Bananza B-1000 Fired Air Handler Manuals

Table of Contents

5

SECTION 1: Air Handler Safety

9

Description of Operation

9

Inspection and Setup

9

Safety Labels and Their Placement

9

California Proposition 65

10

Label Placement

11

Figure 2: B-650 and B-1000

11

Figure 3: B-2000 and B-3000

12

Figure 4: B-4000 and B-5000

12

Figure 5: B-Series Interior

13

SECTION 2: Installer Responsibility

14

Wall Tag

14

Corrosive Chemicals

14

National Standards and Applicable Codes

15

Required Equipment

15

SECTION 3: Critical Considerations

16

Required Clearances to Combustibles

16

Purge of Supply Duct

17

Hardware

17

SECTION 4: National Standards and Applicable Codes

18

Gas Codes

18

Installation Codes

18

Aircraft Hangars

18

Parking Structures and Repair Garages

19

Electrical

19

Venting

19

High Altitude

19

SECTION 5: Specifications

20

Figure 6: B-350 Upright Model Dimensions

20

Figure 7: B-350 Horizontal Model Dimensions

21

Figure 8: B-650, B-1000, B-2000 and B-3000 Upright Model Dimensions

22

Figure 9: B-650, B-1000, B-2000 and B-3000 Horizontal Model Dimensions

23

Figure 10: B-4000 and B-5000 Upright Model Dimensions

24

Figure 11: B-4000 and B-5000 Horizontal Model Dimensions

25

SECTION 6: Lifting an Air Handler

28

Lifting an Air Handler

28

Figure 12: Lifting a Horizontal Air Handler

28

Figure 13: Lifting an Upright Air Handler (B-350 - B-3000)

29

Figure 14: Lifting an Upright Air Handler, a (B-4000 and B-5000)

30

Figure 15: Lifting an Upright Air Handler, B (B-4000 and B-5000)

30

SECTION 7: Roof Curb

31

Roof Curb Assembly and Installation

31

Air Handler Mounting to Roof Curb

32

Figure 16: Roof Curb Assembly

32

Figure 17: Curb Mounting

33

SECTION 8: Upright Stand Mounting (B-350 - B-3000)

34

Upright Stand Installation

34

Attaching Air Handler to Stand

34

Figure 18: Upright Stand Detail (B-350)

34

Figure 19: Upright Stand Detail (B-650 - B-3000)

34

Figure 20: Upright Stand Mounting Detail

35

SECTION 9: Leg Mounting

36

Leg Mounting

36

Leg Mounting - Horizontal Air Handler (B-350 - B-3000)

36

Figure 21: Leg Mounting Holes (B-350 - B-3000)

36

Leg Mounting - Upright Air Handler (B-4000 and B-5000)

37

Figure 22: Stud Positioning

37

Figure 23: Leg Bolt Detail

37

Figure 24: Leg Mounting (B-4000 and B-5000)

38

Figure 25: Horizontal Air Handler - Leg Pad Location (B-4000 and B-5000)

38

Figure 26: Upright Air Handler - Leg Pad Location (B-4000 and B-5000)

39

SECTION 10: Indoor Suspension Mounting - Horizontal Air Handler

40

Suspension Kit Assembly and Installation

40

Figure 27: Indoor Suspension (B-350)

41

Figure 28: Indoor Suspension (B-650 and B-1000)

42

SECTION 11: Filter Section

43

Filter Section (B-350)

43

Filter Section Assembly (B-650 and B-1000)

44

Filter Section Assembly (B-2000 and B-3000)

48

Filter Section (B-4000 and B-5000)

55

Filter Section Support Assembly

56

Figure 29: Filter Section Support Assembly

57

Figure 30: Filter Section Support (B-4000 and B-5000)

58

Filter Section Installation - Horizontal Air Handlers

59

Filter Section Installation - Upright Air Handlers

59

Figure 31: Filter Section Installation on Horizontal Air Handler (B-650 - B-3000)

59

SECTION 12: Inlet Hood

60

Inlet Hood Assembly (B-350)

60

Figure 32: Inlet Hood Assembly (B-350)

60

Inlet Hood Assembly (B-650 and B-1000)

61

Inlet Hood Assembly (B-2000 and B-3000)

70

Inlet Hood Assembly (B-4000 and B-5000)

81

Inlet Hood Installation

93

Figure 33: Inlet Hood Positioning

93

SECTION 13: Service Platform (B-4000 and B-5000)

94

Service Platform Installation

95

Figure 34: Service Platform Installation

95

SECTION 14: Dampers

96

Discharge Damper

97

Figure 35: Motorized Discharge Damper (B-350 - B-3000)

97

Inlet Damper

98

Figure 36: Motorized Inlet Damper (B-350 - B-1000)

98

Figure 37: Motorized Inlet Damper (B-2000 and B-3000)

99

Figure 38: Motorized Inlet Damper (B-4000 and B-5000)

100

SECTION 15: Discharge Heads and Splash Plates

101

One-Way and Three-Way Discharge Head Installation

101

Figure 39: Three-Way Discharge Head (B-350 - B-3000)

101

Figure 40: One-Way Discharge Head (B-4000 and B-5000)

102

Splash Plate Installation

103

Figure 41: Splash Plate

103

Figure 42: Hole Location (B-350 - B-3000)

104

Figure 43: Hole Location (B-4000 and B-5000)

104

SECTION 16: Duct Considerations

105

Inlet Duct Work

105

Return Duct Work

105

Discharge Duct Work

105

SECTION 17: Gas Piping

106

Gas Manifolds

106

Gas Piping and Pressures

106

Main Gas Regulator Venting

106

Vent Line Installation

106

Figure 44: ANSI/FM/XL-Compliant Manifolds (B-350)

107

Figure 45: ANSI-Compliant Manifold (B-650 - B-3000)

107

Figure 46: FM-Compliant Manifold (B-650 - B-3000)

108

Figure 47: XL Insurance (Former IRI)-Compliant Manifold (B-650 - B-3000)

108

Figure 48: ANSI-Compliant Manifold (B-4000 and B-5000)

109

Figure 49: FM-Compliant Manifold (B-4000 and B-5000)

109

Figure 50: XL Insurance (Former IRI)-Compliant Manifold (B-4000 and B-5000)

110

Gas Piping

111

Pressure Test Ports

111

Line Pressure Test - Leak Testing

111

Figure 51: Plug Tapping (B-350)

111

Figure 52: Plug Tapping (B-650 - B-5000)

111

SECTION 18: Electrical

112

Wiring and Electrical Connections

112

Remote Panel

112

Motor Current Draw

112

Control Current Draw

112

Safety Systems

112

Figure 53: Wiring Diagram Key

114

Figure 54: Basic Remote Wiring Diagram (B-350)

115

Figure 55: Standard Discharge Control Remote (SDC) Wiring Diagram (B-350)

116

Figure 56: Deluxe Temperature Control Remote (DTC) Wiring Diagram (B-350)

117

Figure 57: Basic Remote Wiring Diagram (B-650 - B-5000)

118

Figure 58: Standard Discharge Control Remote (SDC) Wiring Diagram (B-650 - B-5000)

119

Figure 59: Deluxe Temperature Control Remote (DTC) Wiring Diagram (B-650 - B-5000)

120

Figure 60: BMS-Ready Control MUA Style (B-350)

121

Figure 61: BMS-Ready Control MUA/FR Style Units (B-650 - B-5000)

122

Figure 62: BMS-Ready Control am Style Units (B-650 - B-1000)

123

Additional Control Wiring

124

Figure 63: Additional Control Wiring for VAV Style (B-650 and B-1000)

124

Figure 64: Additional Control Wiring for VAV Style (B-2000 - B-5000)

125

Figure 65: BMS-Ready Control for VAV Style (B-650 and B-1000)

126

Figure 66: BMS-Ready Control for VAV Style (B-2000 - B-5000)

127

Figure 67: BMS-Ready Control for VAV Style with Inlet Damper (B-2000 - B-5000)

128

Figure 68: Additional Control Wiring for VAV Style with Inlet Damper (B-2000 - B-5000)

129

Figure 69: am Style for B-650 and B-1000

130

Figure 70: am Style for B-2000 - B-5000

130

Carbon Dioxide Interlocks

131

Control Options

131

Figure 71: CO2 Sensor Interlock for FR and MUA Style

131

Figure 72: CO2 Sensor Interlock for am and VAV Style (B-650 and B-1000)

131

Figure 73: CO2 Sensor Interlock for am and VAV Style (B-2000 - B-5000)

131

Figure 74: CO Sensor Interlock for FR and MUA

132

Figure 75: CO Sensor Interlock for am and VAV

132

Figure 76: CO Sensor Interlock for am and VAV with Photohelic

132

Figure 77: CO Sensor Interlock for am with Building Pressure

132

Optional Exhaust Motor Starters, Variable Frequency Drives

137

Figure 78: J-1000 1 Pot 7.5HP or Less

137

Figure 79: V-1000 1 Pot 10-25HP

137

Figure 80: P7 1 Pot 30HP or more

138

Figure 81: J-1000 VFD 7.5HP or Less with Photohelic

138

Figure 82: V-1000 VFD 10 to 25HP with Photohelic

139

Disconnect Fuse Sizing

140

Figure 83: P7 30HP or more with Photohelic

140

SECTION 19: Sequence of Operation

141

Air Handler Configuration

141

Figure 84: Air Handler Styles

142

HVAC Remote Panels and Panel Options

143

Basic Air Handler Sequence of Operation

145

Figure 85: Selectable Configuration Jumpers

145

Figure 86: S8600 Flame Control (B-350)

146

Figure 87: RM7890 Flame Control (B-650 and B-1000)

147

Figure 88: RM7897 Flame Control (B-2000 - B-5000)

148

SECTION 20: Start-Up Procedures

149

Installation of Recirculating Air Handler

150

Mechanical

150

Figure 89: Sheave Alignment

150

Electrical

151

Airflow

151

Figure 90: Belt Tension

151

Gas Piping and Initial Pressure Settings

152

Figure 91: Honeywell Flame Module

152

Safety Shut off Valve Check

153

Temperature Control System Calibration

154

Figure 92: MR 212 Valve (B-650 - B-5000)

155

Figure 93: M611 Valve (B-350)

156

Figure 94: Regulator (B-350)

156

SECTION 21: Maintenance

157

General

158

Unit Exterior

158

Blower Section

158

Manifold and Controls

161

Burner

161

Figure 95: 6" (15.3 CM) Straight Cast Iron

162

Figure 96: 12" (30.5 CM) Straight Cast Iron

162

Figure 97: 12" (30.5 CM) Tee Cast Iron

162

Optional Equipment

163

SECTION 22: Replacement Parts

164

Figure 98: Control Panel Layouts

164

Figure 99: Power Panel Layout

165

Figure 100: Blower Layout

168

SECTION 23: Troubleshooting

170

Initial Checks

171

Motor and Blower

171

Burner

172

Temperature Controls

173

A1014 Amplifier - Field Checklist

174

A44 Amplifier - Field Service Checklist

176

Section 24: Bananza

179

B-Series Start-Up Procedures

179

SECTION 25: the BANANZA B-Series Warranty

181

Bananza B-1000 Fired Air Handler Manuals

Bananza B-1000 Installation, Operation & Service Manual (186 pages)

Table of Contents

Bananza B-1000 Manual (101 pages)

Table of Contents

Table of Contents

SECTION 1: B-Series Air Handler Safety

SECTION 2: Installer Responsibility

SECTION 3: Critical Considerations

SECTION 4: National Standards and Applicable Codes

SECTION 5: Specifications

SECTION 6: Lifting an Air Handler

SECTION 7: Roof Curb

SECTION 8: Legs for Horizontal Mounting

SECTION 9: Upright Installation

SECTION 10: Filter Section

SECTION 11: Inlet Hood

SECTION 12: Dampers

SECTION 13: Discharge Heads and Splash Plates

SECTION 14: Duct Considerations

SECTION 15: Gas Piping

SECTION 16: Electrical

SECTION 17: Sequence of Operation

SECTION 18: Direct Fired Burner

SECTION 19: Direct Fired Process Air Heaters

SECTION 20: Start-Up Procedures

SECTION 21: Maintenance

SECTION 22: Replacement Parts

SECTION 23: Troubleshooting

SECTION 24: Bananza ® B-Series Start-Up Procedures

SECTION 25: the Bananza ® B-Series Warranty

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