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General Installation and Start-Up Instructions for Heat-X-Changer

READ INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING TO ASSEMBLE, SERVICE OR OPERATE XETEX HEAT-X-CHANGER UNITS. FAILURE TO COMPLY WITH INSTRUCTIONS COULD RESULT IN PERSONAL INJURY AND/OR PROPERTY DAMAGE!

SPECIAL WARNING: No untrained person should attempt to install, maintain, or service XeteX Heat-X-Changer units.

RECEIVING THE UNIT AT THE JOB SITE

• Check the unit over to see that no damage has occurred during the shipment process. If any damage is found, report it on the bill of lading and immediately notify the trucking company.
• Check the listed approximate weight of the unit before removing it from the truck. It should correspond with the unit ordered.
• Using spreader bar, remove the unit from the truck.
• Remove any of the shipping hardware from the fans, vibration isolators, and any other moving parts.
• Remove the hold down straps and any supporting devices used in shipping. Readjust and secure the vibration isolators for proper operation.

Roof-top Installation:

• Major support should be provided at the perimeter of the unit and at the furnace section. (The unit can rest on the angle iron perimeter frame, but do not rest the unit where there is not unit framing underneath.
• Apply sealant to the top edge of the roof curb and lift the unit onto the curb. (Factory ordered curbs are shipped knocked down. This allows for an easier field assembly.)
• Secure and fasten the unit to the curb.
• Units may require additional job site sealing on the joints, corners or gasketed components, particularly on large units that tend to loosen in shipment and rigging. Appropriate all-weather caulking should be applied on the outside unit casing at any location where leakage could occur.

Indoor Installation:

• Units may be directly mounted on the Floor, suspended on a platform, or hung from solid threaded rod attached to the unit shipping support brackets.
• Installation must be in accordance with standard air handling structural weight and vibration isolating procedures and requirements.

PLUMBING CONNECTIONS

• Install the drain connections for the location at least the size of the drain outlet connection. Indoor unit drains generally extend through the side. Outdoor unit drains extend through the bottom or into a plumbing and electrical chase that is provided inside the unit. A convenient way to prevent freezing on outdoor traps is to wrap the plumbing drain line and trap with electrical tape. All drains must be trapped, even those outside, to prevent air from being sucked into the drain section from outside the case thus preventing water from draining freely out of the drain pan.
• Pipe and trap the condensate drains (provided by the contractor). This should be done to the nearest floor drain or drain pipe. An 8" trap must be supplied close to each drain outlet to assure a standing water column at least equal to the total system air pressure to be experienced at the drain. Each drain must be trapped separately and independently to assure that pressure from one trap does not affect the others
• Check to make sure that the drain pans are not punctured by piping, electrical conduit or by other means to assure that potentially damaging water leaks do not occur.

ELECTRICAL CONNECTIONS

• Check the power and voltage that is required. The electrical diagram is located on the back panel of the main electrical enclosure.
• Connect the fused power and control voltage to the unit (if this is not provided with transformer).
• Wire any remote mounted equipment and controls (remote panels, thermostats, etc.)
• Provide the main disconnect if it is not provided on the unit.

SHEET METAL CONNECTIONS

• The sheet metal duct work must be connected to the unit in accordance with acceptable sheet metal procedures as outlined by the Sheet Metal and Air Conditioning National Association, Inc (SMACNA).
• Duct sizing, material weight, composition, and connection methods must be in accordance with the engineering plans and specifications.
• Vapor sealed insulation should be installed in accordance with the engineering specifications.

START UP

• Check the following before attempting to start the unit
  • Main disconnect MUST BE OFF
  • Fan switches MUST BE OFF (the remove panel should also be OFF)
  • Power and control voltage and phase supplied to the unit must be checked to assure that they correspond to the unit installed electrical components.
  • Before power is turned on, tighten all electrical screw connections on the control panels and all power panels.
  • Check all control sequences in accordance with the wiring diagrams for the unit to assure proper functioning of controls.
  • Fans must rotate freely and in the correct direction.
  • Each fan must be checked for RPM settings required in the engineering performance documents. Fan to motor RPM ratios may be checked by comparing the number of turns the motor pulley takes in relation to one complete revolution of the fan pulley. i.e.
    (fan RPM) / (motor RPM) = (motor pulley Pitch Diam.) / (fan pulley Pitch Diam.)
  • Belt tension and alignment must be correct.
  • Drain traps must be primed with water.
  • Drain pans and exterior casing should be visually inspected for leaks and sealed as required.
  • Check the instructions in the next section for start-up instructions on optional equipment.
• After assuring yourself that all electrical, sheet metal, plumbing, and other connections have been properly made, checked all times mentioned above, and are reasonably sure that the unit will be safe to start, turn on main power.
• Momentarily turn on one fan motor at a time. Check the fan rotation and correct the motor wiring as required.

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Installation Instructions for Optional Equipment

DAMPERS

• Check the damper motors for security and linkage connections if applicable.
• The damper should be unobstructed and operating.
• Damper motors must be wired to operate in accordance with system requirements. On-Off motors should generally operate to open the damper to the face in the "ON" position. Modulating motors need to operate in accordance with the system wiring diagram.

DEFROST SYSTEMS

• Defrost systems need to be checked for proper electrical and mechanical functions.

Supply Fan Shut-off:

• Thermostat should turn off supply fan on a temperature drop below set point. Differential temperature setting should be adjusted to about 4 degrees to assure supply is restarted when this higher temperature is reached.

Supply Face or Face and Bypass Damper:

• Thermostat should be set to close the face dampers on a fall in sensed temperature.

Defrost plates:

• Traversing defrost plates are not typically operated under positive control

COILS

• Coil piping extends through the outside wall or, if provided, extends down through the plumbing and electrical chase inside the unit. Piping to the coil is provided by the mechanical contractor.

FURNACES AND DIRECT FIRED HEATERS

• Follow the Furnace/Direct Fired Heater manufacturer's Installation and Maintenance Guide supplied.

INDIRECT EVAPORATIVE COOLING UNIT

• Install the make-up water valve and recirculation pump if they are not provided by the factory. Check spray manifold and pump for proper operation.

WATER WASH

• Connect the water valves and piping to the water wash manifold/nozzle assembly located in each unit (if not provided by the factory).
• If provided, check the manual on/off ball valve. It should be in the water line before nozzle/manifold assembly.
• The detergent tank, if provided, must be mounted at the same level as the control panel in the water wash system.

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Maintenance Instructions for General Equipment

HEAT-X-CHANGERS

• Periodically check the four exchanger face surfaces to assure unobstructed, clean surfaces. Plate a light in the exhaust outlet and examine the inside of the Heat-X-Changer from the Exhaust Inlet. Examine the inside of the Supply air in the same way as the exhaust. Use a power washer, water spray hose, or vacuum cleaner as appropriate to clean the Heat-X-Changer.

BLOWERS

• Grease the bearings at regular intervals. If the unit is not used for an extended period of time, rotate the fan periodically and re-grease it as necessary.
• Check the security of the mounting bolts.
• If provided, check the security of the vibration isolators.

Direct Drive Blowers

• Check blower and motor using the guidelines detailed elsewhere in these instructions. Electrically connect the correct motor leads to obtain the appropriate RPM if the motor is multiple speed.

V-Belt Drives

• Check and adjust the belt tension and alignment as necessary. After the initial start up and 80 hours of operation, re-tighten the belt tension.
• It is important that the drives be in good alignment, with motor and blower shafts parallel. Motor must be adjusted until about 3/4" deflection of the bolt is noted with finger pressure in the middle of belt. Small changes in motor adjustment from this start may be needed for smoothest operation. Belts stretch over a period of time and motor should be adjust to compensate for this.
• Excessive deflection is an indication that the belt is not tight enough and if not corrected could result in slippage causing loss of blower speed and belt failure through water.
• Too small a deflection indicates that the belt is too tight and if not slackened somewhat could cause noise from excessive vibration, premature bearing failure, and shorter belt life. Excessive belt tension can create such a power demand as to actually overload a motor that otherwise would be quite adequate. A belt should be just tight enough to avoid slippage.
• Good pulley alignment is also very important in order to conserve belt life as well as eliminate the possibility of unnecessary noise.
• Periodic inspection should be made to determine if the unit is still soundly mounted and the belt is not slipping. Accumulations of dust and oil on the wheel will impair its performance and put the unit out of balance. If this occurs, it is necessary to clean the wheel and housing. It is especially dangerous to allow large amounts of oil to accumulate in a system, for this represents a fire hazard.

MOTORS

• Lubricate the bearings (if the unit is not provided with the permanently lubricated bearings).
• Check the security of the motor mount bolts.

DRAINS

• Insure that drains are opened and unobstructed. Drain lines must be free of foreign material.

DISPOSABLE FILTERS

• Inspect the filters and change or clean them as required based on the environmental conditions.

EXHAUST AIR STREAM

• Visually inspect the leading edges of the entry side of the exhaust air stream on the heat recovery elements.
• Inspect the exhaust blower intake, blower wheels, and blower housing. Clean these as necessary.
• If necessary, the heat recovery element can be cleaned by using a power washer. Detergents and solvents with a neutral pH are preferred. Initial inspections must be conducted in order to determine the necessity and the frequency needed for cleaning the heat recovery elements. *Note: the unit must be shut down (supply and exhaust fans) during cleaning and at any time the unit is being serviced.

SUPPLY AIR STREAM

• The supply air side of the heat recovery element should not require wash down if the disposable filters are maintained regularly according to the environmental conditions.

DUCT WORK SEALS

• Periodically examine the duct work connection seals since the entire heat recovery unit may be negative pressure during operation.

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Maintenance Instructions for Optional Equipment

FURNACES AND DIRECT FIRED HEATERS

• Inspect the area near the unit to be sure there is no combustible material near the burner.
• Turn off the manual gas valve, manual pilot valve, and electrical power to the gas duct furnace prior to working on this unit.
• Follow the detailed heater manufacturer's installation and maintenance guide supplied with this manual.

COILS

• Check and clean the coil surfaces if needed.

DAMPERS

• Check the bearing and motor operation to assure smooth operation. Periodically clean the damper blades and components.

INDIRECT EVAPORATIVE COOLING SYSTEM

Prior to seasonal start-up (where temperatures exceed 85 degrees):

• Clean the drain pan of any debris.
• Check the float operated makeup valve to be sure it is operating freely.
• Fill the recirculation pump side of drain pan with fresh water to the overflow level.
• Set the float on the makeup valve to shut the valve off when the float is approximately 1/2 inch below the overflow level.
• Inspect the water riser and distribution header for loose fittings, closed valve, etc. Adjust valves for maximum flow without water carry-over off evaporative media.

Seasonal Shutdown:

• Close shut-off valve in water makeup line and drain all exposed make-up piping.
• Turn off IDEC system.

Recirculating Pump:

• The pump should be inspected regularly. Any trash or debris which may have accumulated in the sump or on the strainers should be removed.
• Each month in operation, the pump should be drained, cleaned, and flushed with fresh water to remove the silt and sediment which normally collects in the sump during operation.

Make-up Valve

• The float controlling the valve can be adjusted. Set the valve so it is completely closed when the water level in the cold water sump is 1/2 inch below the overflow level.
• The operating water level should be checked monthly with the circulating pump running. Also check the float to maintain the recommended level.
• The valve should be inspected annually for leakage. The valve seat should be replaced if necessary.

Water Distribution Riser and Head:

• Check to see if the water is covering the evaporative media.