Turbonics SelecTemp H-12, Application, Installation, Operation, And Maintenance Manual

Page 1: ...j elcclaullw e4492 MODULATING ZONE HEATING C 4001 PEARL ROAD CLEVELAND OHIO 44109 216 741 8300 FAX 216 741 7768 ...

Page 2: ...ying the necessary information for the application installation and service of the Selec Temp heating system under normal conditions Inquiries for additional in formation on unusual applications or special conditions should be directed to TURBONICS INC 4001 PEARL ROAD CLEVELAND OHIO 44109 216 741 8300 FAX 216 741 7768 Printed in U S A Form No 2594H ...

Page 3: ...ral 29 25 Design and Operation 29 26 Putting System in Service 30 27 Calibration of Thermostat 30 28 Steam Boiler Cleaning Procedure 31 29 Water Treatment for Steam Boilers 31 30 Addition of Make Up Water to Residential Boilers 31 31 Check List for Unit Performance 32 32 Check List for Pressure Valve Performance 33 33 Check List for Condensate Pump 33 34 Replacement of Needle Bulb and Bellows in U...

Page 4: ...unit should be located on an outside wall or close to an outside wall and as near to the floor as practical It should not however be located so close to the floor that carpeting will interfere with the removal of the grille When located in a corner the unit should be mounted so the thermostat side is at least four inches from the adjacent wall 4 DETERMINE BOILER SIZE The required output of the boi...

Page 5: ... steam and condensate are flowing in the opposite direction either in a vertical riser or in a horizontal line with an upward pitch selecting pipe large enough to obtain quiet operation is necessary In tubing supply take offs both the pressure drop and the maximum vertical lift must be considered but the pitch is not a factor Locating supply piping underneath concrete slabs is not recommended The ...

Page 6: ... course also be employed on any installation to best fit the particular building layout and available space a PERIMETER MAIN UP FEED TO UNITS Figure 1 and 2 This system employs a return main generally parallel to the supply In a single or two story building this permits short supply and return tubing connections be tween the mains and the units In multi story buildings the same system may be used ...

Page 7: ...SUPPLY TUBE STEAM SUPPLY MAIN CONDENSATE RETURN TUBE CAUTION MAKE ADEQUATE PROVISIONS FOR EXPANSION OF PIPING CONDENSATE PUMP IF CONCRETE FLOOR IS USED RETURN MAIN SHOULD BE INSTALLED IN TROUGH WITH COVER PLATE AS SHOWN Section I APPLICATION gee cliam Figure 3 Central Main System Up Feed to Units With Tubing Take Offs Figure 4 Central Main System Down Feed to Units With Tubing Take Offs Page 6 ...

Page 8: ...ts With Tubing Take Offs 11 CI ED co 0 NOLLV OI lddY FLOAT TRAP STEAM SUPPLY MAIN CAUTION MAKE ADEQUATE PROVISIONS FOR EXPANSION OF PIPING CONDENSATE PUMP IF CONCRETE FLOOR IS USED RETURN MAIN SHOULD BE INSTALLED IN TROUGH WITH COVER PLATE AS SHOWN ...

Page 9: ...m in smaller buildings a complete new piping installation is usually desirable but in larger buildings some or all of the present piping may be Page 8 utilized On two pipe systems the existing piping will frequently be satisfactory providing the supply pipes are properly insulated and both supply and return piping is correctly pitched If the existing piping on a one pipe system is used as a supply...

Page 10: ...ld be used as a normal design basis The pressure required at the units as discussed in Article 2 will generally be 6 to 7 psi Therefore the difference available for pressure drop in the piping system will be about 2 psi which is divided between the steam supply main and tubing Table II shows the pressure drop through 3 8 and 1 2 0 D copper tubing for various lengths and steam flow rates The tubing...

Page 11: ... may be designed for larger systems by dividing the main into two or more sections and sizing each section separately Table IV can be used for finding the pressure drop in these cases This table is based on 100 feet of pipe and for other lengths the pressure drop will be increased or decreased in direct proportion to the length For example if the section were 75 feet long the pressure would be 75 ...

Page 12: ...op calculations for supply mains pitched down in the direction of steam flow should be based on the steam flow required for the calcu lated heat loss plus pick up if applicable rather than the total maximum capacity of connected units Selection of pipe sizes from Table V vertical risers or horizontal runouts on the other hand should be based on the maximum unit capacity at the operating pressure T...

Page 13: ...oint farthest from the condensate return pump Maintain ing the minimum pitch of not less than one inch in 20 feet is extremely important in both return mains and tubing Although it is possible to use 1 2 conden sate return mains for low flows it is preferable to use 3 4 condensate returns for 3 units or more 9 SELECT AUXILIARY EQUIPMENT The final step in the application of a SelecTemp system is to...

Page 14: ...trap is recommended for this purpose such as the Part No 203300 This 3 4 trap has a discharge capacity of about 200 pounds of water per hour under SelecTemp system oper ating conditions During running periods the trap handles only the small amount of conden sate formed to offset the heat lost from the pipe main During start up periods however the trap handles the condensate required to heat the ma...

Page 15: ... be used In some installations to obtain other sizes or numbers of outlet and inlet tappings a similar separator can best be fabricated on the job f SUPPLY PIPE AND TUBING INSULATION All supply mains and vertical pipe supply risers must be insulated Where steam pressure is maintained most of the time on the SelecTemp system the heat loss from uninsulated supply piping is greater than in on off typ...

Page 16: ...apters provide a metal frame 5 in depth and about 1 2 larger than the unit in length and width The bottom of the frame is open as shown in Figure 13 The frame can be used to mount a unit on a masonry or other wall where the recessed unit mounting is not feasible The frame can also be used on installations where the wall studs are less than 3 5 8 and the unit can be only partially recessed into the...

Page 17: ...OLE 5 1 2 INSTALL UNIT ABOVE BASEBOARD Figure 18 Unit Dimensional Drawing Metal plaster stop frames for lath and plaster walls are available with dimensions as shown in Figure 16 These frames insure a substantial finished edge to the wall opening After the plastering has been completed the unit is mounted in the framed opening using the wood screws which are provided with the unit Figure 17 Detail...

Page 18: ... diam holes or one 2 diam hole should be drilled in the left hand stud as shown in Figure 17 If the tubes approach from under neath similar holes would have to be drilled in the floor plate but as far to the left as possible in the adjoining stud space so a sharp bend would not be made in the tubes If the supply tube approaches from overhead or other stud spaces one 3 4 diam hole is required in ea...

Page 19: ...more of the three flanges must be fastened to lath and plaster dry wall or other panels which are not backed up by wood framing molly screw anchors or equivalent fasteners should be used After the mounting holes have been located which is easily done by sliding the unit into the prepared opening and using a pencil to mark the wall through the opening in the flanges a pilot opening for wood screws ...

Page 20: ...alve If the main is larger or smaller than 1 1 4 a reducing coupling from 1 1 4 to the desired main size should be used A pipe union should be provided near the valve The valves are tested and set at the factory for a discharge pressure of approximately 5 lbs but this setting can be increased to a maximum of 10 lbs To increase the pressure one pound turn the adjusting screw 1 1 2 turns clockwise T...

Page 21: ...r any local municipal or state regulations which ma apply Check motor nameplate to be sure voltage and cycle correspond to elec tric current to be used The hot line goes from the disconnect switch through terminals 1 and 2 on the No 42 low water cut off and pump control before being connected to the valve e ADJUSTMENT OF FLOAT SWITCH The two collars on the float rod should be reset from the shippi...

Page 22: ...the actual job site If it is necessary to make major variations in the main locations the main may have to be resized for the new conditions b PITCH Unless otherwise specified the steam mains should be pitched downward a minimum of 1 in 40 in the direction of flow and the con densate return mains a minimum of 1 in 20 in direction of flow Additional pitch is most desirable and if conditions permit ...

Page 23: ... 100 feet The substitution of tubing for an air vent as shown in Figure 27 is satisfactory for small re turn mains 3 4 or 1 2 If this method is used on larger return mains the loop should be at least 1 2 the size of the horizontal main 16 TRAP AND DRIP MAIN CONNECTIONS a TYPE Float type non thermostatic steam traps are used to drain the condensate from any low points and the end of the steam mains...

Page 24: ... AND RETURN TUBES a TYPE AND SIZES Soft copper refrigeration tubing is used for the supply and return tube connections between the mains and the units Normally 3 8 O D used for the supply and return tubes respectively although 1 2 supply tubes are recommended for single units with runs longer than 10 If these larger sizes are used they can be reduced before entering the unit with sweat type reduci...

Page 25: ...he tubes are to be located underground supports are not generally used but it is nec essary to keep both the supply and return tubes as short as possible and the return main well below the units in order to assure adequate pitch e OTHER PRECAUTIONS Supply and return tubes should never be in direct contact with each other since the condensate return line could become overheated and cause erratic op...

Page 26: ...mended Particular care must be paid to obtaining a waterproof joint at the point where the in sulation covering the supply tube is butted against the steam main insulation By using the same size insulation on the tubing take off an expansion pocket is provided for the supply tube at the point it is joined into the main When pouring the slab pipe sleeves should be used at the point where the supply...

Page 27: ...round the opening exposing the blower housing 2 Place damper into the upper cabinet knock out inserting the curved blades into the unit blower opening Then fasten the upper air duct to the cabinet with the sheet metal screws provided The damper rod must be located in the air duct notches before screws are tightened Then install unit into framed opening 3 Next place the grille over the wall opening...

Page 28: ... Preformed Glass Fiber insulation 1 inch thick greatly preferred cuts heat loss to al most one half that obtained using Air Cell permanent and neater in appearance 6 Insulate underground piping with waterproof glass fiber insulation or other suitable ma terials 7 Float trap always used at end of main and at any point of rise from the uniform downward pitch away from boiler 8 Condensate from trap c...

Page 29: ... of tubing with pliers while instal ling and leave sealed to avoid contamination until unit is actually connected Leave about 6 inches excess on both supply and return tubing before cutting to final length at unit 10 Ream ends of 3 8 inch O D tubing before connecting to unit 11 Always use tube benders for bending tubing 12 Make certain strainer is installed in supply tube at coupling on unit 13 Do...

Page 30: ...e return line E Room air enters the unit through the lower grille opening F passes through an air filter G the heat transfer core and the circulating fan The warm air is then discharged into the room through ad justable vaned openings H and I which control the vertical and horizontal distribution of the heated air A highly sensitive but rugged thermostat controls both the heat output and the speed...

Page 31: ...n the initial startup condense all of the steam as rapidly as it is being de livered through the turbine nozzle This will cause live steam to pass on through the units into the return line for a few minutes until the return line temperature control heats up suf ficiently to throttle back the steam supply When first starting up a system the units will operate for several minutes regardless of therm...

Page 32: ...oiler water should be brought to a boil soon after filling so that all the compound used for treatment will be thoroughly mixed in the boiler water and the oxygen and the other gases dis solved in the water will be driven off While the water is being heated the main steam valve should be left open so that the gases can escape through the system and out the vent opening on the condensate return If ...

Page 33: ...ess plaster around unit frame or frame being bent or warped out of line during installation 8 Dirty air filter or heat transfer core filters must be in place at all times If core is dirty clean with vacuum cleaner attachment Clean or replace air filter 9 Heat deflecting off walls or furniture overheating thermostat 10 Excess air circulating around back of unit Seal all openings around piping where...

Page 34: ... leak by since the valve does not provide a 100 shut off The No 203160 valve will admit steam to the distribution system at all times although it will not regulate until the boiler pressure exceeds the valve setting The valve bodies on No 203100 and No 203160 are identical and the pressure adjustment is made similarly on both The operating parts on the two valves are interchangeable with the part ...

Page 35: ...sembly in a SelecTemp unit may be indicated when unit runs at full speed and will not modulate or shut off or by one that will modulate down to a low speed but will not come to a complete stop Before concluding that the control assembly is faulty the following items should be checked 1 Check to see if bulb is in support clip and centered in chimney 2 Make certain that damper is not caught on botto...

Page 36: ...T MODULATE OR SHUT OFF NOTE IF THE BULB AND BELLOWS IS REPLACED IT IS MOST IM PORTANT THAT THE COPPER CHIMNEY ASSEMBLY BE THOR OUGHLY WRAPPED WITH GLASS FIBER INSULATION BEFORE THE CONTROL BOARD STEP NO 6 IS RE INSTALLED IF THE CHIMNEY IS NOT THOROUGHLY INSULATED THE HEAT LOSS MAY BE EXCESSIVE THUS WHEN THE DAMPER CLOSES THE TEMPERATURE INSIDE THE CHIMNEY MAY NOT BE HIGH ENOUGH FOR THE ALCOHOL TO ...

Page 37: ... REMOVE PIECE OF FIBREGLAS INSULATION AND THE TAKE OFF BEARING COVER BY REMOVING THREE SHEET METAL SCREWS REMOVE AND DISCARD OUTBOARD BEARING AND COVER CD REMOVE TWO SHEET METAL SCREWS jal FIBREGLAS INSULATION Jl Procedure Continued on Figure 40A C efecl ev Section III MAINTENANCE SERVICE 35 INSTRUCTIONS FOR REPLACING OUTBOARD BEARING ASSEMBLY NO 200811 ON FAN WHEEL SHAFT OF SELECTEMP UNITS Figure...

Page 38: ...CIAL LUBRICANT MUST BE USED THIS IS AVAILABLE IN HALF PINT CANS FROM THE FACTORY SPECIFY PART NO 200923 DIFFUSER ASSEMBLY IMPORTANT CLEAN FAN WHEEL SHAFT USING CARBON TETRACHLORIDE OR ACETONE ONLY USE A CLEAN CLOTH AND BE VERY CAREFUL NOT TO MAR THE SUR FACE OF SHAFT ATTACH BEARING HOLDER WITH 1 2 NO 8 SHEET METAL SCREW FURNISHED BEARING HOLDER BEARING WASHER BARRIER OIL DUST OUTBOARD BEARING ASM ...

Page 39: ...h bearing lubricant is available For larger installations a No 204745 pressure type applicator along with 1 2 pint cans of the special No 200923 outboard bearing lubricant will prove more useful The tip of the applicator Figure 42 must be in serted under the brass dust shield of the outboard bearing and a liberal quantity of lubricant applied The blower shaft should then be rotated and also worked...

Page 40: ... into the condensate receiver The amount of inhibitor in small systems need not be maintained in an exact ratio How ever excessive quantities will not give greater Section III MAINTENANCE SERVICE protection and are not recommended because the boiler will tend to prime and foam if the concentrate is too high For a system operating on district steam an automatic mechanical feeder will be required b ...

Page 41: ...FIREMAN STEAM BOILERS USED WITH SELECTEMP SYSTEMS MODELS WATER CAPACITY IN GALS AT NORMAL WATER LEVEL BA 55 REQUIRED QUARTS SBI COMPOUND REQUIRED 10 OZ CANS OIL FIRED GAS FIRED BTO 112 BTG 142 23 1 1 MSO 114 MSG 142 26 1 2 1 1 SOV 114 SGB 145 27 1 1 SOV 115 SGB 144 18 1 1 MSO 140 MSG 175 31 1 1 SOV 143 SGB 175 34 1 1 SOV 144 SGB 180 26 1 1 BTO 160 BTG 200 33 1 1 MSO 180 MSG 225 42 1 4 2 2 SOV 198 ...

Page 42: ...MODULATING ZONE HEATING 4001 PEARL ROAD CLEVELAND OHIO 44109 216 741 8300 FAX 216 741 7768 ...