflow switch are in
good condition, replace tubes
or switch if necessary.
Unit runs for
10 Minutes and
shuts down.
DH Motor Not Running (Rotation Fault)
Check the fuse for rotor motor
and replace if necessary. If
fuse is good check to make
sure there is power to the
motor, replace motor if necessary, or see (DH Rotor Not
Turning)
High Limit Tripped
Make sure the switch is set
for 325 to 350° and then reset
high limit switch, if you can
not reset you may need to
replace.
64
PROBLEM
POSSIBLE CAUSE
CORRECTIVE ACTION
Unit runs for
10 Minutes and
shuts down.
(cont.)
Rotation Switch or proximity
sensor not hitting contacting
with magnet or cam on the
rotor
Adjust sensor to come in
contact with the magnet on
the rotor or adjust the limit
switch to trigger when the
switch is half way up the
ramp.
Unit runs for
15 Minutes and
shuts down.
Temperature not staying above
95° F on the reactivation outlet
See (Low Reactivation Temperature under “Red Fault
Lights On” in Fault light Section)
65
--- Reactivation Section --PROBLEM
No Blower
Operation
POSSIBLE CAUSE
CORRECTIVE ACTION
Mode Selector Switch
Switch in OFF position
Control Transformer
Place switch in proper mode
No input voltage
Check disconnect and supply
fusing
Replace control fuse
Blown control fuse
Defective transformer
Motor Protection
Replace transformer
Overload on motor tripped
Reset overload and check
motor amps/overload setting
Fuse blown
Replace fuse
Motor Starter
Defective motor starter
Motor
Replace motor starter
No input voltage
Check fusing
Improper wiring Correct wiring
Defective motor
Replace motor
Blower Damage
Defective or locked bearings
Replace bearings Check for physical damage
Replace or repair blower
Wheel came loose from shaft
Realign and tighten
66
PROBLEM
No Blower
Operation
POSSIBLE CAUSE
CORRECTIVE ACTION
Control Relays
Improper part
Improper wiring
Check relay voltage
Check wiring
Defective relay Replace relay
Open Humidistat (Optional)
Humidistat satisfied
Defective humidistat
Blower Runs;
No Reactivation
Heat;
Switch in VENT position
Manual Gas Valve
Main burner gas valve closed
Adjust humidistat, if applicable
Replace humidistat
Open gas valve
Airflow Switch
Blower running backwards
Blocked intake or discharge
Clogged airflow tube or pickup
ports
Defective switch Flame Safeguard Relay (FSR)
No input voltage
Reverse motor direction
Find and remove obstructions
Clean or replace tubing or
pickup ports
Replace switch
Moisture in FSR
Checking wiring
Dry out FSR
Defective FSR
Replace FSR
67
PROBLEM
CORRECTIVE ACTION
POSSIBLE CAUSE
Blower Runs;
No Reactivation
Heat;
Igniter (During trial for ignition:)
No current (open igniter)
Check igniter current and spark
No voltage
Check FSR output to spark rod
High Limit
High limit tripped
Reset high limit
High limit does not reset
Replace high limit
Gas Valve
Main valve does not open
Check FSR output to main
valve during ignition trial.
Check gas valve circuit and
wiring.
Compare supply voltage to
nameplate voltage.
Inlet gas pressure too high.
Defective solenoid
Regulator Clean and/or replace gas valve
parts.
Replace solenoid or valve assembly.
Clogged vent orifice
Clean or replace orifice
No supply pressure
Check all gas cocks and piping
Improper manifold pressure
Adjust regulator
Defective regulator
Replace regulator
68
PROBLEM
Blower Runs;
No Reactivation
Heat;
POSSIBLE CAUSE
No Flame Signal
Flame rod oxidized
Scrape oxide coating off rod
or replace flame rod.
Dirt buildup on insulator
Clean dirt deposit from insulator surface and install protective boot.
(Low fire not properly adjusted)
Low fire set to low Adjust low fire.
Flame rod ceramic cracked
Flame Safeguard Relay
(FSR)
Defective FSR
High Limit
Tripped
CORRECTIVE ACTION
Replace flame rod.
Replace FSR
High Limit
Temperature reading for high
limit went above 325º F
Reset high limit
High limit will not reset
Replace high limit
Airflow Restricted
Blower running backwards
Reverse motor direction
Belts slipping
Tighten and/or replace belts
Blocked intake or discharge
Find and remove obstruction
Continuous High Fire
Foreign material holding valve
open
Clean, replace valve and/or
seat if necessary
Plunger jammed
Clean, or if necessary, replace plunger
Faulty amplifier
Replace faulty amplifier
69
PROBLEM
High Limit
Tripped
Modulating
Valve Does Not
Modulate;
Continuous
High Fire
POSSIBLE CAUSE
CORRECTIVE ACTION
Unit Over firing
The discharge temp with burner
operating exceeds allowable
temp rise for the heater
Modulating Valve
Adjust modulating valve or
regulator to obtain temperature
rise specified for unit
Foreign material holding valve
open
Plunger jammed
Disassemble valve remove
foreign material replace valve
and/or seat if necessary
Clean or if necessary replace
plunger
Discharge Or Entering Air
Temperature Sensor Open circuit in discharge temperature sensor
Replace the sensor Temperature control system out
of calibration range
Perform temperature control
system calibration
Sensor cross-wired to controller
Amplifier (SC11B)
Correct wiring terminations
Faulty amplifier
Modulating
Valve Does Not
Modulate;
Continuous
Low Fire
Amplifier (SC11B)
Three position dip switches on
circuit board not set to correct
position for 4-20mA or 0-10 volt
input signal
Set dip switches to desired
position for operation
SC11B input not phased correctly for + & -
Switch wires around to match
+ or -
Faulty amplifier
70
PROBLEM
Modulating Valve
Does Not Modulate;
Continuous
Low Fire
POSSIBLE CAUSE
Transformer
No voltage output to amplifier
Replace transformer (also
check for short in modulating
valve coil)
Modulating Valve
Valve coil is open or shorted
Replace coil if its resistance is
less than 40W or greater than
85W. Plunger jammed
Clean or replace plunger
Ruptured main or balancing
diaphragm
Determine diaphragm condition and replace if defective
CORRECTIVE ACTION
Carel Controller
No output from to SC11B
71
Replace if defective
---- Process - Supply Section ----
No Blower
Operation
CORRECTIVE ACTION
POSSIBLE CAUSE
PROBLEM
Switch in OFF position
Control Transformer
No input voltage
Check disconnect and supply
fusing Blown control fuse
Replace control fuse
Defective transformer
Replace transformer
Motor Protection
Motor overload tripped
Fuse Blown
Reset motor overload and
check motor amps
Replace Fuses
Motor Starter
Defective starter
Replace motor starter
Motor
No input voltage
Check fusing
Improper wiring Correct wiring
Defective motor
Blower Damage
Replace motor
Defective or locked bearings
Replace bearings Check for physical damage
Replace or repair blower
72
PROBLEM
No Blower
Operation
POSSIBLE CAUSE
Control Relays
CORRECTIVE ACTION
Improper part
Check relay voltage
Improper wiring
Check wiring
Defective relay Open humidistat (Optional)
Replace relay
Humidistat satisfied
Adjust humidistat, if applicable
Defective humidistat
Replace humidistat
73
------ Fault Lights -----
PROBLEM
Red Fault Lights
On
POSSIBLE CAUSE
CORRECTIVE ACTION
Other Faults
Supply Airflow Switch does not
make to close R4 relay within 1
minutes time.
If supply motor is not running see (No Supply Blower
Operation). If supply motor is
running make sure the tubes
attached to the airflow switch
are in good condition, replace
tubes or switch if necessary.
Alarm on the Honeywell Flame
Safety (Gas Units Only) Reset the Honeywell flame
safety and then the Fault Reset button.
Some Customer supplied
device is tied into the external
faults relay.
Make sure that any external
device provided by customer
are not causing the alarm to
the unit.
Phase Monitor (Option If Installed) ON light not lit up
Check all of the setting on the
phase monitor to be sure they
are properly set to the voltage
you are operating the unit at
and then check rotation of the
motors on the unit to make
sure it is correct, check to
make sure you have proper
voltage supplied to the unit &
that the amp draw on all three
power legs is approximately
the same. If this does not
solve the problem call CDI
Customer Service Department @ 507-451-2198
74
PROBLEM
Red Fault Lights
On (cont.)
POSSIBLE CAUSE
Rotation Faults
DH Motor Not Running
CORRECTIVE ACTION
Check the fuse for rotor motor
and replace if necessary. If
fuse is good check to make
sure there is power to the
motor, replace motor if necessary, or see (DH Rotor Not
Turning)
High Limit Tripped
Reset high limit switch
Alarm on the Honeywell Flame
Safety (Gas Units Only) Reset the Honeywell flame
safety and then the Fault Reset button.
Rotation Switch not hitting cam
on the rotor
Adjust switch to hit the cam
on rotor when the switch is
half way up the ramp.
Rotation Switch is not closing
when triggered
Change out switch
Low Reactivation Temperature (Electric)
Bad Inlet or Outlet sensor
causing the unit to drop to a set
maximum output.
Replace sensor
Breakers tripped or Fuses
blown for some of the electrical heater elements
Reset Breakers and or replace Fuses
Coil on electric heater elements
burned out or broken (Inspect
the electric heater elements
to make sure they are in good
shape with no broken wires)
Replace the electric heater
elements if bad or defective.
75
PROBLEM
POSSIBLE CAUSE
CORRECTIVE ACTION
Red Fault Lights
On (cont.)
No power from the Carel controller to the SCR
After call for DH unit will not
have any power output for 60
seconds and then should have
an output. If no output replace
Controller.
3 Phase power to the SCR but no Check to see if there is a 0-10
power out to the electric heater VDC out to the SCR , if none
check to see if there is any
output power coming from the
Carel Controller.
If you have power from the
Controller and have power to
all three legs entering the SCR,
the SCR could be bad, Please
call 507-451-2198 for more
troubleshooting.
Low Reactivation Temperature (Gas)
Bad Inlet or Outlet sensor causing the unit to drop to a minimum
burner output
Replace sensor
Manual gas valve to the burner Shut unit off and open the gas
is closed not allowing gas to flow valve, then restart the unit.
to main burner.
Spark Rod not set properly or Adjusts spark rod to proper lois dirty.
cation between two of the holes
on the pilot tube.
Crack in porcelain of flame rod
or spark rod causing grounding
of the rod.
Replace if cracked
Dirty Flame Rod
Clean or replace flame rod.
76
PROBLEM
Red Fault Lights
On (cont.)
POSSIBLE CAUSE
Low Reactivation Temperature (Gas) cont.
No gas getting to the pilot assembly.
CORRECTIVE ACTION
Pilot regulator plugged or Bad,
Replace if you have a good
flame but no signal, after making sure to check the condition
of the wire.
Pilot regulator plugged or Bad
Make sure pilot regulator is not
plugged and replace if necessary.
Gas valve for pilot not opening
Check for voltage to the coil
and replace if necessary.
No gas to unit or main valve Turn main gas valves open
closed
and then bleed the gas line if
necessary.
No power from the RRC controller to the SC11B Maxitrol Selectra Signal Conditioner
Power to the SC11B Maxitrol
Selectra Signal Conditioner but
none out
77
After call for DH unit will not
have any power output for 60
seconds and then should have
an output. If no output replace
RRC card.
Check to make sure the SC11B
has 24 volt power supply between terminals 1 & 2. If you
have power and an inlet voltage to terminals 5 & 6 but no
output from 3 & 4 you will need
to replace the defective part.
PROBLEM
Green Lights Not
On
POSSIBLE CAUSE
Process Fan Light Not On
Unit selector switch not in the
Vent or DH position
CORRECTIVE ACTION
Check to see if unit is calling for
DH mode to run. Make sure the
jumper plug is plugged in or the
optional humidistat or selector
switch is in the proper mode
Process Air Flow Light Not On
Process Airflow switch is not
closing
Check to make sure the process fan is running, if not check
to make sure the breaker for
the fan is not tripped.
If Process/Supply motor is not
running see (Process Motor
Doesn’t Run)
If supply motor is running make
sure the tubes attached to the
airflow switch are in good condition, replace tubes or switch
if necessary.
Reactivation Fan Light Not On
Unit Not Calling for DH
Check to see if unit is calling for
DH mode to run. Make sure the
jumper plug is plugged in or the
optional humidistat or selector
switch is in the proper mode
High Limit May Be Tripped
Reset high limit switch
78
PROBLEM
Green Lights Not
On (cont.)
POSSIBLE CAUSE
Reactivation Air Flow Light
Not On
Reactivation Airflow switch is not
closing.
CORRECTIVE ACTION
Check to make sure the reactivation fan is running, if not
check to make sure the breaker
for the fan is not tripped.
If Reactivation motor is not running see (Reactivation Motor
Not Running)
If reactivation motor is running
make sure the tubes attached
to the airflow switch are in
good condition, replace tubes
or switch if necessary.
Amber Lights
Not On
Power Light Not On
Selector switch is in the off position
Move selector switch to the
Auto or Manual position
Main Power Disconnect Switch
in the off position
Move Disconnect switch to the
ON position
Call For Dehumidification
Light Not On
Selector switch is in the OFF Move selector switch to the
position
Vent or DH position
Unit Not Calling for DH
79
Is the “Call for Dehumidification” relay energized, if not
adjust humidity transmitter to
a lower set point to make the
unit call for Dehumidification.
MAINTENANCE LOG
Model No._______________________________________ Serial No. _____________
Date
Activity
80
Technician
MAINTENANCE LOG
Model No._______________________________________ Serial No. _____________
Date
Activity
81
Technician
Notes
82
Notes
83
Property of
84

DH Operation and Installation Manual

Transcription

Similar documents

Processing Rotor Trail Cutter Rotor

Quick Start Guide for HERMLE Centrifuges

Beagle Autogyro

the Consultex IQ-141 Brochure

High-Speed Rotor Balance

A Flettner-Driven Catamaran (draft 23 February 2007)

DBA T2 Street Series Slotted Rotors - Front Pair (94

Espada Single Distributor Cap/Rotor/Points

MeriCRUSHERS

Brochure - HERMLE Labortechnik