EngA Engineered Air XES-SC Series User manual

IOM-58 June 14 R5

INSTALLATION, OPERATION

AND MAINTENANCE MANUAL

FOR

XES-SC SERIES

INDOOR INDIRECT GAS FIRED

SEPARATED COMBUSTION HEATING UNIT

UNIT MODEL NO. _________________

UNIT SERIAL NO. _________________

SERVICED BY: ___________________

TEL. NO: ________________________

CANADIAN

HEAD OFFICE

AND FACTORY

USA

HEAD OFFICE

AND FACTORY

CANADIAN

FACTORY

1401 HASTINGS CRES. SE

CALGARY, ALBERTA

T2G 4C8

Ph: (403) 287-4774

Fx: 888-364-2727

32050 W. 83rd STREET

DESOTO, KANSAS

66018

Ph: (913) 583-3181

Fx: (913) 583-1406

6130 97th STREET

EDMONTON, ALBERTA

T6E 3J4

Ph: (780) 430-0310

Fx: (780) 434-6272

SALES OFFICES ACROSS CANADA AND USA

Retain instructions with unit and maintain in a legible condition.

Please give model number and serial number when contacting

factory for information and/or parts.

www.engineeredair.com

A XES SC MANUAL

IOM-58 2 of 30 June 14 R5

TABLE OF CONTENTS

You Have Responsibilities Too .....................................................................................................................................................3

Introduction .................................................................................................................................................................................3

Warranty ......................................................................................................................................................................................5

Parts .............................................................................................................................................................................................6

Receiving ......................................................................................................................................................................................6

Temporary Storage.......................................................................................................................................................................6

Installation....................................................................................................................................................................................7

Codes............................................................................................................................................................................................7

Minimum Clearance For Service And To Combustibles ...............................................................................................................8

Mounting......................................................................................................................................................................................8

Shipping Materials........................................................................................................................................................................9

Suitable Locations ........................................................................................................................................................................9

Assembly Of Two Piece Xess ........................................................................................................................................................9

Separated Combustion...............................................................................................................................................................10

Combustion Air Duct ..................................................................................................................................................................11

Venting Products Of Combustion...............................................................................................................................................12

Natural Gas And Propane Installation........................................................................................................................................18

Gas Line Testing (External To The Unit) .....................................................................................................................................18

Electrical Installation ..................................................................................................................................................................18

Split Unit Wiring .........................................................................................................................................................................19

Recommended 24v Field Wiring Size: ........................................................................................................................................20

Duct Mounted Te-6000-Ea3 Temperature Sensor .....................................................................................................................21

Before Start-Up ..........................................................................................................................................................................21

Start-Up Check List .....................................................................................................................................................................21

Operation ...................................................................................................................................................................................23

Combustion And Final Unit Check For Units Without Trac Controls..........................................................................................23

Unit Shut-Down Instructions......................................................................................................................................................24

Service Shut Down .....................................................................................................................................................................24

Maintenance ..............................................................................................................................................................................25

Electrical.....................................................................................................................................................................................25

Operating Instructions ...............................................................................................................................................................25

Belt Adjustment .........................................................................................................................................................................26

Set Screws ..................................................................................................................................................................................26

Bearing Setscrew Torques..........................................................................................................................................................26

Fan Lubrication...........................................................................................................................................................................27

Motor Lubrication ......................................................................................................................................................................27

Inspection And Cleaning.............................................................................................................................................................27

Filters..........................................................................................................................................................................................27

Controls......................................................................................................................................................................................27

Outdoor Air Intakes, Mixing Sections And Dampers..................................................................................................................28

Safety Shutoff Valve Leak Test:..................................................................................................................................................28

Troubleshooting .........................................................................................................................................................................29

Start-Up Record..........................................................................................................................................................................30

A XES SC MANUAL

IOM-58 3 of 30 June 14 R5

YOU HAVE RESPONSIBILITIES TOO

This installation, operation and maintenance manual cannot cover every possibility, situation or

eventuality. Regular service, cleaning and maintaining the equipment is necessary. If you are not capable

of performing these tasks, hire a qualified service specialist. Failure to perform theses duties can cause

property damage and/or harm to the building occupants and will void the manufacturers’ warranty.

INTRODUCTION

Engineered Air units are high quality products designed and manufactured to provide many years of

trouble-free operation. Engineered Air recommends that is manual be read thoroughly to ensure proper

installation, efficient operation and proper maintenance of this equipment. The submittal record is

considered to be part of the Installation, Operation and Maintenance Manual. Please report any

omissions to the national service manager.

SAFETY PRECAUTIONS

Read, understand and follow the complete manual before beginning the installation, including all safety

precautions and warnings.

WARNING:

FIRE OR EXPLOSION HAZARD

Failure to follow safety warnings exactly could result in serious injury, death or property damage.

Be sure to read and understand the installation, operation and service instructions in this manual.

Improper installation, adjustment, alteration, service or maintenance can cause serious injury, death or

property damage.

—Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other

appliance.

—WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance.

Do not touch any electrical switch; do not use any phone in your building.

Leave the building immediately.

Immediately call your gas supplier from a phone remote from the building. Follow the gas

supplier’s instructions.

If you cannot reach your gas supplier, call the fire department.

—Installation and service must be performed by a qualified installer, service agency or the gas supplier.

A XES SC MANUAL

IOM-58 4 of 30 June 14 R5

Warning:

Pool, laundry and common cleaning products often contain fluorine or chlorine

compounds. When these chemicals pass through the heater, they can form strong acids.

The acid can eat through the heat exchanger wall, causing serious damage and

presenting a possible threat of flue gas spillage into the building.

Warning:

This unit is connected to high voltages. Electrical shock or death could occur if

instructions are not followed. This equipment contains moving parts that can start

unexpectedly. Injury or death could occur if instructions are not followed. All work

should be performed by a qualified technician. Always disconnect and lock out power

before servicing. DO NOT bypass any interlock or safety switches under any

circumstances.

A XES SC MANUAL

IOM-58 5 of 30 June 14 R5

WARRANTY

LIMITED WARRANTY

ENGINEERED AIR will furnish without charge, F.O.B. factory, freight collect, replacement parts for, or

repairs to products covered herein which prove defective in material or workmanship under normal and

proper use for a period of twelve (12) months from the initial start-up or eighteen (18) months from the

date of shipment, whichever expires sooner, provided the customer gives ENGINEERED AIR written notice

of such defects within such time periods and provided that inspection by ENGINEERED AIR establishes the

validity of the claim and all pertinent invoices have been paid in full. The repairs or replacements will be

made only when the complete product(s) or part(s) claimed to be defective are returned to ENGINEERED

AIR or a depot designated by ENGINEERED AIR, transportation charges prepaid. Repairs or replacements

as provided for by this paragraph shall constitute fulfillment of all ENGINEERED AIR's obligations with

respect to this warranty. The refrigerant charge is not included in any part of this warranty. This warranty

does not apply to any products or parts thereof that have been subject to accident, misuse or

unauthorized alterations, or where ENGINEERED AIR's installation and service requirements have not been

met.

The foregoing warranty is in lieu of all other warranties, express or implied. ENGINEERED AIR specifically

disclaims any implied warranty of merchantability and/or fitness for purpose. Under no circumstances

shall ENGINEERED AIR be liable to, nor be required to indemnify, Buyer or any third parties for any claims,

losses, labour, expenses or damages (including special, indirect, incidental, or consequential damages) of

any kind, resulting from the performance (or lack thereof) of this Agreement or the use of, or inability to

use the goods sold hereunder, including, but not limited to, damages for delay, temporary heating/cooling

costs, loss of goodwill, loss of profits or loss of use. Furthermore, the parties agree that the Buyer's sole

remedy under this Agreement shall be limited to the limited warranty set forth in the preceding paragraph

relating to the repair or replacement of any defective goods. Under no circumstances shall any claim or

award against ENGINEERED AIR exceed the original contract price whether awarded through arbitration,

litigation or otherwise.

ENGINEERED AIR Warranty is void if:

1. The unit is not installed in accordance with this manual.

2. The start-up and operation of the unit is not performed in accordance with this manual.

3. The unit is operated in an atmosphere containing corrosive substances.

4. The unit is allowed to operate during building construction.

5. The unit is allowed to operate in atmospheres where chlorine or chlorine compounds are present

or which contain any contaminant (silicone, aluminum oxide etc.) that adheres to the spark ignition

flame sensing probe.

A XES SC MANUAL

IOM-58 6 of 30 June 14 R5

PARTS

WARNING:

Any replacement part must be of equivalent listing or certification and be functionally

equivalent. The replacement part must meet the original’s specification in terms of

functionality including certifications, timing, input and output range, accuracy and

operation.

Failure to replace parts or components with equivalent parts can cause property

damage, injury or death.

1. Motors:

Motor manufacturers have service centers that will repair or replace motors as required.

2. Parts Other Than Motors:

Contact the nearest Engineered Air sales office or factory. Be sure to include Model Number, Serial

Number, date of installation and nature of failure along with the description of the parts required.

Some parts may not be stocked items that must be made or ordered.

RECEIVING

Refer to the back of the packing slip for receiving unit instructions.

On receipt of the unit, check for damage. Inspect protective covers for punctures or other signs that there

may be internal damage. Remove protective covers and check for internal damage. Replace covers if the

unit is not being assembled or installed at this time. Open access doors and check for internal damage.

Close access doors when the inspection is complete.

All units are pre-tested at the factory immediately prior to shipping and are ensured to be in good

operating condition at that time. If damage is found follow the instructions on the packing slip.

On receipt of the unit, check electrical characteristics (see rating plate) to make sure the unit voltage is

compatible with that available for the unit. All parts for field installation are listed on the shipping order

form.

TEMPORARY STORAGE

If a unit is to be stored prior to installation the following precautions are required:

•Store in a well drained area that will not accumulate surface water.

•Store in an area where the unit will not get damaged.

•The entire perimeter and any full height cross members of the unit must be supported by a level

surface and the supporting surface must be adequate for supporting the entire weight of the unit.

•All protective coverings that were provided for shipping must be in place.

•Protect from rain and snow.

A XES SC MANUAL

IOM-58 7 of 30 June 14 R5

INSTALLATION

Warning:

This unit is not rated for hazardous locations and cannot be installed in areas requiring

any hazardous location rating.

Caution:

All wiring, piping and fuel line installation must be completed by qualified persons in

accordance with all federal, state, provincial and/or local codes.

Note: Installation shall be in accordance with this manual and all other associated component and

control Installation, Operation and Maintenance Manuals.

CODES

In Canada:

1. The installation of this unit shall be in accordance with the latest edition of the Canadian Electrical

Code, Part 1 –C.S.A. Standard C22.1, Provincial and Local Codes, and in accordance with the local

authorities having jurisdiction.

2. This unit shall be electrically grounded in accordance with the latest edition of the Canadian

Electrical Code, Part 1 –C.S.A. Standard C22.1, Provincial and Local Codes, and in accordance with

the local authorities having jurisdiction.

3. The installation of this unit shall be in accordance with the latest edition of the Canadian Natural

Gas and Propane Installation Code, C.S.A. Standard B149.1, Provincial and Local Codes, and in

accordance with the local authorities having jurisdiction.

4. In accordance with local authorities having jurisdiction or CSA. Standard B149.1 a readily accessible

approved manual shut-off valve shall be installed in either the drop or riser as close as possible to

the valve train (gas manifold).

5. The installation of this unit shall be in accordance with the latest edition of the National Plumbing

Code of Canada, Provincial and Local Codes, and in accordance with the local authorities having

jurisdiction.

6. The installation of this unit shall be in accordance with all other National, Provincial and Local

Codes, and in accordance with the local authorities having jurisdiction.

In USA:

1. The installation of this unit shall be in accordance with the latest edition of the National Electrical

Code (ANSI/NFPA 70), State and Local Codes and in accordance with the local authorities having

jurisdiction.

A XES SC MANUAL

IOM-58 8 of 30 June 14 R5

2. This unit shall be electrically grounded in accordance with the latest edition of the National

Electrical Code (ANSI/NFPA 70), State and Local Codes and in accordance with the local authorities

having jurisdiction.

3. If the unit has not been provided with an electric disconnect switch, one of adequate ampacity

shall be installed in accordance with Article 430 of the National Electrical Code (ANSI/NFPA 70).

4. The installation of this unit shall be in accordance with the latest edition of the National Fuel Gas

Code ANSI/Z223.1/NFPA 54, State and Local Codes and in accordance with the local authorities

having jurisdiction.

5. In accordance with local authorities having jurisdiction or NFPA 54 an accessible approved manual

shutoff valve shall be installed within 6 ft (1.8 m) of the valve train (gas manifold).

6. The installation of this unit shall be in accordance with the latest edition of the National Standard

Plumbing Code (NSPC), State and Local Codes and in accordance with the local authorities having

jurisdiction.

7. The installation of this unit shall be in accordance with all other National, State and Local Codes,

and in accordance with the local authorities having jurisdiction.

MINIMUM CLEARANCE FOR SERVICE AND TO COMBUSTIBLES

For Safety and Service, the following minimum clearances on the units shall be observed, in inches (mm):

Heaters must be installed to meet at least the minimum clearances shown on the rating plate. The rating

plate is located in the burner compartment. Be sure to allow enough clearance in front of the unit for

removing the burners and above for removing fan motors and blades.

MODEL

COMBUSTIBLE CLEARANCE

SERVICE CLEARANCE

TOP

FRONT

BACK

SIDE

BOTTOM

FLUE

SERVICE/

BURNER

SIDE

CONTROL

PANEL Þ

XES

1" (25)

6" (152)

C‡

6" (152)

24"

(610)

42”

(1068)

Þ - As required by the Canadian Electrical Code or the National Electrical Code.

* - Service Clearance For Burner & Blower Access, 24" (610).

‡- XES with suffix CF on combustible floor requires special base Part# CB(2,3,4,5,7,8, & 10).

MOUNTING

Units must be mounted level. Failure to do so can cause operational problems that can void warranty.

Failure to do so can result in injury or death, damage to the equipment and/or building and can be a cause

of poor indoor air quality. Equipment must be installed so that sufficient working clearance and

component access is provided. Consult the Submittal Record for specific unit mounting.

A XES SC MANUAL

IOM-58 9 of 30 June 14 R5

SHIPPING MATERIALS

Remove shipping materials. Shipping materials may include, but are not limited to:

-Protective covers over openings, inlets etc.

-Protective covers over split sections if provided.

-Tie-down bolts, straps and blocks on fan vibration isolators.

-Indirect fired heat exchangers may be supported with wood for shipping. Remove.

SUITABLE LOCATIONS

These appliances are suitable for use in aircraft hangars, parking structures and repair garages when

marked and installed, as applicable, in accordance with:

-Standard on Aircraft Hangars, ANSI/NFPA 409

-Standard for Parking Structures, ANSI/NFPA 88A

-Standard for Repair Garages, ANSI/NFPA 88B

-Installation Code for Natural Gas and Propane Installation Code, CSA B149.1

ASSEMBLY OF TWO PIECE XESs

This procedure covers the required field assembly of XES units.

HB (HIGH BOY) UNITS

a) Place the heat section on top of the fan section so the heat section is 1/2" (13 mm) behind the fan

section.

b) Carefully slide the heat section forward until the back and sides of the heat and fan section are

flush. This will lock the two pieces together at the back as the locking clip engages. Do not damage

foam tape which acts as air seal between sections.

c) Remove the fan section door, then lift the front of the heat section and block the front open about

4" (102 mm).

d) Feed the motor wires through the grommet between the sections and allow the wire to hang in the

fan compartment.

e) Lower the heat section back onto the fan section. Check alignment of the pieces then drive sheet

metal screws up from the fan section into the heat section. Holes are provided in the fan section at

the front sides for locating screws. Make sure the motor wires are not pinched between sections -

but feed smoothly from one section to the other.

f) The unit is now one piece locked together at the rear by a clip and at the front by two sheet metal

screws.

g) Follow the wiring diagram on the unit to connect motor wires to motor.

h) Inspect and test electrical components and motor operation.

CF (COUNTER FLOW) UNITS

a) Place the fan section on top of the heat section so the fan section is 1/2" (13 mm) forward of heat

section.

A XES SC MANUAL

IOM-58 10 of 30 June 14 R5

b) Carefully slide the fan section back until the back and sides of the heat fan section are flush. This

will lock the two pieces together at the back as the locking clip engages. Do not damage foam tape

which acts as air seal between sections.

c) Remove the outer fan door, vent pipe, shipping cardboard and inner fan door. Drive sheet metal

screws from the fan section into the heat section. Holes are provided in the front vestibule at sides

for locating two sheet metal screws.

d) The unit is now one piece locked together at back by clip and at front by two sheet metal screws.

e) Motor wires and upper limit control wires are clipped at top of heat section. Feed both of these

wire pairs into the fan compartment, through the hole provided. Wires should be neatly clipped in

place and taut so they will not contact the hot draft hood parts.

f) Connect the motor wires to the motor and upper limit control wires to the limit as shown on wiring

diagram.

g) Install the inner fan door.

h) Connect the vent pipe between the heat section and the top collar of the fan section. The vent

connector piece should be secure and located at the top of the fan section.

i) Inspect and test the electrical components and motor operation.

SEPARATED COMBUSTION

Warning:

Separated combustion equipment is not designed or approved for use in

atmospheres containing flammable or chlorine vapors.

Warning:

The installation of separated combustion systems must be completed by

qualified persons in accordance with all federal, state, provincial and/or local

codes.

Warning:

Do not operate this heater without all combustion air and flue gas piping

installed.

The heater shall not be connected to a venting system serving any other gas, liquid or solid fuel fired

appliance. Installation shall be in accordance with the requirements of authorities having jurisdiction and

ANSI Z2231/NFPA 54 or CSA B149.1. The vent shall be installed in such a manner that access to the

appliance or unit rating plate is not obstructed.

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