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Simba Run Appeal Materials
Department of Community Development 75 South Frontage Road Vail, CO 81657 Tel: 970-479-2128 www.vailgov.com Development Review Coordinator Appeals Form D EC Row IE GCT 2 3 2014 TOWN OF VAIL General Information: This form is required for filing an appeal of a Staff, Design Review Board or Planning and Environmental Commission action/decision. A complete form and associated requirements must be submitted to the Community Development Department within twenty (20) calendar days of the disputed action/decision. Action/Decision being appealed: THE APPROVAL OF THE PROJECT REFERENCED AS THE "SIMBA RUN CONDOMINIUM SWIMMING POOL BUILDING HUMIDITY MITIGATION PROJECT", CONSISTING OF: THE INSTALLATION OF LARGE ABOVE -GROUND COMMERCIAL "DESERT AIRE" DEHUMIDIFICATION SYSTEMS AND CONDENSERS; THE CONSTRUCTION OF SURROUNDING AND ADJACENT WALLS, SCREENS, ROOFING AND GATES; THE INSTALLATION OF HYDRONIC PIPING, REFRIGERANT PIPING, CONDENSATE PIPING AND NATURAL GAS PIPING; CONSTRUCTION OF ALL OTHER RELATED AND INCIDENTAL STRUCTURES AND COMPONENTS; AND THE PROPOSED EXTENSIVE REGRADING OF EXISTING LAND AND REMOVAL OF MATURE VEGETATION. Date of Action/Decision: OCTOBER 15, 2014, AND ALL PRIOR ACTIONS OF THE TOWN OF VAIL DESIGN REVIEW BOARD OR ITS STAFF THAT ARE APPEALABLE AT THIS TIME AND UNDER THE CIRCUMSTANCES PRESENT IN THIS APPEAL, INCLUDING ANY ADDITIONAL TIME FOR APPEAL ATTRIBUTABLE TO THE FAILURE OF THE ORIGINAL APPLICANT OR THE DESIGN REVIEW BOARD TO PROVIDE NOTICE TO THE APPELLANTS. Board or Staff person rendering action/decision: TOWN OF VAIL DESIGN REVIEW BOARD AND STAFF, WARREN CAMPBELL, PLANNER Does this appeal involve a specific parcel of land? YES If yes, are you an adjacent property owner? YES Names of Appellants: ROBERT W AND MADELAINE M KLEINMAN Mailing Address: ROBERT W KLEINMAN 61 L'ORANGE PLACE KAILUA, HI 96734 Phone: 970 331 4654 and 970 688 4765 Physical Address in Vail: UNIT 2310, SIMBA RUN CONDOMINIUMS 1100 NORTH FRONTAGE ROAD VAIL, CO 81657 Legal Description of Appellant (s) Property in Vail: SEE ATTACHED PROPERTY TAX BILL FOR LEGAL DESCRIPTION Appellants Signatures: Dated: October 17, 2014 SEE THE ATTACHED SUBMITTALS SUBMITTAL REQUIREMENTS 1. On a separate sheet or separate sheets of paper, provide a detailed explanation of how you are an "aggrieved or adversely affected person". 2. On a separate sheet or separate sheets of paper, specify the precise nature of the appeal. Please site specific code sections having relevance to the action being appealed. 3. Provide a list of names and addresses (both mailing and physical addresses in Vail) of all owners of property who are the subject of the appeal and all adjacent property owners (including owners whose properties are separated from the subject property by a right-of-way, stream or other intervening barrier). 4. Provide stamped, addressed envelopes for each property owner listed in (3). Submit this form and all submittal requirements to: Town of Vail Community Development Department 75 South Frontage Road Vail, CO 81657 For Office Use Only: Date Received: 10- �? 3 I q Activity No.: �R(3 iHOybi Planner: _i J C - Project No: PS ;T a- D��3 Nov 2013 Robert and Madelaine Kleinman 1100 North Frontage Road Unit 2310 Vail, CO 81657 October 21, 2014 Warren Campbell, Planner Town of Vail Department of Community Development 75 South Frontage Road Vail, CO 81657 OCT 2 3 2014 TOWN OF VAIL Re: Appeal dated October 17, 2014 of approvals relating to the Simba Run Condominium Swimming Pool Building Humidity Mitigation Project Dear Mr. Campbell: As requested in your email to me of October 21, 2014, I have attached stamped envelopes addressed to the President, Board of Directors, of the Homeowners' Association for Savoy Vail, Vail Run and Casolar Vail. I have also attached, as a supplement to our Appeal, the Installation and Operating Manual for the Desert Aire SA Series Dehumidifiers, which Applicant proposes to install just feet from our home. Section 2.1 (at page 11) of the Manual provides: Do not install the unit near occupied rooms such as offices or guest rooms. There are over 30 occupied 2 -bedroom condominiums in Building Two at Simba Run, nearly all of which are "near" the proposed installation. Applicant failed to provide this information to the Design Review Board or its Staff, failed to disclose this information to any owners at Simba Run, and failed to explain how its proposed installation of this equipment in contravention of the manufacturer's own admonition is in the best interests of the unit owners. We respectfully request that you consider this supplemental information in your review of our Appeal. Thank you again for your cooperation and assistance in connection with this matter. Should you need anything further from me, please get back to me via email, or call my cell at 970 331 4654. Very truly yours, //VII J�' -/-)) jW w• A('� Madelaine Kleinman Robert Kleinman ATTACHMENT 1 TO APPEAL DATED OCTOBER 17, 2014 ROBERT AND MADELAINE KLEINMAN, APPELLANTS How Appellants are an "aggrieved or adversely affected person" — We own Simba Run condominium unit no. 2310, the home that is immediately adjacent to the proposed Project. We have included with this Appeal as Attachment A the Construction Documents prepared by R & H Mechanical, the construction contractor for the Project, and previously submitted by the Applicant to the Design Review Board. The square with dotted lines marked "Project Location" on page 1 to Attachment A delineates the location of the proposed construction. The straight line immediately opposite the upper left corner of the square delineating the Project Location is the patio doors to our living room. We live in our Simba Run home as our principal residence, and live there approximately seven months each year, during the summer and winter months. What is being proposed is the above -ground installation of commercial sized condensers and dehumidification systems, and structures to surround such equipment, resulting in the placement of this equipment and structures immediately outside of our home, within feet of our living space. The main structure will be approximately the size of a railroad freight car, will destroy our views and will create a noise and general nuisance. Inexplicably, this Project was planned and submitted for approval without ANY notification to us, the immediately impacted homeowner, by either the Applicant or the Town of Vail. As described in the following attachments, this Project violates the spirit and letter of the Town of Vail Design Review Board ordinances and the laws of the State of Colorado, including, without limitation, the Design Review Standards and Guidelines of the Town of Vail and the Noise Abatement statutes of the State of Colorado, including C.R.S. 25-12-101 through 103, et seq. Appellants are available to provide any additional information required by the Department of Community Development to resolve this Appeal and wish to receive timely notice of and to participate in any further hearings or other actions taken in connection with the Project, the application or this Appeal. ATTACHMENT 2 TO APPEAL DATED OCTOBER 17, 2014 ROBERT AND MADELAINE KLEINMAN, APPELLANTS Nature of the Appeal, with reference to specific code sections — Noise and other Nuisance Laws — Included in the Project are condensers and dehumidifiers that are of large commercial grade (the dehumidifier alone has an operating weight of 7,500 pounds — See Page 4 to Attachment A) and which are not suitable for installation so close to residences. The condenser operates at a sound level of 65dB, and will cycle on and off 24 hours a day, 365 days a year, creating a shrill noise at start up. The dehumidifier fan moves 8,200 cfm of air and the air supply fan uses a 10hp motor (See page 4 to Attachment A). The noise from the dehumidifier is in addition to the 65dB noise created by the condenser. These noise levels are beyond the permissible noise levels for residential areas under the State of Colorado's Noise Abatement statutes, including C.R.S. 25-12-101 through 103, et seq. The proposed operation of this equipment will also constitute a general nuisance that is actionable under the laws of the State of Colorado and the ordinances adopted by the Town of Vail. Design Review Standards and Guidelines — The compatibility and suitability of any proposed structure to its surroundings and to the environment are at the essence of the Town of Vail's Design Review Standards and Guidelines (the "Standards"). See, e.g., Paragraph A of Section 14- 10-2 of the Standards ("Structures shall be compatible with existing structures, their surroundings, and with Vail's environment"). The above -ground installation of noisy, commercial sized condensers and dehumidifiers in close proximity to residential dwellings, and with containment buildings and structures made of stucco, metal and other non -natural products (all of which are inconsistent with the composition of the surrounding buildings), with a construction plan that contemplates the extensive regrading of the surrounding topography, cannot possibly be approvable under the Standards, should have been rejected, and must now be rejected on Appeal. The following are just some of the way in which the Project is violative of the Standards: I . Buildings are to fit into their sites so as to preserve the natural landforms and features intact. (Paragraph B of Standards Section 14-10-2. See also Paragraphs A, B and C of Standards Section 14-10-3). The Project will require the total regrading of the entire site area, and the removal of mature Aspen trees and other established vegetation. We have been advised that truckloads of overburden will need to be removed from the site to accommodate the Project. The proposed regrading is described in Attachment A. 2. Ancillary buildings are to be constructed of the same or a complimentary material to the main building's exterior finish. (Paragraph C of Standards Section 14-10-10). The walls of the Project will be stucco, an unfavored building material and one that is wholly incompatible with the existing building. (See Attachment A, page 3). The roof of the Project will be a Kalwall Roof System, also not a favored construction material and totally inconsistent with the existing exterior materials of the present building. Note that these artificial roof panels will be fully visible from the dwelling units in the existing building. They may also reflect direct sunlight onto the adjacent dwelling units, in contravention of the requirements of Paragraph F of Standards Section 14-10-5. 3. All utility service systems shall be installed underground. (Paragraph C of Standards Section 14-10-10). While the original pool equipment was installed underground, in a manner compliant with the Standards, the Project will be fully above ground, which creates the noise, esthetic and other issues addressed in this Appeal. Applicant should not be allowed to construct the Project (consisting of utility service equipment or its equivalent) above ground, and should not be allowed to construct the Project in a manner that destroys the unique topography of the existing site. No consideration by the Applicant of other less objectionable solutions — The Project has been described by the Applicant as needed to reduce damage to metal support structures in its pool building due to exposure to chlorine and chlorine derivatives. These chemicals arise from Applicants use of traditional chlorinating products to sanitize its pool and hot tub water. The use or overuse of such products constitute obsolete technology, as there are currently better ways to effectively sanitize pool and hot tub water without the use of such chemicals in the quantities now being used by Applicant. These include conversion to salt chlorination, where the only added chemical is sodium chloride, or the use of ultra violet disinfecting units, that significantly reduce the need for traditional swimming pool chlorine and related chemicals. The following is a partial list of web sites describing these better options, none of which were appropriately considered by Applicant: http://www.american-pools.coi,n/salt-water-pool-conversion-from-chlorine/ http://www.deltauv.com/?page_id=62 No legitimate need for this Project — Applicant's own consultant has advised Applicant that the damage to the pool building is far less than was originally thought when this Project was initially proposed. The pool building is now over 30 years old and is showing only minimal deterioration from the humidity and chemical interactions that the Project is designed to ameliorate. More conservative maintenance methods would address the minimal damage currently present in the pool building without the nuisance that would result from completion and operation of this Project. ATTACHMENT 3 TO APPEAL DATED OCTOBER 17, 2014 ROBERT AND MADELAINE KLEINMAN, APPELLANTS List of property owners that are the subject of this Appeal or are adjacent property owners — The applications for the Project were submitted by the Board of Directors, Simba Run Condominium Homeowners' Association. Their address is: Board of Directors Simba Run Condominium Homeowners' Association 1100 North Frontage Road Vail, CO 81657 The following are the names and addresses of the unit owners at Simba Run that are most immediately impacted by the proposed Project, other than the Appellants: Danielle Gooden Unit 2304, Simba Run Condominiums 1100 North Frontage Road Vail, CO 81657 Francisco Roman Unit 2306, Simba Run Condominiums 1100 North Frontage Road Vail, CO 81657 Ethan Schaff Unit 2308, Simba Run Condominiums 1100 North Frontage Road Vail, CO 81657 Stamped, addressed envelopes to each of the persons or entities listed above are included with this Appeal. /Dle,o-S/ Dein [ L /2 U � 2[sSo (Z T �-ciJ401 uN TY 145s-.00 [ 04 T/ o N,1N c. /oda �roNS(7&-d" VA[c, co jams -7 P1045,5/ DeFAJ r s� y GL%1' S �SSaC• /hyo 4 /0 NS R4 [D G'67' IVf4 ! 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Nna vgmswa LLJ z rl DEPNsERlr //SIRE • Select Aire (SA) systems are duan refrigeration circuit, packaged dehumidifiers, • Systems remove between 55 and 340 pounds of moisture per hour. Refrigeration circuits consist of scroll compressors for high performance and long life. Models feature 8 -row evaporator coils for high moisture removal capacity. P SA systems include an exclusive exhaust air heat recovery system and patented air flow balancing. • SA°s dual refrigeration circuit design allows staging to minimize energy consumption and optimize energy recovery. IP, C E 0 W [E n OCT 2 3 2014 1 TOWN OF VAIN SA Series Energy Recovery Natatorium Dehumidifiers Installation and Operation Manual P , MD 'eS35i� , SA System ONLY TRAINED, QUALIFIED PERSONNEL SHOULD INSTALL ANDIOR SERVICE DESERT AIRE EQUIPMENT. SERIOUS INJURY, DEATH AND PROPERTY DAMAGE CAN RESULT FROM IMPROPER INSTALLATION/SERVICE OF THIS EQUIPMENT. HIGH VOLTAGE ELECTRICAL COMPONENTS AND REFRIGERANT UNDER PRESSURE ARE PRESENT. Desert Aire Dehumidification Equipment Standard Limited Warranty Desert Aire warrants the dehumidifying unit to be free from defects in materials and workmanship subject to the terms, conditions and limitations stated herein, TERMS Desert Aire warrants all components (except as noted) for a period of two (2) years from the date of shipment. This warranty shall be limited to the supply of new or rebuilt parts for the part which has failed because of defects in workmanship or material, and does not include the cost for labor, transportation or other costs not herein provided for. Replaced parts are warranted only for the remaining portion of the original warranty period. CONDITIONS The warranty is subject to the following conditions: 1. The unit must be properly installed and maintained in accordance with the Desert Aire "Installation and Operation Manual" provided with each unit and/or other documentation provided. Z The Start -Up Report must be completed and returned to Desert Aire within 30 days of the start-up. 3. This warranty shall not apply to any part that has been tampered with, or has been subject to misuse, negligence or accident. A warranty can be obtained for altered equipment but only with written consent from Desert Aire. 4. The following parts and components are excluded from the warranty: belts, filters, driers, fuses and refrigerant. ;. Refrigerant coils or other components that corrode due to improperly balanced pool chemistry or corrosive air quality will not be warranted, 6. All replacements or repairs will be FOES Germantown, WI. 7. This warranty shall be null and void if defects or damages result from unauthorized opening of the refrigerant circuit, tampering with factory set controls, or operating outside the original design conditions. 8. Desert Aire shall not be liable for labor costs incurred in diagnosing the problem, or the removal or replacement of the part or parts being repaired. 9. Desert Aire must preauthorze all warranty coverage described herein. Desert hire - SA Manual 3 Extended Warranty: Your Desert Aire unit may have extended warrantees beyond this Standard Limited Warranty document. Extended warrantees are only available at the time of the purchase of the original equipment. These extended war- rantees are covered under a separate document and their terms and conditions are separate from this document. It is mentioned in this document for informational purposes only. Any and all incidental or consequential damages are expressly excluded from this warranty. Some states do not allow the exclusion of incidental or consequential damages for personal injury, so the above limitations may not apply to you for certain damages. This warranty gives you specific legal rights, and you may also have other rights, which vary from state to state. No person or representative is authorized to make any warranty or assume any liability not strictly in accordance with the aforementioned. Inquiries regarding warranty matters should be addressed to: Desert Aire Corp c/o Service Manager N120 W18485 Freistadt Road Germantown, W1 53022 PH: (262) 946-7400 FAX: (262) 946-7401 E-MAIL: service@desert-aire.com desert-aire.com Additional copies of this manual can be purchased for a nominal fee from Desert Aire. Submit requests to the contact information listed above. 4 Desert Aire - SA Manual Safety Labels are used throughout this manual. They comply with the ANSI 2535.4 Standard. Please be familiar with the following labels and their definitions. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury. l DIndicates an imminently hazardous situation which, if not ANGER E avoided, will result in death or serious injury. WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. JF!'J CAUTION Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. Caution used without the safety alert symbol indicates a CAUTION potentially hazardous situation which, if not avoided, could result in property damage. Desert Aire - SA Manua! CJ Desert Aire - SA Man vat TABLE OF CONTENTS 1 Introduction...................................................................................................................... 9 1.1 Inspection............................................................................................................... 9 1.2 Damage Claims...................................................................................................... 9 1.3 Rigging..............................................................,.........,.......................................... 9 1.3.1 Rigging the Dehumidifier............................................................................. 9 2 Installation ....................................................................................................................... 11 2.1 Position and Service Clearance............................................................................. 11 2.2 Outdoor Air Duct.................................................................................................... 15 2.2.1 Outdoor Air Duct Unit without Integral Exhaust ......................................... 15 2.2.2 Outdoor Air Duct Unit with Integral Exhaust .............................................. 17 2.2.3 Exhaust Duct Unit with Integral Exhaust ................................................... 17 2.3 Condensate Drain Piping....................................................................................... 18 2.4 Pool Water Piping .... .................................................................................... ........... 20 2.5 Auxiliary Heat Coil Piping....................................................................................... 22 2.6 Remote Condenser (Optional).............................................................................. 23 2.7 High Voltage Wiring............................................................................».................. 24 2.8 Controls and Sensors.........................................................,.................................. 25 2.8.1 Air Temperature/Humidity Sensor............................................................. 25 2.8.2 Water Temperature Sensor ................ ........ 25 2.8.3 Installation of Sensors for the SelectAireTM with Integral Exhaust Fan ..... 25 2.8.3.1 Indoor Static Sensor Installation.................................................. 26 2.8.3.2 Outdoor Static Sensor................................................................... 26 2.8.4 Installation of Optional VOC Monitoring Sensor ......................................... 28 2.9 Auxiliary Heating Control Wiring............................................................................ 28 2.9.1 Auxiliary Heating - Dry Contact Closure .................................................... 29 2.9.2 Auxiliary Heating - Proportional Signal ...................................................... 29 2.10 Auxiliary Pool Water Heating.................................................................................. 29 2.11 Smoke Alarm Interlock........................................................................................... 30 3 Start -Up Procedures..................................................................................................... 31 3.1 Preliminary Inspection............................................................................................ 31 3.2 Airflow Balancing.................................................................................................... 32 3.2.1 Airflow Setup of SelectAireTM without Integral Exhaust Fan ...................... 33 3.2.2 Airflow Setup of SelectAireTM with Integral Exhaust Fan ........................... 35 3.2.3 Final Air Balancing............................................................... 3.3 Refrigeration Testing.............................................................................................. 43 3.4 General Testing..................................................................................................... 45 3.5 Routine Maintenance Schedule.................................................................. ..... 45 OesertAire • SA Manual 7 3.5.1 Service Every Month................................................................................. 3.5.2 Service Every Six Months......................................................................... 4 Troubleshooting............................................................................................................. 4.1 The Blower Does Not Run...................................................................................... 4.2 The Compressor(s) Do Not Run.............................................................................. 4.3 High Pressure Alarms 1 Readings Above 575 PSIG............................................... 4.4 Low Pressure Alarms 1 Evaporator Coil Icing......................................................... 4.5 The Pool Water Is Too Cold................................................................................... 5 Appendix 5,1 Compressor Failure................................................................................................ 5.1.1 Compressor Replacement......................................................................... 5.2 Recommended Duct Design................................................................................... 5.3 Pool Water Chemistry...........................................................,................................. 5.4 Recommended Controller Settings......................................................................... 5.4.1 Controller Set Points................................................................................. 5.5 System Operating Modes.......................................................... 5.6 Component Replacement, Charge, Evacuation, & Leak Instructions ..................... 5.7 System Rating Plate.................................................................... 5.8 Start -Up Supervision Supplemental Information.................................................... 5.9 System Start -Up Report......................................................................................... Start -Up Report...................................................................................................... Compressor Replacement Form............................................................................ 8 Nsen Aire - SA Manua; 45 46 47 47 47 48 48 49 51 51 51 54 55 55 55 55 56 60 60 63 64 69 1 Introduction Desert Aire dehumidifiers are designed to provide years of reliable service when installed properly. Read these instructions carefully before you install the dehumidifier, 1.1 Inspection Desert Aire inspects and tests each dehumidifier before it leaves the factory so that you receive a quality piece of equipment. Unfortunately, equipment may become damaged in transit. Inspect the dehumidifier carefully before signing the receiving papers. Check for both visible and concealed damage. Use a halogen leak detector to check the piping for refrigerant leaks. 1.2 Damage Claims If the dehumidifier has been damaged, document the extent of the damage. Take pictures if possible, Next, obtain a claim form from the carrier. Promptly fill out and return the form, Carriers may deny claims that you have not filled out within a week of delivery. Notify Desert Aire of any damage. 1.3 Rigging 1. Failure to observe rigging instructions may lead to equipment damage, personal injury or death. 2. Lifting method and procedure must comply with all local and national codes and regulations. 3. The use of safety slings in addition to lifting lugs is required. 4. Do not lift the dehumidifier in high winds or above people. Desert Aire dehumidifiers are solidly built and can be very heavy. Avoid personal injury and damaged equipment by planning the installation carefully. Use moving equipment whenever possible, 1.3.1 Rigging the Dehumidifier Desert Aire dehumidifiers are equipped with four or more lifting lugs. Use spreader bars and safety straps when you use these lugs for rigging. • Utilize all of the lifting lugs provided when hoisting unit. • Test -lift the dehumidifier to verify that it is properly balanced. • Do not lift the dehumidifier in high winds or above people. • The top panels are not designed to support the weight of persons. The top panels are weather proofed and excessive weight may cause water to penetrate through cracked seams. Damage incurred through caved or distorted top panels will not be covered under warranty. If you must walk on the top panels, carefully walk on the edges where structural integrity is greatest. Desert Ake - SA Manual 9 Large System Rigging Notes; 1. The number of lifting points will vary between units. All lifting points must be used to lift unit, 2. Spreader bar must be used. Unit top panel 2x4 E is not designed to handle loading. 3. Lifting methodtprocedure to comply with all local and national regulations. 4, Use safety slings (not shown) in addition to lifting lugs. 5. Be sure that the lifting hooks do not contact the sides of the unit. 6. Use appropriate lifting strategy for unit. a03s.oar Figure 1 - 'Typical Rigging for the 5A Dehumidifier 1. Do not tip the dehumidifier on it's side. 2. Avoid dropping the unit down stairways or subjecting it to severe mechanical shock. 10 Desert Aire - SA Manwt 2 Installation Manual applies to standard unit configurations only. 2.1 Position and Service Clearance Desert Aire dehumidifiers require routine maintenance to operate efficiently.. • Allow a minimum of 36 inches of clearance around the service side of the dehumidifier for piping, electrical connections, and service access. Install the unit on a sturdy, level mounting base or platform that will prevent vibration and sound transmission. Never install the dehumidifier on a wooden platform without consulting the design engineer for spring isolation requirements and sound control materials. Do not install the unit near occupied rooms such as offices or guest rooms.. • Level the dehumidifier to ensure proper condensate drainage. • Install blocks under the unit if necessary to provide clearance for the condensate trap. Install blocks underneath each corner and each lifting lug. Figure 2 - Dehumidifier with Blocks Installed for Trap Clearance • Install outdoor dehumidifiers equipped with an outdoor air intake away from plumbing vents, furnace flues, or equipment which could contaminate the air supply. • If the dehumidifier is to be mounted on a roof curb, make sure that the curb has been properly mounted and supported. Place gasketing around the perimeter of the curb before setting the dehumidifier in place. This will help prevent air or water leaks. • You must not install an indoor rated dehumidifier in an unconditioned space or where ambient temperatures can fall below 45°F. If you must install the dehumidifier outside or in an unconditioned space, you must use an outdoor rated dehumidifier. Desert. Aire equips outdoor -rated units with weatherproofing and thicker insulation. You can determine if your unit is outdoor -rated by inspecting the unit rating plate. (See Section 5.7 in the Appendix for details.) • Duct design and installation should conform to ASHRAE and SMACNA low velocity duct standards. See Section 5.2 in the Appendix for additional duct recommendations. Desert Aire - SA Manual 11 H:y7, til: CO`•C E'=SF F' 12 DesedAke - SA Manuai Mechanical Room • 6ESERT +�j'r I TOP V¢W l +t Durr CONNECTOR WEATHER-PROOF INTAKE HC": s MOTOR OPERATED DAMPER INSULATED OUTSIDE AIR INTAKE DUCT. (SIZE FOR CSIR_WIHEM¢NTSI �- ,y`!INSTALL TURNING VANES �, N Ail ELBOWS. Y LOCATE ANODIZED ALUMIN,_ RETURN AIR GRILLE AS HIGF• AS POSSIBLE IN ROOM. -�-- TEMPERATURE AND HUMIDITY CONTROLS v SKYLIGHT --r-' Pool Room MECHANICAL EXHAUST WITH HACK-ORAFT DAMPEN (WALL OR ROOF MOUNTED) NOTE: CAPACITY SHOULD NOT EXCEED INTAKE VOLUME, Figure 3 - Basic Pool Room Layout C Use turning vanes whenever the duct makes an abrupt turn, especially in the return air duct. Poor return air distribution will reduce the moisture removal. VAPOR BARRIER WINDOW SUPPLY PIPING LOOP SYSTEM POOL DECK ANODIZED ALUMINUM j r FLOOR DIFFUSERS {S12E FOR PROPER AIR FLOW) DESERT AIRE DEHUMIDIFIER ANODIZED ALUMINUM RETURN AIR GRILLE _ _£KATE AS HIGH AS POSSIBLE AUX. HEATING - --- - RETURN AIR DUCT FILTER RACK 1I I _ FLEX FBLE DUCT CONNECTIONS 'm S+' CONDENSATE PIPING POOL ii '�,- MIS, l� Figure 4 - Typical In -Ground Duct layout y P.C.D. COATED SPIRAL GALVANIZED PIPE • You may use galvanized sheet metal ducts for all but underground installations and severely corrosive environments. • Do not use fiberglass duct boards or acoustic duct liner for air distribution in highly humid applications, such as pool room dehumidification. • If a duct must be installed in an unconditioned area, or if you are installing an outdoor air intake duct, insulate it with two inches of fiberglass duct wrap with an intact vapor barrier. • Direct the supply air toward skylights, exterior walls and windows, and spectator areas. Since air movement will increase the evaporation rate of the pool, direct the supply air grilles away from its surface. Desert Aire - SA Manual 13 SKYLIGHT ANODIZED AA SIDEWALL RE DESERT HIRE ANODIZED Al RETURN AIR LOCATE AS H RETURN AIR E FLEK411LE DUI CONNECTION 14 assert Aire - SA Manuel Figure 5 - Soffit Duct Layout with Skylight Grille ANODIZED ALUMINUM CEILING WFUSER VAPOR BARRIER WINDOW • Install return air grilles or louvers as high as possible in the enclosure, Normally, one centrally -located grille will be adequate. Avoid under sizing this grille or "short-circuiting" of air with nearby supply registers. • Select grilles and diffusers for low static pressure loss and proper throw and CFM rating. • keep the noise criteria levels of the grilles between 35 and 45 dB, • Use anodized aluminum grilles to prevent premature corrosion, 2.2 Outdoor Air Duct Standard Desert Aire dehumidifiers are equipped with an opening which will draw outdoor air into the conditioned space. This will help you to comply with ASHRAE Standard 62, which requires the introduction of outdoor air into commercial buildings. The SA controller features a seven-day programmable time clock. The clock will open and close the outdoor air damper based on the building occupancy schedule. Note that condensation may occur when cold outdoor air is mixed with warm, humid return air inside of the dehumidifier. During the winter months, this moisture can freeze and cause serious damage to the equipment. Desert Aire dehumidifiers are equipped with an internal temperature sensor which will close the outdoor air damper if it senses freezing temperatures inside the unit. If outdoor temperatures in your area drop below 32°F, and outdoor air code compliance is required at all times, you must install a preheating coil. System failures caused by improper outdoor air duct installations are not covered by the Desert Aire warranty. The ducting method you use depends on the SA type of dehumidifier you have. 2.2.1 Outdoor Air Duct Unit without Integral Exhaust There are three possible configurations for the outdoor air opening: 1. The SA units without Integral Exhaust have a duct connection with outdoor air damper and actuator between the evaporator and the reheat condenser coils. The unit controller will energize a set of dry contacts during occupied times. Use these dry contacts to control an additional outdoor air damper if required and/or the exhaust blower. The exhaust blower and the outdoor air louvers, filters, additional dampers, and actuators must be field -supplied. O/A Duct Field -Installed Duct Connection wtr Filters, Dampers, & Louvers by Others Figure 6 - Indoor Dehumidifier with Outdoor Air Duct Connection with Damper Desert Aire - SA Manuaf 15 2. An optional module can be provided which contains filters and a factory -installed damper and actuator. This module, which is designed for indoor installations, has a flanged opening for a field -installed outdoor air duct. The unit controller will energize a set of dry contacts during occupied times. Use these dry contacts to control the exhaust blower. Outdoor air louvers and the exhaust blower must be field -supplied. Field -Installed Duct Louvers by Others Figure 7 - Indoor Dehumidifier with Filter and Damper Module 3. An optional module can be provided, which contains filters and a factory -installed damper and actuator. This module, which is designed for outdoor installations, has an outdoor air intake protected by a weather hood. The unit controller will energize a set of dry contacts during occupied times. Use these dry contacts to control the field -supplied exhaust blower. Figure 8 - Outdoor Dehumidifier with Filter and Damper Module The outdoor air duct used for options 1 and 2 must be insulated to prevent condensation from forming on it during the winter. Since cold outdoor air can cause moisture to condensate and freeze on surfaces when it mixes with the warm, humid return airstream, you must preheat the outdoor air whenever possible. 16 Desert Aire - SA Manual 2.2.2 Outdoor Air Duct Unit with Integral Exhaust There are two possible configurations for the outdoor air opening: 1. The standard SA unit with Integral Exhaust contains a module which handles outdoor makeup air and exhaust air, This factory -installed module includes filters, dampers„ actuators, and an exhaust blower. The unit controller will open the dampers during occupied times. This module, which is designed for indoor installations, has flanged openings for the outdoor and exhaust air ducts. The ductwork and louvers must be field -supplied. -------------------------------- ......................... ------------ ----------------- ------------ Figure 9 - Indoor Dehumidifier Showing Outdoor Air and Single Exhaust Ducts 2. The standard SA unit with Integral Exhaust contains a module which handles outdoor makeup air and exhaust air. This factory -installed module includes filters, dampers, actuators, and an exhaust blower. This module, which is designed for outdoor installations, has an outdoor air intake protected by a weather hood. 2.2.3 Exhaust Duct Unit with Integral Exhaust There are two possible configurations for the exhaust air opening: 1. The module ordered for an outdoor unit discharges the exhaust air to the atmosphere. No duct connection is required. 2. The module ordered for an indoor unit will have one or two discharge flanges, depending on the volume of exhaust air. You must duct the exhaust air to outside the building. The combined resistance of the duct and the discharge grille must not exceed 0.5" W.C. The humid exhaust air may form an icy fog when it blasts outside during the winter. Install the outlet grille in a location where this fog will not damage the building or create a safety hazard. Desert Aire - SA Manual 17 ................. -------------- - ---------- Figure 10 - Indoor Dehumidifier Showing Outdoor Air and Dual Exhaust Ducts 2.3 Condensate Drain Piping The condensate drain connection on the standard Desert Aire SA series dehumidifiers is a 1-1/2" ID PVC stub which penetrates the base rail of the unit. Figure 11 - SA Standard Condenser Drain Location An SA series dehumidifier ordered for roof curb mounting has its drain connection on the underside of the unit to help prevent freezing. This drain has a 1-1/2" MPT fitting. 18 Desert Aire - SA Manual Figure 12 - SA Roof Curb Unit Showing Condensate Drain Location Whichever type of drain your dehumidifier has, it must be trapped to prevent condensate from backing up in the drain pan. The cabinet of the dehumidifier is under negative pressure whenever the supply blower is running. If you do not trap the drain, condensate will be sucked into the cabinet, where it may cause premature corrosion and property damage. Figure 13 - Sectional View of Condensate Trap Requirements Trap the condensate connections as shown in Figure 13. The P -trap dimensions in Figure 13 are sized for a maximum return air static of 2,0" W.C. If your return air static exceeds this specification, consult Desert Aire for help in resizing the P -trap. You may also need to install a cleanout tee or plug near the trap. Note that the drain opening in the drain pan is off -center is simplify its cleaning and servicing. Once you have designed and installed the trap, follow this sequence: 1. Connect the trap to a main drain line with 114" of downward pitch per linear foot of run. Desert Aire - SA Manual 19 Support the drain pipe every five feet to prevent sagging. After you install the drain piping, prime the trap by pouring water into the drain pan of the dehumidifier. Condensate drain lines installed in an unconditioned space must be heat taped to prevent freezing. Check the heat tape yearly before winter operation. 2.4 Pool Water- Piping The Desert Aire dehumidifier may be equipped with an optional pool water heating condenser. Use copper or schedule 80 CPVC pipe and fittings to adapt to the water circuit of the dehumidifier. See Figure 14 for recommended pool water piping. Note that this figure is intended to be a general guide only, and may not match your installation exactly. All piping must meet state and local codes. 20 Desert Airs - SA Manual I►w1 1 Supply Air 2 Duct Heater (Gas, Electric, Etc.) 3 Flex Duct Connector 4 Piping to Remote Condenser 5 Desert Aire Dehumidifier 6 Filter Rack Assembly with Filters 7 Return Air a Vibration Isolators 9 P -Trap 10 Base (If Required) 11 Check Valve 12 Ball Valve 13 Flow Meter 14 Main Pool Heater 15 Auxiliary Pump 16 Fitter Assembly 17 Main Pool Pump 18 Aquastat Sensor (Dry Well) 19 Water Inlet 20 Water Outlet Figure 14 - Typical Pool (Nater Piping ,diagram Desert Aire - SA Manual 21 • You may not need an auxiliary pump if the main pool pump has sufficient pressure to overcome the elevation and the resistance of the water piping to the dehumidifier. If the main pump will be cycled on and off, you must use an auxiliary pump. • If you use an auxiliary pump and you intend to cycle the main pump, you must size the auxiliary pump to overcome the resistance of the main pool piping and filters. • The dehumidifier is equipped with a built-in flow switch. If there is no water flow to the unit, the refrigeration circuit will be locked out of the pool water heating mode. All other modes, such as dehumidification and cooling, will function normally. [desert Aire recommends continuous water flow to the unit to prevent vapor lock, pump cavitations, and nuisance head pressure trips. • You must install an air eliminator at any high points in the pool water piping. Excess air in the Desert Aire ,pool water condenser will cause inadequate pool heating and high operating temperatures and may shorten the life of the dehumidifier. Dehumidifiers equipped with the pool water heating option come with a factory -supplied water temperature sensor and an aqua stat well. See Section 2.8 for details on control and sensor location, Water Circuit Size Water Flow Rate and Pressure Drop: Pool Water Flow Rate and Pressure Drop: Spa 9/10 Ton 20 GPM @ 25 ft W.C. 27 GPM @ 35 k W.C. 15 Ton 30 GPM @ 25 ft W.C. 40 GPM @ 35 ft W.C. 20 Ton 40 GPM @ 25 ft W,C. 53 GPM @ 35 ft W.C_ 25 Tan 50 GPM @ 25 ft W.C. 67 GPM @ 35 ft W.C. 30 Ton 60 GPM @ 25 ft W.C. 80 GPM @ 35 ft W.G. Figure 15 - Standard Unit Water Flow Rates (for Units Equipped with this Option) 2.5 Auxiliary Heat Coil piping The Desert Aire dehumidifier may be equipped with an optional hot water or steam air heating coil. This coil, when properly sized, will provide space heating during the winter months. • You must use proper practice when you design and install the coil piping to prevent poor coil performance, shortened service life, or damage to the coil. • The supply connections must not be supported by the coil headers. • The control valve should be sized according to the pressure and flow rate requirements, not the coil connection size. • On steam systems, size the trap for at least 2-1/2 times the design condensing rate to allow for high condensate flow on system start-up. • On steam systems, use strainers, dirt pockets, and isolation valves to prevent clogging the control valve and to simplify service. • Install swing joints in the connection piping to prevent damage to the coil header for thermal expansion. • Use a backup wrench on the pipe stubs when attaching connections to prevent damage to the header. 22 Desert Are - SA Manual 2.6 Remote Condenser (Optional) SA Series Remote Condenser Line Size (R -410A) Model Circuit A Circuit B Hot Gas Line (Discharge) Liquid Line (Return) Hot Gas Line (Discharge) Liquid Line (Return) SA18 1-118 518 1-118 518 SA20 1-118 518 1-1/8 518 SA24 1-118 518 1-318 314 SA30 1-318 314 1-318 314 SA35 1-318 314 1-318 718 SA40 1-318 314 1-318 718 SA45 1-318 718 1-318 718 SA50 1-318 718 1-518 1-118 SA60 1-518 1-118 1-518 1-1/8 Figure 16 -,Remote Condenser Lime Size Summary (for Units Equipped with this (Option). Performance rated at return air conditions of 82'F160%RH, 50'Actual line length162.5' Equivalent line length. Desert Aire SA series dehumidifiers are pre -charged with enough refrigerant to fill the Remote Condenser and up to 50 feet of refrigerant lines. No additional charge is required unless your line set is longer than 50 feet. CONSULT WITH DESERT AIRE IF YOU MIDST INSTALL THE REMOTE CONDENSER MORE THAN 100 FEET BELOW OR 50 FEET AWAY FROM THE DEHUMIDIFIER UNIT. Check Rating Piate label or consult factory in regards to specific charge and/or remote condenser line sizes. Support and clamp condenser tubing at regular intervals. Maximum span between clamps should be limited to the following. Tube Size Span Between Clamps 112° — 718" 5' maximum 1-118" 6' maximum 1-318" 7' maximum 1-5/8" 8' maximum The first clamp after the cabinet penetration should also be located such that the maximum span is maintained. Provide means of preventing dissimilar metal contact such as copper clamps, plastic coated hangers, or similar. Rubber isolation at connection is recommended for applications where there may be sensitivity to noise or vibration. Follow ANSI/MSS SP -69 clamping guidelines. DeseR Aire - SA Manual 23 Consider the use of U -Loops or Z -Bends for extended lengths of straight tubing subject to wide ranges in temperature conditions. Refer to ASHRAE Handbook HVAC System and Equipment for examples. Ensure tubing is centered within pipe seal grommet at cabinet penetration before fully tightening any field installed clamps and brackets. Forces occurring during mode shifts may move piping slightly. After tightening check to ensure there is a minimum of 112" clearance around all field installed tubing to any structure or other obstruction. 2.7 High Voltage Wiring You must follow all local codes when you connect the high-voltage wiring to the dehumidifier. Attach the wires to the three -pole power block mounted on the electrical panel, Test the phasing by "bumping" the blower contactor, Verify that the blower rotates in the proper direction. If it turns the wrong way, switch any two of your wires at the power block. 1 1. Disconnect power before servicing. The unit contains high voltage wiring and moving parts which may cause serious injury or death. 2. Failure to properly wire the dehumidifier may create the possibility of shock and can lead to premature system failure. I Ground Lug Factory Supplied Wiring Ground Wire L1 L2 L3 Main Power Supply from Disconnect Box Main Power Block in Unit Figure 17 - A Typical Desert Aire Three-phase Power Block Some equipment may contain a variable speed drive for the supply fan. The fan will run the correct direction regardless of the input power. In these cases, the compressor must be "bumped" to determine if it is pumping correctly. Use the controller display to view the analog inputs and briefly energize one of the compressor contactors. The discharge pressure should increase and the suction pressure should decrease when phasing is correct. Do not run the compressors in reverse rotation for an extended period of time as damage will result. 24 Desert Aire - SA Manua) 2.8 Controls and Sensors The standard Desert Aire SA series dehumidifiers are controlled by a microprocessor controller. This controller monitors conditions such as room humidity and temperatures and controls the dehumidifier accordingly. A separate controls manual has been provided. Refer to this separate manual for controller specifications, operation, and options. 2.8.7 Air Temperature/Humidity Sensors Duct Mount Temperature/Humidity Sensor Install the duct -mount sensor in the return air duct upstream of any outdoor air intakes. • Do not mount the sensor in a section of duct where false readings may occur due to dead air regions, solar heat gain, or thermal losses in winter. • Do not mount the sensor where water is likely to drip on it, Liquid moisture will ruin the humidity sensing element in the sensor. Wall Mount Temperature/Humidity Sensor If your dehumidifier was ordered with a wall -mount humidity and temperature sensor, mount the sensor about five feet above the pool deck on an interior wall with natural air circulation. Avoid the following locations: • Hot spots near concealed heating pipes, warm air ducts, supply register outlets, or solar radiation, • Cold spots due to a cold wall or drafts from stairwells, doors, windows, or supply register outlets, • Dead spots such as behind doors or in corners where room air cannot circulate freely. A supply air temperature sensor and duct holder is also provided to be installed downstream of any field provided heaters. Mount this in the supply duct and seal the penetration. Install at least 5 ft, downstream of all heaters and not in the "line of sight" of the heater elements as the radiant heat produced by the heater may affect the reading. 2.8.2 Water Temperature Sensor Desert Aire dehumidifiers ordered with the pool water heating option are supplied with a water temperature sensor and an aqua stat well. • Screw the well into an adapter fitted into the pool water piping. The well is equipped with a 112" MPT connection.. • Install the sensor upstream from the dehumidifier or the auxiliary pool water heater. • The sensor must be installed in a location where it will accurately sense the pool water temperature. This means you must have continuous water flow at the sensor location. 2.8.3 Installation of Sensors for the SelectAireT°" with Integral Exhaust Fan In pool applications, it is critical to maintain negative space pressurization relative to adjacent spaces and the outside ambient. This prevents moisture laden air from being driven into the wall Desan Arre - SA Manual 25 cavities and condensing. The SelectAire'll unit includes provisions to measure the differential in static pressure between the space and the outdoors and helps to maintain this negative static pressure in the space. 2.8.3.1 Indoor Static Sensor Installation The indoor static pressure sensor should be mounted in a location not subject to damage from occupants. 'Place the sensor as far as practical from doors, grilles, and operable windows that may cause pressure fluctuations. Locate a minimum of 3' above the floor level in the pool area. Note that in rooms with extremely high ceilings {greater than 30'} it is preferable to locate the sensor a minimum of halfway up the wall. This is due to building stack effect where the pressure may become higher at the ceiling than at the floor. The sensor can be mounted directly to drywall or to a standard single gauge electrical box. 50' of 118" clear pressure tubing is supplied with the sensor. Route the tubing such that it will not be subject to damage. Do not directly attach the tube to surfaces that may become very cold such as suction lines or supply ducts as condensation may occur in the tubing. Connect the tubing to the static pressure differential transducer in the unit. The correct port is labeled for the indoor air sensor. Figure 18 - Indoor Static Pressure .Sensor (rear view) 2.8.3.2 Outdoor Static Sensor A complication in measuring the building static pressure is the dynamic action of the wind, Measuring the wind's pressure instead of the true outdoor static pressure will alter the actual static pressure reading. Proper mounting of the outdoor static sensor will help ensure accurate readings. The outdoor air static pressure sensor should be mounted at least 12 inches above 26 ©.serf Aire - SA Manual surrounding obstacles and a minimum of 24 inches from a wall or Air Dandling Unit. Do not mount under awnings or other projections within fifteen feet. Do not mount near economizers, intakes or exhaust fans, or barometric dampers. Do not mount within 10' of building corners or parapet walls. L MR C=] Figure 99 - Outdoor Static Pressure Sensor A detailed drawing of the outdoor static sensor assembly is included with the package. Assemble mounting bracket and tubing per this drawing. 50' of 118" opaque pressure tubing is supplied with the sensor. Route the tubing such that it will not be subject to damage. Do not directly attach the tube to surfaces that may become very cold such as suction lines or supply ducts as condensation may occur in the tubing. It is recommended that all of the tubing length be used as this helps buffer any fluctuation in the sensor readings due to wind gusts. Excess tubing should be coiled at some convenient location rather than cut. Connect the tubing to the static pressure differential transducer in the unit. The correct port is labeled for the outdoor air sensor. Closely observe that the indoor static pressure sensor and outdoor static pressure sensor are installed on the proper ports as labeled. Deserl Aire - SA Manual 27 2.8.4 Installation of Optional VOC Monitoring Sensor Desert Aire offers an optional VOC monitoring sensor that can trigger a greater flow rate of outdoor air when indoor contaminants reach a user determined concentration. This sensor can be mounted in a space that represents the typical breathing zone for occupants. The back mounting plate is suitable for mounting on a 2" x 4" J -Box or directly to drywall. Screws are provided. Three wires are required and terminals on the sensor can accommodate 16 to 22 AWG. 18 AWG wire can be used up to 500 ft. runt. Terminate wires as shown on the low voltage diagram,. Check to ensure that the sensor output has been set for 0-5 VDC output. The J3 jumper should be set in the storage position. See data sheet supplied with sensor for additional details. 2.86 in, (72.7 mm) a Figure 20 - VOC Monitoring Sensor gym} Closed Cell Foam 2.9 Auxiliary Heating Control Wiring Note: You must use the Desert Aire control system to control or interlock with the room heating system. This prevents wide fluctuations in room air temperature. It also prevents the heater from trying to heat the room while the dehumidifier is running in cooling. Desert Aire will provide a signal to operate the auxiliary pool room heating system. The signal can either be a binary dry contact closure or a proportional voltage with an optional dry contact closure to operate an interlock or pump. The heating output type is pre-set from the factory based on the request at the time of order.. 28 Da.ertArre - SA Manual 2.9.1 Auxiliary Heating — Dry Contact Closure Desert Aire will provide a dry contact closure to interlock with the building heating system. This contact closure is normally used to interlock with a gas or electric duct heater which has its own power supply transformer. When the room air temperature drops below the set point, the dry contact will close to energize the auxiliary heater. See the dehumidifier wiring diagram for details. 2.9.2 Auxiliary Heating — Proportional Signal Desert Aire will provide a proportional signal to modulate a heating coil control valve on units equipped with an integral heating coil. This signal is reverse acting or direct acting depending on the settings in the controller. It is critical that units with hot water and steam coils be set properly for freeze protection. See controller manual for details on the settings and outputs. The SA dehumidifiers are equipped with a local man -machine interface on the face of the unit controller located inside the electrical box of the unit. A separate, optional remote display terminal can be ordered for service or remote access. See the controller manual for details on wiring and environmental limits. Most proportional valves have either three or four terminals for field -installed wiring. • Four -terminal valves have two terminals for 24 VAC power and two terminals for the signal input. • Three -terminal valves have one terminal for the "hot" 24 VAC input, a second terminal for the "positive" signal input, and a third, common terminal for the "neutral" 24 VAC input and the "negative" signal input. You must follow the instructions included with the valve cut sheet. Observe the proper polarity, or you may damage both the valve and the Desert Aire controller. See the unit wiring schematics for information on signal wire connection points. When the proportional signal is ordered, the binary heating output acts as an interlock. This can be used to activate a pump, valve, or interlock that needs to be coordinated with the proportional heating signal. The contact rating is shown on the electrical schematic. Use a transformer and relay to energize loads that are higher than the contact rated current draw or power. 2.10 Auxiliary Pool Water beating A properly sized Desert Aire dehumidifier equipped with the pool water heating option can maintain the pool water temperature under normal conditions. However, like any refrigerated dehumidifier, the Desert Aire unit may require days to heat a recently -filled pool by itself. For this reason, you should install an auxiliary pool heater. Desert Aire dehumidifiers ordered with the water heating option are provided with a set of dry contacts for controlling an auxiliary pool water heater. The dehumidifier will be the primary source of water Desert Aare - 5A Manual 29 heating. If it cannot keep up with the demand for pool heat, the Desert Aire controller will then energize the auxiliary water heater. Note: Do not use the aqua stat mounted on the auxiliary heater for temperature control. This can lead to excessive water temperature fluctuation, it may also permanently prevent the dehumidifier from heating pool water if the set point of the heater aqua stat is higher than the water heating set point of the dehumidifier. 2.11 Smoke Alarm Interlock Desert Aire SA series dehumidifiers are equipped with a set of terminal blocks for interlocking with the smoke alarm (alarm provided and installed by others). The smoke alarm contacts must be rated for at least 15 amps at 24 VAC. The contacts must break when smoke is present. This will shut off the blower(s) and compressors. See the dehumidifier wiring diagram for connection details. 30 DesedAi. - SA Man.. 3 Start -Up Procedures Read this section thoroughly before attempting to commission the Desert Aire dehumidifier. A complete start-up will minimize operational problems and expensive callbacks. The start-up will be quicker and easier if there is a heat and humidity load present in the space. Energize any auxiliary air and pool water heaters before the start-up so that the air and water are at their design temperatures. Crankcase heater should be energized for 24 hours before refrigeration system is allowed to operate. 3.1 Preliminary Inspection Verify that all contractors have completed their work. Find the Desert Aire "SA Start -Up Report", which is located near the back of this manual. You must fill out the start-up report to validate the dehumidifier warranty. Check the following items: • Before starting unit, remove wooden shipping blocks found beneath compressor(s). • Before starting unit, remove shipping restraining brackets on supply blower equipped with the spring isolation base, if applicable. • Verify that the incoming power supply matches the rating plate of the dehumidifier, The fused disconnect and the power supply wiring must be rated to handle the minimum ampacity rating printed on the rating plate. • With the power supply disconnected and locked, tighten all field and factory electrical connections. • Check and adjust the belt tension for ,proper deflection at the midpoint of the blower belt(s). • The deflection is based on the belt length. The belt length can be found on the belt itself. Determine the force using the Belt Deflection Force table on page 32. Specified Belt Deflection Belt Length deflection 25" to 50" 0.25" 51 " to 70" 0.375° 71 " to 110" 0.625" Figure 21- Specified Belt Deflection Table Desert Aire - SA Manual 3 Belt Deflection Force New Belt Force (lbs.) Used Belt Force (lbs.) Hp 1 Belt 2 Belts 3 Belts 1 Belt 2 Belts 3 Belts 0.5 3 2-2.5 1 1.5 2 3 7 5-6 5 7.5 10 12 7 9-10 5-6 15 20 25 12 8-9 30 12 8-9 40 Figure 22- Belt Deflection Force Table • Check for proper phasing (three-phase units) by momentarily energizing the supply air blower, If the blower runs backwards, switch two of the power supply wires at the power block of the dehumidifier. When the glower rotates properly, the remainder of the motors in the system will be properly phased. • Check for proper phasing of the optional remote condenser power supply. The fans will blow air vertically upward when they are phased correctly. • Inspect the air filters in the dehumidifier. Replace them if necessary. • Check the pool water piping on units equipped with the water heating option. Inspect for leaks and proper installation of components. Verify that the auxiliary pump operates, if one is used. Purge all air out of the pool water piping, • Check the heating control valve and piping on dehumidifiers equipped with an optional hot water or steam heating coil. • Verify that all sensors are installed and operating properly. Verify that all external wiring to dampers, exhaust blowers, auxiliary heaters, etc. is properly connected. • Slowly open all refrigerant service valves, and tighten the valve stem packing nuts. • Check the field and factory piping for leaks. The internal piping may have been damaged during shipping. 3.2 Airflow Balancing To ensure code compliance and long equipment service life, proper airflow must be verified by a qualified air balancer. Before you balance the airflow, locate the motor control switches located in the electrical compartment of the dehumidifier. 32 Desert Aire - SA Manual Figure 23- The Motor Control Switches are the Disconnect Terminal Blocks with knife disconnect. These are thin gray terminal blocks with an orange top that can be flipped open. Open the compressor switches to prevent the refrigeration system from running while you balance the air. 3.2.1 Airflow Setup of SelectAireTM without Integral Exhaust Fan The total airflow of a Desert Aire SA system can be checked by measuring the static pressure drop across the reheat condensers and the evaporator coils. The dehumidifier features an adjustable blower sheave to simplify air balancing. Supply Air a Outdoor Air a \ •4 Return Air a Figure 24- Dehumidifier Side View Showing Location of Air Balance Ports (Balancing Port locations are symbolic, refer to Unit Labels for specific locations) Deser[ Aire - SA Manual 33 3 1 2 0 Return Air a Figure 24- Dehumidifier Side View Showing Location of Air Balance Ports (Balancing Port locations are symbolic, refer to Unit Labels for specific locations) Deser[ Aire - SA Manual 33 Procedure: 1. Check the condition of the return air and outdoor air filters. They should be relatively clean during the setup procedure. If in doubt, a measured pressure drop should be taken. Expected pressure drop is less than 0.5" WC for return air filters and 0.3" WC for outdoor air filters. 2. On the display, go to SERVICE MENU +-J AIRFLOW SETTINGS +-J AIRFLOW SETUP +-J SUPPLY AIRFLOW SETUP. Set the Unocc Override to "On". 3. Confirm outdoor air damper is closed. 4. Use a manometer or magnehelic pressure gauge to measure the static air pressure differential across the reheat condenser (ports #2 and #3 above). 5. Compare the actual value read with the value displayed for reheat coil pressure drop in the Reheat dp on the controller display. If these values differ more than 0.02" WC, adjust the offset of the controller pressure differential using the SENSOR OFFSETS screen in the SERVICE MENU such that the values agree. Ensure that the manometer or magnehelic pressure gauge is properly calibrated before making any adjustment. 6. The value for Reheat dp should be the same as the Target Reheat dp +/- 0.02" WC. Should the Reheat dp be lower than the target, disconnect unit from power and adjust the sheave on the supply fan motor by turning this in and increasing the belt speed. Should the Reheat dp be higher than the target, open the adjustable sheave to decrease the belt speed. 7. On the display, press the down arrow to go to the DAMPER SETTINGS screen. Set Unit Override to "Unocc". 8. Use the manometer or magnehelic pressure gauge to measure the static pressure differential across the evaporator coil (ports #1 and #2 above). Reading should be within limits indicated on the label attached to the unit near the air balance ports. Adjust the evaporator bypass damper opening by using the control interface to adjust the "Evap" "Unocc" damper setting. This is located in the DAMPER SETTINGS menu under the SERVICE MENU. Adjusting the value to a greater percentage will open the damper and decrease the pressure differential. Adjusting the value to a lower percentage will close the damper and increase the pressure differential. Use only the controls to adjust the damper position. Do not manually limit the stroke of the damper by using mechanical stops. 9. Use a manometer or magnehelic pressure gauge to re -check the static air pressure differential across the reheat condenser (ports #2 and #3 above). Adjust the fan speed as required to achieve the indicated pressure differential. 10. Set Unit Mode to OCC. Confirm outdoor air damper opens and exhaust fan (by others) is energized. 11. Measure outdoor airflow rate with hood, duct traverse, or other measurement method appropriate for the installation. Airflow rate can be adjusted by the "OK "Occ" damper setting in the DAMPER SETTINGS menu of the controls. Note that the flow rates for outdoor air are application specific. Refer to the 34 Desert Aire - SA Manual mechanical equipment schedule or other indication from the building designer for required flow rates. 12. Use the manometer or magnehelic pressure gauge to measure the static pressure differential across the evaporator coil (ports #1 and #2 above). Reading should be within limits indicated on the label attached to the unit near the air balance ports. Adjust the evaporator bypass damper opening by using the control interface to adjust the "Evap" "Occ" damper setting. 13. Measure exhaust system air flow rate at the fans or blowers by others with hood, duct traverse, or other measurement method appropriate for the installation. Note that the flow rates for exhaust air are application specific. Refer to the mechanical equipment schedule or other indication from the building designer for required flow rates. Poolroom applications will require the exhaust air flow rate to be greater than the outdoor air to maintain a negative static pressure in the space. 14. Continue damper setup procedure for Event, Max OA, and Purge modes if the unit is equipped for any of these modes. Note that it is important to complete in this order as once Purge is initiated and then released from the override, the post -purge timed sequence that eliminates outdoor air is active. Controller power must be removed to discontinue post -purge timer early. 3.2.2 Airflow Setup of SelectAireTM with Integral Exhaust Fan The SelectAireTM systems include features to help automate the setup and operation of the unit. Afew checks need to be completed and initial limits may need to be placed into the unit controller at the time of startup. In pool applications, it is critical to maintain negative space pressurization relative to adjacent spaces and the outside ambient. This prevents moisture laden air from being driven into the wall cavities and condensing. The SelectAireTM unit includes provisions to measure the differential in static pressure between the space and the outdoors and help to maintain this negative static pressure in the space. The Desert Aire SA unit with exhaust fan contains operational controls that assist in maintaining the poolroom envelope at a negative static pressure. Proper setup allows these controls to operate as intended; however, these are not safety controls. It is the responsibility of the owner/operator to ensure that proper space pressurization of the envelope occurs. It is recommended that the pressurization be checked on a regular basis to ensure proper operation of all building systems and any issues corrected immediately. Desert Aire - SA Manual 35 Supply Air a Outdoor Figure 25 - Dehumidifier Side View Showing Direction of Airflow Supply Airflow Setup must air a Return Air a 1. Check the condition of the return air and outdoor air filters. They should be relatively clean during the setup procedure. If in doubt, a measured pressure drop should be taken. Expected pressure drop is less than 0.5" WC for return air filters and 0.3" WC for outdoor air filters. 2. With the unit supply fan and exhaust fan disabled, check the reheat pressure drop and space static pressure readings on the controller display. Each should be indicated as 0.00 +/- 0.02. If out of tolerance, a small offset can be placed in the control under SERVICE MENU +--J SENSOR OFFSETS SCREEN. Also note that the wind direction and nearby objects can have an impact on the outdoor pressure reading. Review the installation guides for proper positioning. Review the tubing running to each location for kinks or obstructions. Review adjacent spaces for impact on poolroom pressure. 3. On the display, go to SERVICE MENU r -J AIRFLOW SETTINGS .-J AIRFLOW SETUP +-J SUPPLY AIRFLOW SETUP. Set the Unocc Override to "On". 4. The value for Reheat dp should be the same as the Target Reheat dp +/- 0.02" WC. Should the Reheat dp be lower than the target, disconnect unit from power and adjust the sheave on the supply fan motor by turning this in and increasing the belt speed. Should the Reheat dp be lower than the target, open the adjustable sheave to decrease the belt speed. Unoccupied Exhaust (Except Low Exhaust Option Equipped Units) In unoccupied mode the warm exhaust damper will index to the minimum position and the exhaust fan speed will modulate to maintain the programmed negative static pressure in the zone. The following procedure will be used to set the flow rates in unoccupied mode: 1. Use the controller display under SERVICE MENU +-J AIRFLOW SETTINGS .—J AIRFLOW SETUP +-J EXHAUST AIRFLOW SETUP to set the Unit Mode Override to "Unocc". Set VFD to "VFD Max". Do not change the Exhaust Mode at this time. 2. There may be instances where the return air static pressure or exhaust duct static pressure is much lower than originally specified. This will increase the exhaust flow rate to a point much higher than specified. In these 36 Desert Aire - SA Manual circumstances, a warning for high current may display on the Variable Frequency Drive (VFD). Should this be the case, adjust Max Warm Exhaust value lower until warning is no longer present. 3. Set Unit Mode Override to "Auto". The exhaust fan VFD will modulate to maintain the space pressurization setpoint. 4. Review the actual space static pressure through the use of independent measurement device such as a manometer or magnehelic. This can usually be done by slipping the manometer tubing through a door leading outside. Repeat for other doors or windows to ensure the negative space pressurization is sufficient. Occupied Modes and Unoccupied with Low Exhaust Option Exhaust Desert Aire SelectAireTM units can be equipped with several different types of outdoor air and exhaust air modes of operation. A unit may be equipped with one or more of these modes of operation. Each mode will include a separate specification for outdoor air flow rate that is specified at the time of order. These modes may include: • Unoccupied Mode (When Equipped with Low Exhaust Option) • Occupied Mode • Event Mode • Max. OA Mode The unit shall be balanced with the highest outdoor air flow rate with the following steps: 1. Use the controller display under SERVICE MENU +-J AIRFLOW SETTINGS +-J AIRFLOW SETUP +--1 EXHAUST AIRFLOW SETUP to set the Set Unit Override to "Occ". Set Exhaust Mode to "Cool'. Set VFD to "VFD Max". 2. Unit will open the Cool Air Exhaust Damper downstream of the evaporator coil. Unit specified with high amounts of outdoor air may also open the exhaust damper upstream of the coil in this mode. The exhaust fan speed command will increase to maximum. 3. Should the motor current be higher than design due to low static pressure, a warning for high current will be displayed on the VFD and the frequency will be automatically limited to a lesser value. If the warning is being displayed, adjust VFD Max % lower until the warning is no longer displayed. 4. There may be instances where the space requires additional fan speed to achieve negative static pressure in the zone. The Max Fan Speed Output Setting can be increased. If the high current warning is displayed on the VFD, the physical limitations of the system have been reached. 5. Set Exhaust Mode to "Warm". 6. Should there be a lower than specified return air static pressure or exhaust duct static pressure, a high current condition may be displayed on the VFD and the frequency will be automatically limited to a lesser value. Should this be the case, adjust Max Warm Exhaust value lower until warning is no longer present. Desert Aire - SA Manual 37 Purge Mode Unit equipped with Purge Mode have the capability for a very high flow rate of outdoor air and exhaust airflow. During Purge Mode the compressors are disabled and heating is shifted to an alternate minimum supply air temperature control to prevent condensation without unnecessary conditioning air to be exhausted. Only the warm exhaust damper will open during the Purge Mode of operation. The unit shall be balanced in Purge Mode with the following steps: 1. Set Unit Override to "Purge". 2. Set Exhaust Mode to "Auto". 3. Set VFD to "VFD Max". 4. A high current condition maybe displayed on the VFD and the frequency will be automatically limited to a lesser value. Should this be the case, adjust Max Warm Exhaust value lower until the warning is no longer present. Record the final set points on the Start -Up Report. It should be noted that filter changes are important to ensuring that exhaust air and outdoor air are able to be maintained at the proper flow rates. The SelectAireTM system operation will automatically adjust to accommodate normal increases in static pressure drop, but excessive filter loading will restrict airflow. Filters should be monitored and replaced as required. Evaporator Settings and Cool Exhaust Airflow There may be additional display screens for the evaporator and cool exhaust airflow. The values are preset from the factory and optimized. No adjustment is required unless instructed by Desert Aire Service. 3.2.3 Final Air Balancing Once the supply air and exhaust air setup have occurred, the unit will automatically adjust the damper positions and drive speed in each mode of operation. The outdoor air damper will open and modulate to achieve the pre -determined pressure drop set point of the outdoor air stream pressure plate. This has been determined by the customer requested occupied mode flow rate and tested at the factory. The exhaust will be controlled by space pressurization and maintains the negative static pressure set point. This is also a good opportunity to ensure that the commands for operational modes are being properly sent to the equipment. Command each mode of operation through the method that will be used on site. Depending on the mode and installation specific, this may occur through the internal time schedule, a contact closure, or the Building Management System. 38 Desert Aire - SA Manual In unoccupied mode, check and record the following: • Return duct static pressure to atmosphere • Supply air flow rate and static pressure to atmosphere • Supply fan motor current In each outdoor air mode of operation, check and record the following: • Exhaust air flow rate and static pressure due to atmosphere (indoor units) • Outdoor air flow rate and static pressure to atmosphere (indoor units) • Exhaust fan motor current (use True RMS meter only on VFD drives) Space pressure relative to outdoors and adjacent spaces Note that once Purge is initiated and then released from the override, the post -purge timed sequence that eliminates outdoor air is active. Controller power must be removed to discontinue post -purge timer early. Should the requirements for outdoor air in an application change or the readings of pressure sensors are affected by the installation, the settings can be changed for each mode under SERVICE MENU +-J AIRFLOW SETTINGS +-J AIRFLOW SETUP scrolling down will show the set points the unit is controlling for each OA mode of operation. Always ensure that the zone is negative relative to adjacent spaces should this be changed. The Desert Aire SA unit with exhaust fan contains operational controls that assist in maintaining the poolroom envelope at a negative static pressure. Proper setup allows these controls to operate as intended; however, these are not safety controls. It is the responsibility of the owner/operator to ensure that proper space pressurization of the envelope occurs. It is recommended that the pressurization be checked on a regular basis to ensure proper operation of all building systems and any issues corrected immediately. Auxiliary Heating Ensure that the supply air temperature sensor is downstream of any field installed auxiliary heaters. The pre-programmed values for the deadbands, differentials, and PID values are expected to create a good balance between temperature control and stability in the typical applications. Occasionally the heater may have larger or smaller capacity relative to the space or sensor placement may be in an atypical location. If space conditions vary greatly or frequent cycling between modes are apparent, the values Desert Aire - SA Manual 39 may need to be changed. Modification to the parameters and tuning should be done with care. If it is determined that a specific application would benefit from modification, time and patience will be required to ensure that the desired effect is achieve. Staged Heating When installed in a relatively mild climate with minimal outdoor air requirements, there is a relatively small amount of heating capacity. In these cases, staged heating is a cost effective and simple method. The auxiliary heating outputs come set from the factory for control of staged control or modulating control as specified at the time of order. When set for Staged, the dry contact associated with the heating output will close on a drop in temperature of the zone set point minus the deadband minus the differential. The contact will remain closed until the temperature reaches the zone set point minus the differential. Heater On = Zone Setpoint — Heating Deadband — Heating Differential Heater Off = Zone Setpoint — Heating Deadband Example: Zone Setpoint: 85°F Heating Deadband: 2°F Heating Differential: VF In this example, the heater output will close at 82°F and will open at 83°F. Due to some system capacitance and sensor hysteresis, the actual zone condition may overshoot these values slightly, but should not overshoot these values to cause the unit to shift into a cooling mode. Should the heater be very oversized and the overshoot significant, it may be necessary to increase the deadband to prevent cycling between modes. It should be noted that the nature of the staged heating will create a significant variation in the supply air temperature as the heater is turned on and off. Heaters are sized for extreme conditions (typically the 99th percentile heating capacity). At many times of the year the heater is essentially oversized. Depending on the location of the supply ducts and diffuser configurations, the variations may create drafts within the space. Also, if the air temperature is very low and the heater cycles off, the supply air temperature may be lower than the space dew point. This would cause condensation on ducts, diffusers, and surfaces. Should there be issues with supply temperature variations, modulating heat should be considered. 40 Desert Aire - SA Manual Modulating Heating When the application has a moderate to extreme climate and outdoor air is specified, it is recommended that auxiliary heating be modulating. When the controls are set for Modulating heat output, both the binary heat output contact and the modulating heat output are active. The binary heat output acts as an enable contact that can activate a gas heater enable signal or start a hot water coil pump system. The modulating output is intended to vary the gas valve, SCR electric heater, or hot water coil water flow rate. The Modulating heating sequence works based on a Zone Reset of the Supply Air Temperature. When the zone temperature decreases to the Zone Temperature minus the Heating Deadband, the controller enables heating mode and starts to increase the calculated Supply Air Temperature Set Point. The heater output will modulate to maintain the calculated Supply Air Temperature Set Point. The heating mode is always disabled if the zone exceeds the Zone Temperature Set Point. Resetting the supply air temperature in heating not only closely maintains the zone temperatures, but helps ensure the supply air temperature is held to minimum values. The default values used for the zone PID, supply air PID, and deadband are appropriate for most applications and heater sizes. Should the commanded Supply Air Temperature change too quickly, the PID action for the reset can be slowed by increasing the tuning values. Should the heater not be able to closely maintain the calculated Supply Air Temperature Set Point, the values for the heater output loop can be adjusted. Heater Enabled = Zone = Zone Setpoint — Heating Deadband Heater Disabled = Heat Output PID Loop < 5% or Zone = Zone Set Point Example: - Zone Setpoint: 85°F - Heating Deadband: 2°F In this example, the binary heater contact will close at 83°F and the analog output will start to increase. The PID loop will modulate to maintain the zone at the 83°F temperature. Should the analog signal for heat decrease to less than 5%, the binary contact will open. In addition, if the zone is sensed at greater than 85°F at any point, the contact will open, limiting heater overshoot due to poorly tuned loop. Final Review of the Unit Operation Under typical circumstances, the unit will cycle into and out of a mode of operation over a period of time. This will typically continue until the environmental conditions change or another outside influence causes the load to differ. The duration of each cycle will depend on the unit capacity and the activity within the space as well as the Desert Aire - SA Manual 41 building construction, set point, and ambient conditions. The controller is programmed with minimum mode times that prevent short compressor cycles and quick indexing of modes. This minimum mode time is set at 360 seconds as a default. When the loads are very low and the unit is relatively large for the application, this may cause a slight overshoot in space condition for cooling and dehumidification. Frequent cycling between heating and cooling is not expected, however. It is recommended that as a final check that the unit be released from all overrides, offsets, and returned to the expected set points. Observation of the typical operation under load is an invaluable tool in ensuring that all aspects of the system are working as anticipated. Observing the unit control the space for a few cycles is recommended. This can be done reasonably well as the tools and site is being cleaned up at the end of a startup or service call. The following are examples of how the unit will be expected to operate in the typical loads encountered. Note that there are many variables in conditions and unit sizing. These are included to give basic understanding of the expected operation. Ambient Condition Cool and Humid (Typical Spring Day) Unit will be primarily in dehumidification mode and may cycle in 1 st and 2nd stages of dehumidification. The hot gas reheat coil will be active most times. The unit may occasionally shift to cooling mode on one or both circuits, especially during mid-day when the solar load is high. During the night-time hours when the unit is unoccupied and ambient starts to cool, the unit will be in dehumidification mode less frequently and auxiliary heating may become active. Ambient Condition Hot and Humid (Typical Summer Day) Unit will be primarily in dehumidification mode and cooling active. The remote condenser will be active most times. The unit may occasionally shift to dehumidification mode on one circuit, especially as the solar load starts to decrease in the afternoon. During the night-time hours when the unit is unoccupied and ambient starts to cool, the unit will be in cooling mode less frequently and more frequently in dehumidification. Ambient Condition Hot and Dry (Typical Early Fall Day) Unit will be primarily in cooling mode with one or two circuits active. Depending on the load one or both of the circuits may cycle on and off to maintain condition. During the night-time hours when the unit is unoccupied and ambient starts to cool, the unit will be in cooling mode less frequently and auxiliary heating may become active. 42 Desert Aire - SA Manual Ambient Condition Cold and Dry (Typical Winter Day) If the unit is equipped with exhaust energy recovery, and the controller senses the zone is dehumidified and temperature within the space is dropping, it will shift to energy recovery mode. This will energize the Circuit A compressor(s) and open the cool exhaust damper. This uses the refrigeration as a heat -pump to recover the energy in the exhaust air. This energy recovery can be considered the first stage of heating and will occur before the auxiliary heating is activated. During the daytime the unit may occasionally be in dehumidification mode. Energy recovery will index on as required and auxiliary heating will become active as required to maintain space conditions. Note that it is not uncommon for the unit to occasionally shift into cooling mode in the wintertime when the solar load is high and the envelope contains high number of south facing windows. This can occur down to 30°F or even lower in some cases. Note, that in extreme cool and dry conditions when in occupied mode the outdoor air may dry the space significantly. When this is the case, the exhaust air may no longer have the energy to recover. The unit controls will disable the energy recovery mode when this occurs if the unit is equipped with the option. 3.3 Refrigeration Testing Refrigerant based cooling systems are sometimes referred to as "sealed systems". This is in reference to the refrigeration system being hermetically sealed, no refrigerant can leave the system and no contaminants are allowed inside. Factory equipment and procedures ensure a clean and tight refrigeration system where only the specified refrigerant and oil are in the system. This is a critical component to the longevity of the system. Some Desert Aire systems are shipped in sections to allow for installation of some of the sections in a location much different than another. An example is a unit with a remote condenser ready circuit. The dehumidifier may be installed indoors near the conditioned space while the remote condenser used to reject waste heat is located outdoors. The piping of the condenser is completed in the field before the unit is commissioned. The design and processing of the field piping is just as important as the factory piping in ensuring the longevity of the system. Selection of quality components, quality procedures, and full testing help to ensure that sealed system failures are minimized wherever possible. Nonetheless, the mechanical nature of many components creates some unforeseen wear and failure in certain instances. Some units may need service at a point in the life of the product that requires opening of the hermetic refrigeration system. Special care must be taken to ensure that the system is returned to service without contamination. DesertAire - SA Manual 43 Whenever servicing Desert Aire equipment, observe the following: • Use only equipment rated for the pressures of the refrigerant being serviced. • Use only equipment dedicated to service of the refrigerant in the system. Do not use equipment to service multiple refrigerant types. • Purge all hoses and equipment of non -condensable gasses before connecting to the sealed system. • Use only original equipment parts or factory approved equivalent for servicing. • Use required refrigeration system oil. • Minimize the time the system is open to atmosphere while servicing. Cap all connections where there is no active service work on the system. This is particularly important with units that contain POE oils as moisture will be absorbed quickly and cannot be removed with a vacuum. • Never open the system while under a vacuum. Should system require opening to repair a leak or other service when a vacuum, fill with dry nitrogen to atmospheric pressure before opening. • Have a Schrader core replacement tool available when servicing the refrigeration system. Although rare, defective or damaged Schrader valve cores can contribute to refrigerant loss. • Charge system only by weight after servicing. Review the rating plate and any field charge labels. • When servicing, additional liquid line filter dryers and suction filters may be required. This does not apply to installation of remote condensers. • Charge refrigerant blends, including R-41 OA and R -407C, with liquid only. Charging should be done into the high side of the system wherever possible. Refer to Section 5.6 for additional procedures related to charging. Note that superheat should be stable within 7 degrees. The temperature and relative humidity listed in Figure 26 is the Return Air. Minimum value for superheat at compressor in all modes: Figure 26 - Superheat Minimum Values Chart 44 Desert Aire - SA Manual Superheat Minimum Values Chart Temp (°F) Relative Air Temperature (°F) 60.0 - 65.0 65.1 - 70.0 70.1 - 75.0 75.1 - 80.0 80.1 - 85.0 85.1 - 90.0 30.0-40.0 12 13 14 15 15 16 40.1 -50.0 13 14 15 15 16 18 w 50.1 -60.0 13 14 15 16 18 18 a E 60.1 -70.0 14 15 15 16 18 19 = 70.1 - 80.0 14 15 16 18 19 20 Figure 26 - Superheat Minimum Values Chart 44 Desert Aire - SA Manual 3.4 General Testing After you balance the airflow and test the refrigeration circuits, verify that the other equipment and accessories connected to the dehumidifier work properly. Although this may be difficult, since the dehumidifier is usually interlocked with a variety of equipment installed by different contractors, you must not skip this step. Each of these devices (which may include auxiliary air and water heaters, smoke alarms, circulating pumps, and a building management system) is vital in maintaining the performance and comfort of the swimming pool environment. Many customer complaints are caused by improper interlocks between these devices. Make sure you check the following: • Check the outdoor air and exhaust devices. The outdoor air and exhaust dampers must open when they receive an "occupied" signal from the dehumidifier. If you have installed an exhaust blower, make sure that it is interlocked with the "occupied" signal or with an end switch on the outdoor air damper actuator. Check the condensate drain to make sure it has been trapped and primed with water. Verify that it drains freely, with no leaks. If the drain is outside or in an unconditioned space, make sure it has been heat traced. If you installed a condensate pump, make sure it operates properly. Check the pool water piping to the dehumidifier (on units equipped with optional pool water heating). Make sure that all air has been bled out of the lines, and check that an air bleed valve has been installed at any high points in the water lines. If the circulating pump is not set for continuous operation, make sure it is properly interlocked with the dehumidifier. Temporarily shut off the water flow to the unit to verify that the factory -installed water flow proving switch operates correctly. Verify that the pool water temperature sensor has been installed where water will flow over it continuously. Verify that the pool water temperature sensor is on the water inlet of the unit. Check the operation of the remote condenser (on units equipped with this option). Make sure that the pressure transducers are wired to the condenser fan cycling control, the cut -in and cut-out pressures are correctly set per the remote condenser installation manual. Verify that the fans are blowing vertically upward when they run. Check the temperature and humidity readings displayed on the controller. If you think the values are incorrect, check the sensor or its field -installed wiring for damage. If necessary, check the voltage jumper on the temperature and humidity sensor. It must be set in the "0-10 VDC" position. 3.5 Routine Maintenance Schedule 3.5.1 Service Every Month • Check and replace the air filters in the return duct and the outdoor air duct. • Check for dirty coils in the dehumidifier. Clean them if necessary. Desert Aire - SA Manua! 45 3.5.2 Service Every Six Months • Check the blower belts for wear or glazing. Tighten or replace them if necessary. Do not use belt dressing compound. • Check and tighten all field and factory electrical connections. • Check for dirty coils in the dehumidifier and the optional remote condenser. • Check and clean the drain pans and blow out the condensate drain line. If the drain is plugged, water will back up into the dehumidifier and flood the mechanical room. • Check and adjust the air flow per specifications. Dirty ducts, filters, and coils may have reduced the total air volume. • Check the operating pressures of the refrigeration circuits. • Check the current draw of each blower motor. • Check the current draw of each compressor. • Lubricate the blower motor(s). • Lubricate the supply blower bearings. NOTE: please have the following information available if you need to call the Desert Aire Service Department: • Model Number • Serial Number • Room Temperature • Relative Humidity • Operating Refrigeration Pressures • Water Temperature • Compressor Amperages • Blower Motor Amperage(s) 46 Desert Aire - SA Manual 4. Troubleshooting Although Desert Aire dehumidifiers have been designed for reliable and trouble-free operation, you may occasionally encounter a service -related problem. If you cannot immediately diagnose a fix to the problems, do not be intimidated by the apparent complexity of the dehumidifier. Your common sense and experience can help you solve the majority of these problems. These problems or complaints are frequently caused by improper interlocks between the dehumidifier and the other equipment and accessories at the jobsite. You may need to consult with other contractors who have worked on different portions of this project. Read Section 3.4 for a more detailed list of interlocks. The following list will help you diagnose some of the most obvious symptoms of a system which does not work properly. 4.1 The Blower Does Not Run The standard Desert Aire dehumidifier is designed for continuous blower operation, which helps prevent air stratification, occupant discomfort, and structural damage to the ceiling and upper walls of the poolroom. Check for these problems: • Check for power at the power block on the electrical panel of the dehumidifier. • Verify that the incoming power matches the value printed on the unit rating plate. • Check the branch fusing. Replace any defective fuses and determine why they failed. • Use a voltmeter to trace the low -voltage control wiring. Determine if voltage is applied to the holding coil of the blower contactor. • If there is no voltage at the holding coil, check the blower overload, the control transformer, the smoke alarm interlock, or the optional voltage monitor relay. • if the dehumidifier uses a non-standard controller, or if the blower is cycled by the building management system, consult with the controls contractor. 4.2 The Compressor(s) Do Not Run If a compressor doesn't run even though the humidity in the poolroom is excessive, check the sequence of operation of the dehumidifier. Under certain situations the controller will lock out the compressors to prevent the pool room from overheating. See Section 5.5 in the Appendix for more details. If the problem is not controller -related, check the following: • Check the "Compressor Fault" indicator on the controller display panel (for dehumidifiers with the standard controller). The fault indicator will flash if one of the compressor safety devices has tripped. The indicator will automatically stop flashing when the problem has been corrected. See the low -voltage wiring schematic for details on this fault circuit. • Check for power at the power block on the electrical panel of the dehumidifier. • Verify that the incoming power matches the value printed on the unit rating plate. • Use a voltmeter to trace the low -voltage control wiring. Determine if voltage is applied to the holding coil of the compressor contactor. • If there is no voltage at the holding coil, check the compressor overload and safety devices, the Desert Aire - SA Manual 47 control transformer, the smoke alarm interlock, the airflow proving switch, or the optional voltage monitor relay. • If the dehumidifier uses a non-standard controller, or if the compressors are cycled by the building management system, consult with the controls contractor. • Confirm that the compressor "knife" switches from air balancing section have been closed. 4.3 High Pressure Alarms/Readings Above 575 PSIG The unit contains a pressure transducer and control sequence that will interrupt power to the compressor if the refrigeration system pressure is excessively high. The alarm will be active on the local display and the building management system (if equipped). The alarm can be reset at the main alarm screen on the display. • Check that all service valves and ball valves in the compressor discharge line are fully open. • Verify that the reheat condenser is clean and free from debris. Use a Magnehelic® or an inclined manometer to check the air volume through the reheat condenser. See Section 3.2 for more detailed instructions. • Check that there is adequate water flowing through the pool water condenser (on units equipped with this option). Verify the operation of the water flow switch. • Check the remote condenser fuses, fan motors, and fan cycling switches (on units equipped with this option). Verify that the fans are not obstructed and that they blow the air vertically upward. • Check the three-way heat reclaim valve for proper operation. This valve, which is installed in the compressor discharge line, diverts hot refrigerant vapor to the various condensers (on units equipped with optional pool water heating or remote condensers). The valve spool may be stuck in the middle of the valve, where it blocks the outlets to both condensers. You can verify its operation by first running the compressor and then measuring the temperature of both condenser outlets. If the valve is shifting normally, the active condenser outlet will heat up rapidly. • Check for air or other non-condensables in the refrigeration circuit. Desert Aire installs purge ports in the highest point of each condenser's discharge line. To purge these gases from the system, temporarily run the compressor while you energize the selected condenser. Shut the compressor off, but continue to circulate cooling air or water through the condenser. Slowly depress the Schrader core at the high point purge of the condenser. You can do this procedure to keep the system running, but it is a temporary fix. It is not a longterm substitute for proper evacuation with a vacuum pump. • If the dehumidifier uses an outdoor air duct with a field -installed preheating coil, verify that the coil is only active during the heating season. • If the system is overcharged or excessively cold, migrating refrigerant can liquefy and fill a condenser and its discharge line during the "off -cycle". If the compressor starts and the three-way valve shifts to this flooded condenser, the high pressure switch will trip almost immediately. Remote outdoor condensers are particularly susceptible to this problem during the winter months. 4.4 Low Pressure Alarms/Evaporator Coil Icing The unit contains a pressure transducer and control sequence that will interrupt power to the compressor if the refrigeration system pressure is excessively low. The alarm will be active on the local 48 Desert Aire - SA Manual display and the building management system (if equipped). In this active alarm state, the circuit will stop and not restart until the Suction Pressure in that circuit rises 48 psi above the Low Suction Pressure Trip Set Point. Although the circuit will restart automatically, the red ALARM LED on the display will stay lit until the alarm is acknowledged, even after the alarm condition is cleared, to alert the operator the alarm occurred. The alarm can be reset at the main alarm screen on the display. • Check the return air ductwork. Poorly designed, restrictive ductwork can cause stratification or faulty air distribution. Resize the return air ductwork and grilles, or add turning vanes if necessary. • Verify that the evaporator and return air filters are clean and free from debris. Use a Magnehelic® or an inclined manometer to check the air volume through the evaporator coils. See Section 3.2 for more detailed instructions. • Check the temperature and humidity of the return air. The SA evaporators are designed for maximum efficiency at typical swimming pool conditions. If the return air wet bulb temperature drops below 60°F, these coils may frost. Never introduce unconditioned outdoor air into the return duct of an SA series dehumidifier! • Check that all service valves and solenoid valves in the liquid line are energized or fully open. • Verify that there are no restrictions or debris in the liquid line solenoid, the filter/drier, the expansion valve, or the distributor. • Check to see that the system is properly charged and that the liquid line sight glass shows no bubbles. The refrigerant on an undercharged system can migrate to the coldest condenser on the "off cycle", causing the receiver to lose its liquid seal. 4.5 The Pool Water Is Too Cold This section applies to Desert Aire dehumidifiers with the pool water heating option. If the pool water requires heating, the standard controller will command the dehumidifier to heat the water. If the dehumidifier cannot heat the pool, due to inadequate water flow or no demand for dehumidification, the water temperature will drop slightly. The controller will then energize the auxiliary water heater, if one has been installed. See Section 5.5 in the Appendix for more details. If the problem is not controller -related, check the following: • Make sure that the refrigeration circuit containing the pool water condenser has not locked out on a safety trip. • Check the "Pool Water Flow" indicator on the controller display panel (for dehumidifiers with the standard controller). The fault indicator will flash if the water flow proving switch does not sense water flow. When this happens, the dehumidifier will not run in the pool water heating mode. All other modes will operate normally. The fault indicator will automatically stop flashing when the problem has been corrected. • Temporarily raise the pool water heating set point to verify that the auxiliary pool heater energizes on call for second stage pool heat. • If an auxiliary pool heater has not been installed, remove the "air/water priority" jumper from the electrical panel of the dehumidifier. See the wiring schematics and Section 5.5 in the Appendix for details. • Make sure that the water filters are not clogged. • Verify that the water condenser and pool water lines are free of fouling and scaling. • Check that all service valves and solenoid valves in the liquid line are energized or fully open. Desert Aire - SA Manual 49 Verify that there are no restrictions or debris in the liquid line solenoid, the filter/drier, the expansion valve, or the distributor. 50 Desert Aire - SA Manual 5. Appendix 5.1 Compressor Failure Although some compressors fail because they are mechanically flawed, most failures are due to system -related problems. Compressor failure can be caused by liquid flood back, air or moisture in the refrigerant system, solid contaminants, excessive heat or electrical service malfunctions. To avoid repeated callbacks, you must determine the cause of the failure and then correct it. If the compressor has failed because its motor has burned out, the refrigerant oil, and piping may have become severely contaminated. If a burnout has occurred, use the following procedure to replace the compressor and clean the refrigerant system. Use an oil test kit to determine the severity of the burnout. Make sure you use rubber gloves and eye protection, as contaminated refrigerant and oil can cause severe burns! You must clean the system thoroughly to prevent repeated compressor burnouts. 5.1.1 Compressor Replacement Desert Aire dehumidifiers are designed with scroll compressors. Scroll compressors are known for operating more reliably than other compressors in air conditioning and dehumidification applications due to their ability to cope with occasional periods of liquid refrigerant return. There are fewer moving parts in a scroll compressor subject to wear compared to alternative compressor designs. Nonetheless, there are still many mechanical and electrical parts with close tolerances. Replacement of the compressor may be required during the normal service life of the dehumidifier. Inspection and Initial Diagnosis Generally, the compressor will have two basic failure modes, mechanical and electrical. The compressors are a hermetic design, meaning all components, including the motor, are in a sealed shell. It can be very difficult to determine which issue was the root cause of the failure in the field by inspection of the damaged compressor. For example, an initial bearing failure inside the compressor may create debris that contaminates motor windings. High current draw may be related to a bearing issue or a motor winding issue. The initial inspection must be combined with a final analysis of the machine when returned to working order to confirm diagnosis. Specific items should be noted before the replacement to give the best indications of the failure and complete the diagnosis as the new compressor is installed. The following data should be taken to assist in diagnosis: • Current draw for each leg of power (if the compressor will run and pump) • High side and low side pressure (if the compressor will run and pump) Resistance of each leg to leg on three phase compressor or each leg to neutral on single phase compressors. Desert Aire - SA Manual 51 • Check of continuity from each leg to ground. • Review of all system alarms including the relative timing of the alarms and mode of operation. It is important to note that other components or lines may have been damaged if the compressor has failed. At times the internal damage to a compressor creates extreme levels of vibration before complete failure. Refrigerant lines and connections may be damaged before the compressor stops. Inspect tubing and components of the system before completing the compressor replacement. Compressor Replacement Refrigeration oil must be tested for acid and particulate during any compressor replacement. For the initial testing, the compressor sump should be used to sample the oil. Oil can be recovered through the Schrader port on the low point compressor shell or through the suction line connection after the compressor has been removed. Use Virginia KMP, New -Calgon Phase III, Sporlan Test -All, or equivalent oil test where oil is sampled into a container. Vapor sampling methods may not show particulate and should not be used. Read the oil test kit manufacturer's instructions to determine if there is acid present in the oil. Determine if there are other contaminants by viewing the samples for darkness, cloudiness, or particulate. The following procedures must be used depending on the results of the test above: Any Compressor Service A new filter dryer must be installed when the system has been opened. See Section 5.6 for component replacements. If there is no acid or particulates indicated, the new compressor can be installed and run. Proceed to Testing and Final Diagnosis. Acid Indicated Install a suction line filter shell and charcoal activated core such as a Sporlan or Emerson HH core type or equivalent. The acid levels will be monitored and several core changes may be required. Install ball valves on either side of the suction filter to facilitate these changes. Note that larger Desert Aire systems will have suction filter shells installed from the factory. The shell can be used with charcoal activated cores. Note that a "safety screen" may be required with some manufacturer's cores to prevent small pieces of the core from dislodging and finding their way to the compressor. Follow filter shell and core manufacturer's instructions. Review compressor and suction line for an area where future oil samples can be taken from the system. If an access fitting exists on the compressor shell below the oil level, no further action is needed. If this is not available, an access fitting can be located at the bottom of a trap in the suction line. Braze in a fitting as required to be able to remove an oil sample. Ensure there are access fittings directly upstream and downstream of the suction filter. There is typically one fitting installed on the suction filter. There may be a bulkhead fitting attached to the compressor suction side. 52 Desert Aire - SA Manual Do not use acid neutralizing additives or other chemicals for acid removal. The refrigeration system must contain only oil and refrigerant. Precipitates of additives and acids may be considered contamination in the refrigeration system. Other compounds may be present in additives as carriers. Longterm effects of specific additives or compounds with a particular system or design are unknown without significant controlled testing. Particulate Indicated • Install a replaceable core liquid line filter shell. Note that larger Desert Aire systems will have replaceable core liquid line filter shells installed from the factory. The pressure drop levels will be monitored and several core changes may be required. Install ball valves on either side of the filter shell to facilitate these changes. • Install a secondary filter such as Sporlan FS -series or equivalent 20 micron filter in the replaceable core. • Ensure there are access fittings directly upstream and downstream of the liquid filter. There is typically one fitting installed on the filter shell. There is typically one fitting installed on the outlet side of the receiver. Returning to Service • See Section 5.6 for evacuation and charging. • Restart unit and set unit to run compressors. • Record the pressure drop across the suction filter and liquid line filter dryer. • Check sight -glass indicator for moisture level. • Monitor pressure drop across the liquid and suction filters during the first hour of operation. Compare the reading taken earlier. If the pressure differential across the filters is more than 5 PSI greater than the initial reading, isolate the filters using the valves installed and recover the refrigerant from the filters. Replace cores. If activated carbon filters were installed in the suction side to remove acid, replace with similar cores. If a secondary filter was installed in the liquid line core to remove particulate, install cores and secondary filter in this location. • Run unit for 24 hours and review acid levels (if found previously) and pressure differentials. - If acid is found, replace with activated charcoal cores and test at 24 hour intervals until acids are at acceptable levels. Once acid is no longer detected, replace cores with standard filter elements. Remove outlet screens if they were required by filter manufacturer. If the pressure differential across the liquid line filter is more than 5 PSI greater than the initial reading, replace cores and secondary filter with new components and test at 24 hour intervals until pressure drop is at acceptable levels. Once pressure differential is less than 5 PSI, remove secondary filter and replace cores. Testing and Final Diagnosis It is of critical importance to ensure that the system is operating as expected before unit is returned to normal service. Complete a Compressor Replacement Form located in the Installation and Operation Manual. Validation of this report allows for the continued coverage of the compressor under the original warranty. Desert Aire - SA Manual 53 5.2 It is possible that there was an internal defect in the compressor or normal mechanical wear occurred over time. Compressors longevity generally is a function of load, lubrication, electrical input conditions, and temperatures. There is a cause for the compressor failures that must be identified before unit is placed back into full service. Both the identification of the cause of compressor failure and the proper cleanup of the system must be addressed to avoid repeat compressor damage. Recommended Duct Design You must use proper duct design to ensure that the dehumidifier operates efficiently and without problems. Undersized or restrictive ducts reduce the system airflow, which can cause premature compressor failure. Use the following diagrams as a guide when you design the duct system. Recommended 20° o7rr Less T Discharge Duct Turns Desert Aire W 5W or More For Static Pressure Regain Intake 1 Duct Tums W Desert Aire L 2.5W or More Intake �7� Duct Tums Desert Aire L 54 Desert Aire - SA Manual Not Recommended 30° or More Discharge 1 Desert Aire Intake 1 Desert Aire Intake Desert Aire Figure 27 - Recommended Duct Designs for Desert Aire Dehumidifiers 5.3 Pool Water Chemistry Pool chemistry must be maintained to ensure the proper pH, total alkalinity, calcium hardness, and free chlorine. NSPI recommends the following levels for pool chemistry: • pH: 7.4-7.6 • Total Alkalinity: 100 — 150 ppm • Calcium Hardness: 200 — 250 ppm (Plaster Pool) • Free Chlorine: 1.0 — 3.0 ppm Excessive chemical levels in the pool can be dangerous to users and can damage pool hardware, including the dehumidification system. The Desert Aire warranty does not cover equipment damaged by faulty pool chemistry. 5.4 Recommended Controller Settings 5.4.1 Controller Set Points It is important to determine your comfortable set points and to avoid further controller adjustments. It takes time for the unit to establish equilibrium at a given set point. Therefore, continued set point adjustments will lead to high energy consumption and user discomfort. Continuous blower operation is recommended. This will reduce air stratification and assure that the refrigeration circuit is activated only when it is necessary. RECOMMENDED SET POINTS: Humidity: 50% to 60 % RH Air Temperature: 2° to 4° F above the pool water temperature Never disable a dehumidifier in a pool room application unless the pool has been drained. Even when not in use, pool water continues to evaporate adding moisture to the air. During these periods of high humidity, moisture will seep into walls, ceilings, furniture, etc. Although the dehumidifier may be capable of regaining control of pool room conditions after re -start, in the long run, moisture damage to the pool room will become apparent. 5.5 System Operating Modes The standard sequence of operation of a Desert Aire dehumidifier is relatively simple to understand. Note that the sequence may vary depending on which condenser options have been purchased and installed. The compressor is designed to start on a call for dehumidification. As the refrigerant flows through the evaporator, it absorbs a great deal of heat from the airstream. This heat can either be rejected to the Desert Aire - SA Manual 55 air or to the pool, depending on which needs to be heated. • If neither the air nor the water needs heat, it will be rejected to the remote outdoor condenser. • If no outdoor condenser is available, the compressor will shut off rather than overheat the room air. Although the system cannot dehumidify the air when its compressor is off, overheating the space is unacceptable because it will cause occupant discomfort. • For this same reason, the compressor can start and run on a call for air cooling if another heat sink is available. 5.6 Component Replacement, Charge, Evacuation, & Leak Instructions Note that a new liquid line filter dryer will be required any time a refrigeration system is opened for servicing. New dryer should be of the same capacity as the original or larger. Recovery When there has not been a major refrigeration system leak, the system will contain refrigerant. This refrigerant must be either recovered to separate cylinders appropriate for the refrigerant type of isolated in a portion of the refrigeration system that will not be open for service. In all cases you must comply with Section 608 Refrigerant Recycling Rule of the Clean Air Act. Recovery of Systems with a Refrigeration System Leak As much refrigerant as possible must be recovered into separate refrigerant cylinders appropriate for the refrigerant being serviced. System pressure near the leak site should be monitored closely to ensure this area is not pulled to a vacuum. Isolate sections of the system as required and recover independently to avoid refrigerant contamination. Uncontaminated refrigerant can be reused in the refrigeration system it was recovered from. Recovery of Systems without a Leak Systems that do not have leaks, but still require refrigeration system service, may have charge isolated in receivers and condensers if these particular components do not require direct service. Desert Aire dehumidifiers have different receiver sizes depending on the model and size. Condenser sizes and configurations may also vary. In general, larger receivers will come equipped with isolation valves that will allow for a portion of the charge to be contained in the receiver during servicing. Units equipped with remote condensers will have isolation valves located inside the unit cabinet near the area where the connections are made. The compressor can be used to move refrigerant to the system components that will be used to temporarily hold the charge. Note that cooling a condenser by running as many fans as possible and/or cooling the coil surface with a stream of water can assist in storing charge. The low side pressure should be monitored closely while using this procedure to store charge. Under no circumstances should a compressor be allowed to run in a vacuum. When most of the refrigerant is 56 Desert Aire - SA Manual isolated in the receiver and/or condensers, recover remaining charge into separate refrigerant cylinders appropriate for the refrigerant being serviced. Carefully track the amount of refrigerant charge removed as this exact amount should be placed into the units when re -charging. Repair I Component Replacement • If any portion of the system was at a vacuum, place dry nitrogen in the system until atmospheric pressure is reached. • It is preferred that components are removed by heating the braze alloy to the remelt temperature and mechanically moving the component. When this is not possible due to proximity of cabinet structure or other components, a tubing cutter can be used to remove sections of piping. Where new tube is required for replacement, use dehydrated tube where possible. Use the same type of fittings as original. Route the pipe in the exact manner as originally routed. • Use Type K per ASTM B 88 or ASTM 8819 or Type ACR per ASTM B 280 copper tubing or for all tubes 1-1/8" and smaller. • Tubes 1-3/8" and larger shall use Type K per ASTM B88 or ASTM B819. • Cap sections of tube and components that are not actively being installed to prevent infiltration of moisture and contaminants. • Use only braze alloys to join tube. - The selection of filler metals is highly dependent on the tube fit, clearance, and operator preference for flow. When flux is to be used, care should be taken to ensure that the flux is not introduced to the inside of the tube. It is recommended that phosphorous bearing alloys be considered for copper to copper connections due to their self -fluxing on copper to copper joints. Refer to alloy manufacturer's guidelines for details on compatibility. • Flow nitrogen into tubing to prevent the formation of copper oxides. - Copper oxides form rapidly when copper is heated to temperatures required by the brazing process and exposed to oxygen in the air. Copper oxides flake easily on the inside of the tubing and dislodge easily when the system is filled with refrigerant and oil. The particulate can move throughout the system and cause contamination on valves and other critical components. System filters may become fouled. - Flowing nitrogen into the system and ensuring that the inside of the tube is significantly free from oxygen while brazing ensures that oxides do not form. Schrader valves are placed throughout the system. These valves can be opened to allow for nitrogen to flow without generating pressure behind the braze joint that is being created. • See Section 5.1.1 for special procedures related to compressor replacements. • Replace liquid line filter dryer as last step in system repair. Note that the dryer will readily absorb moisture from the ambient air and must be open only for as long as required for installation. • After completion of all repairs, pressure test system using nitrogen pressure decay test or nitrogen with tracer gas and appropriate leak detector. Evacuation • Carefully inspect pump and related equipment before connecting to system. Ensuring gaskets are in good condition and pump is capable of low vacuum levels can save time. Connect pump(s) to Desert Aire - SA Manual 57 as many locations as possible ensuring all locations are well sealed. If a field charge will be required, connecting a refrigerant tank to the system with a good valve is recommended. Any hose connections requiring purging of non-condensables can be done at this point. Evacuate the line and remote condenser to 400 microns measured at a point on the system furthest away from the pump. - Note that a gauge installed on the pump or in close proximity will give a lower reading while the unit is being evacuated. - A deep vacuum gauge should be used to evaluate the pressure. Compound manifold gauges do not allow for enough accuracy at the pressures required. - The system should be able to hold a vacuum under 500 microns for more than 10 minutes. - If pressure continuously rises at a rapid rate there is likely a system leak. Review all piping connections and correct before continuing evacuation. - Pressure rising above 500 microns and tending to stabilize at a higher pressure indicates the system has moisture above specifications. Continue evacuation until 500 microns or lower can be held for a minimum of 10 minutes. Alternate Evacuation Specification by Process After components have been repaired or replaced, the evacuation procedure should take place. Very small amounts of refrigerant may still be mixed with the oil in the system. Out -gassing of this refrigerant may interfere with the evacuation and vacuum decay testing. IF, AND ONLY IF, a unit has been previously charged with refrigerant, and standard evacuation method has not been successful after 24 hours minimum using the standard procedure, the following alternate method should be used. 1. Check vacuum level. It should be a maximum of 1,500 microns absolute pressure. If this is not the case, review system for leaks and continue evacuation process until 1,500 microns is achieved. 2. Purge system with nitrogen to atmospheric pressure (0 gauge pressure). Ensure all portions of systems are at this pressure. Seal system and wait 10 minutes. 3. Start vacuum pump and draw system to 1,500 microns or less. 4. Purge system with nitrogen to atmospheric pressure (0 gauge pressure). Ensure all portions of systems are at this pressure. Seal system and wait 10 minutes. 5. Start vacuum pump and draw system to 500 microns. Seal system. System may rise to higher level, but should not rise above 1000 microns in 10 minutes timeframe. If unsuccessful, continue evacuation or check for leaks. It is anticipated that the system was clean and tight from the original process and refrigerant only is mixed with oil. Alternate process should not be considered if there is chance of free water entering the system or the system was open for any significant time. 58 Desert Aire - SA Manual Charging • Charge should be weighed into the system using a scale. In cases where the full charge was recovered, weigh in the charge with the recovered refrigerant and add the appropriate amount to meet the rating plate and field charge (if applicable). This should be placed in the high side of the system at the receiver. • In cases where the full charge cannot be added to the system high side, the charge can be added to the low side of the system only when compressors are energized. If this is required, the compressors should be energized and the charge should be slowly metered into the suction line as far as possible upstream of the compressor. If the unit is equipped with an accumulator, the charge needs to be added to the port upstream of this location. The bulkhead fittings on the side of the unit should not be used for charge addition. Monitor superheat at the compressor suction inlet using the bulkhead fitting and a temperature sensor on the suction line near the compressor. Superheat should not drop below 10 degrees during the process of adding charge. Testing and Final Diagnosis Check the oil level in the compressor after the system has been running for 24 hours. Oil may have been contained in the liquid refrigerant when recovered from the system. Most of this oil will be returned if the recovered refrigerant is used. If new refrigerant is added, additional oil should be added based on the following ratio: New Refrigerant Charge Added, lbs. x 0.352 = Oil charge, oz. It is of critical importance to ensure that the system is operating as expected before unit is returned to normal service. Test component replaced and function of the system. Many times a separate component in the system may have set a condition that causes the failure of another. Thoroughly test systems to ensure repeat failures do not occur. Desert Aire - SA Manual 59 5.7 5.8 System Rating Plate The system rating plate is attached near the electrical enclosure of the dehumidifier. System model and rl Serial numbers DESERT Model No. SA50S4AAXXI4072 Serial No. XXXXEXXXX /,SIRE System electrical specifications ti Voltage/Phase/Hz. 460/3/60 Control Voltage24 Minimum Ampacity 123 Maximum Fuse 150 Blower(s) electrical Compressors Blower(s) specifications Compressor r Mtr# RLA LRA Mtr# HP RLA electrical specificationsy 2 18.3 127 1 20 25.0 3 18.3 127 6 N/A N/A Electric heater 4 26.4 187 7 N/A N/A electrical 5 26.4 187 specification Refrigerant Electric Heater r factory charge Factory Charge (lbs.) KW 15 FLA 19.5 CircuitA 66 t— Refrigerant type Circuit B 101 R41 OA ONLY Maximum Design Pressures (psig): 400 High Side .� 150 Low Side System working System wiring pressure range diagrams _may Wiring Diagram Numbers: HNS-340 / 8584LV / 8584AHU This Unit Is For Outdoor Use Indoor or Outdoor Desert Aire Corporation system rating N120 W18485 Freistadt Road Germantown, WI 53022 (262) 946-7400 Fax: (262) 946- 7401 Figure 28 - Typical SA Dehumidifier Rating Plate Start -Up Supervision Supplemental Information A Desert Aire factory start-up is an option which is normally purchased with the equipment. A factory start-up includes several key services: • The expertise of an accomplished, factory -trained mechanic who will supervise the commissioning of the equipment. • This Desert Aire representative will assist the installing contractor with filling out the Start -Up Report. • He will also inspect the installation to make sure that the dehumidifier has been properly integrated with the rest of the equipment on the jobsite. • Finally, he can train the maintenance personnel to operate and service the equipment if necessary. A factory start-up does not include installation assistance. The installing contractor is responsible for ensuring that the system is ready for start-up when the Desert Aire representative arrives. When the installing contractor is confident the system will be ready, he should contact the Desert Aire Sales representative to schedule the start-up. Please call at least two weeks before the desired start-up date to help prevent scheduling conflicts. 60 Desert Aire - SA Manual pl�tlli Start-up request form for pool room N120 W18485 Freistadt Road Mumunits Germantown, WI 53022 /,SIRE Models LC/LV/ND/SA (2621946-7400 FAX: deem -62) ire.co 1 www.desert-aire.com Factory Assisted Start; Up consists of a Desert Aire Service Department Technician to visit the job -site and provide supervisory experience to installing contractors as they perform the required procedures as outlined in our warranty activation start-up report. The company technician will also present an educational review of the dehumidifier's operating and maintenance requirements. Factory Assisted Start -Up is not an installation bid & therefore the system must be ready to run before scheduling CST Start -Up is performed by a local Certified Service Technician who has been trained by Desert Aire. The CST performs all duties listed above. In addition they will supply the "items to be supplied for start-up" as listed below. Please note charges for refrigerant will apply if refrigerant is necessary to complete the start up. Items to be completed by the installing contractor before any Start -Up can be scheduled: ❑ Dehumidifier leak checked and inspected for internal concealed damage — remove access panels and inspect the interior of the unit for transit damage. Contact Desert Aire immediately if damage is noted (800) 443-5276 ❑ Dehumidifier leveled and properly supported per the installation manuals recommendations. ❑ Outside air duct filters and damper installed (if applicable) — See installation manual. ❑ Condensate P Trap installed with heat trace for winter operation. ❑ Remote condenser plumbed, leak checked, evacuated, and charged if necessary. LC and LV Units require additional field charging. Refer to the 1/0 manual for details. Refrigerant added Ibs.(if applicable) ❑ All electrical connections terminated and verified for proper voltage at the unit and the condenser (if applicable) ❑ All field controls, sensors and actuators installed and circuits verified that they are wired correctly. Note: Zone sensors and controllers are shipped separately to ensure delivery. If the controllers are not located on site, please contact Desert Aire to confirm delivery status. (800) 443-5276 ❑ Pool filled, water and air temp minimum 80 degrees. (If applicable) ❑ Pool water heating circuit connected to dehumidifier with flow meter and balancing valves installed in circuit (if applicable) ❑ Verify the installation of the booster pool water -heating pump and purge air from water the lines. (If applicable) Items to be supplied by the installing contractor (Factory Assisted Start -Up only) ❑ Equipped service vehicle and service technician —Technician will be trained. ❑ Refrigerant manifold gauges — 2 sets ❑ Air balancing equipment (magnehelic or manometer differential pressure gauge — one inch scale) ❑ Volt/Amp/OHM meters in working order. ❑ Digital thermometer with sensors. ❑ 50# of the appropriate refrigerant & scale. ❑ Hand pump for adding oil to compressors. ❑ One gallon POE oil — Use POE 32 MAF If you are unable to supply any of the required equipment you must contact Desert Aire before returning this document. I agree that all of the above has been completed as of (Date) If a return trip must be scheduled due to insufficient job -site preparation an additional purchase order must be issued to Desert Aire for re -scheduling. A two week minimum is needed to schedule start-up. Once the form is completed please fax or email both pages to the Desert Aire service department. Fax (262) 946-7400 Email: serviceAdesert-aire. com Jobsite Manager's Signature: (print) Company Name: Phone (sign) SB -010 Desert Aire - SA Manual 61 x'1v Start-up request form for pool room N120 W18485 Freistadt Road DESERT units Germantown, WI 53022 AIRF Models LC/LV/ND/SA 4v (262) 946-7400 FAX: (262) 946-7401 ww. desert -a ire.com Unit Information Model # Serial # Jobsite Information Job site name Job Site Address Contractor Information Installing Contractor: Manager's Name: Phone #: Job Site Contact: Cell # Controls Company Name: Controls Contact: Cell# Test and Balance Company: Contact: Cell# Factory use only — To be filled out by Desert Aire Scheduled Start-up Date: Unit Controls Protocol: JCI Metasys JCI FX Carel Honeywell Other: Diagrams Forwarded to CST: Yes / No email address Installing Contractor Contacted by: Date: Network to be operational at time of start up: yes / no T&B to be on site during start up: yes / no Additional Information: SB -010 62 Desert Aire - SA Manual 5.9 System Start -Up Report A copy of the system "Start -Up Report" can be found on the following pages. This report needs to be filled out thoroughly by a qualified service technician and returned to Desert Aire for warranty validation. Please ensure that the model and serial number of the unit are noted on this form. The model and serial number can be found on the system's rating plate located on or near the electrical compartment service door. Failure to complete and return this form will void the unit's warranty. These reports are also helpful when trying to correct existing problems. Should you need system diagnosis help, fax the completed worksheet to Desert Aire's Service Department using the number provided. Be sure to include your name and a telephone number where you can be reached. Desert Aire - SA Manual 63 �1 DESERT /,SIRE SA Series Start up Report Important — To ensure warranty validation and continued customer satisfaction, complete this form and return it to Desert Aire immediately after start-up. Validation of this report activates the warranty. Desert Aire Corporation c/o Service and Warranty Department N120W18485 Freistadt Road Germantown, WI 53022 (800) 443-5276 Instructions • Warning — Only trained, qualified personnel should install and service Desert Aire equipment. Serious Injury or death can result from improper handling of this equipment. High voltage electrical components and refrigeration under pressure are present. • Before continuing, read the Installation and Operations manual. If you do not fully understand the manual contact the Desert Aire Service Department. Please be prepared with the model and serial numbers located on the rating plate of the unit. • Use one start up report per unit. Print or type all information. If there is not enough space available for readings or comments please attach additional pages directly to the start up report. Installation Name: Installation Address: Desert Aire Representative: Dehumidifier Model #: Remote Condenser Model #: Form Completed By (Print): _ Company Name: Company Address: Application (Pool, Spa, Other): 64 Desert Aire - SA Manua! Location and Unit Information Serial #: Serial #: Signed: Date: Telephone #: ( ) Fax #: - uenores rnar rn►s is a moae► ae enaant item Proper Installation Checklist Installation manual read and ° understood Dehumidifier installed and ° leveled properly Condensate drain trapped ° and primed Verify that the power supply ° matches the rating plate Tighten all field and factory ° wiring Adjust and tighten blower ° belts if necessary Check rotation of blower on 3 ° phase units Check rotation of remote El condenser fans. Open all refrigeration service ❑ valves and tighten packing nuts Check field and factory piping ° for leaks Inspect air filters. Clean or ° replace as necessary 120 volt circuit run to heat trace and powered up. Unit Power Supply Information Voltage at power block - No motors Lt -L2 Control Voltage _ Motors Transformer 1 VA Rating L2-L3 Transformer VA Rating L1-L3 Transformer 3 VA Rating running running ru Line -set Installation — Refer to Installation and operation manual for instructions Lineset Length SN -1 Elevation Change ABOVE / BELOW Hot gas line trapped at every riser Yes / No Inverted traps at top of risers Yes / No Line -set pitched in direction of flow Yes / No Line -set Clamped per 1/0 Manual Yes / No Line Sizes Circuit A Circuit B Hot Gas SNF' Hot Gas OUTR2 Liquid Return Liquid Return Additional R410A Added LBS LBS Additional Oil Added ONT` Ozs ozs Flush Cycle Enabled Yes / No Yes / No Fan Cycle Controller Settings — Refer to Installation and operation manual for instructions SENS SN -1 SN -2 SN -3 OUTR' ON' OFF' ONT' OFT' SNF' SENS' OUTR2 ON' OFF ONT` OFT` SNF2 SENSZ OUTR3 ON' OFF' ONT' OFT SNF3 SENS' OUTR4 ON' OFF' ONT' OFT' SNF" SENS' Desert Aire - SA Manual 65 Air Flow Readings: Refer to Installation and Operations manual for correct balancing procedures. Evaporator Pressure Drop "wc Supply Duct Static Pressure we Reheat Condenser Pressure Drop "wc Return Duct Static Pressure °wc VOC as read off the display* ppm VOC Setpoint" ppm Airflow Settings: Refer to Installation and Operations manual for correct balancing procedures. Amperage at Design Airflow Unoccupied Occupied Event Max OA Purge Design OA CFM CFM CFM CFM CFM Actual OA CFM CFM CFM CFM CFM OA Setpoint "wc "WC Damper Pos Bio Bio Bio Bio % Design Exhaust CFM CFM CFM CFM CFM Actual Exhaust CFM CFM CFM CFM CFM Low VFD Command Bio % Bio % Bio Exhaust.VFD % Bio % Bio Bio Blower Information Amperage at Design Airflow Supply Blower Exhaust Blowers* Ll Ll L, L2 L2 L2 L3 L3 L3 Temperature Readings Room Air Temperature T Room Relative Humidity T Outdoor Air Temperature T Outdoor Relative Humidity T Water Temp (main pool) T Water temp (spa or other)* °F 66 Desert Aire - SA Manual Compressors and Refrigeration in Reheat Mode Circuit A Circuit B Motor # Psig Psig Suction Pressure Psig RLA off nameplate amps amps amps amps Amperage L1 L1 L1 L1 L2 L2 L2 L2 L3 L3 L3 L3 Head Pressure Psig Psig Suction Pressure Psig Psig Refrigerant Sight Glass Clear Yes / No Yes / No Superheat T T Subcooling T T Compressor Oil Level Sight Glass (level should be at least 3/4 full at completion of the start up) 1/2 3/4 F 1/2 3/4 F Compressors and Refrigeration in Pool Water Heating Mode Circuit A Circuit B Head Pressure Psig Psig Suction Pressure Psig Psig Water Inlet Temperature T T Water Outlet Temperature T T Compressors and Refrigeration in Cooling Mode* (Remote Condenser Active) Circuit A Circuit B Head Pressure Psig Psig Suction Pressure Psig Psig Refrigerant Sight Glass Clear Yes / No Yes / No Superheat T T Subcooling T T Compressor Oil Level Sight Glass (level should be at least 3/4 full at '/2 3/4 F '/2 3/a F '/2 3/4 F '/2 3/4 F Desert Aire - sA Manual 67 Auxiliary Water / Steam Coil Information* Communication Type Signal Inlet Temp Outlet Temp Discharge Air Temp Water Coil T T T Steam Coil Baud Rate °F T T Auxiliary Electric Heater Information* Signal L1 Amps L2 Amps L3 Amps Discharge Air Temp Electric HeaterI T of Building Management System Information* Communication Type (circle one) BACnet MS/TP - BACnet Ethernet - Modbus - Lon - N/A BACnet MS/TP Device Instance MAC Address t� X ' Baud Rate BACnet Ethernet IP Address Netmask Gateway Modbus Baud Rate Address Additional Comments: 68 Desert Aire - SA Manual �1 DEiET AQ Compressor Replacement Form Important — To ensure warranty validation and continued customer satisfaction, complete this form and return it to Desert Aire immediately after any compressor replacements. Validation of this report allows for the continued coverage of the compressor under the original warranty. For units that are outside the warranty period, returning the form to Desert Aire assists in service history and confirmations that the unit is operating properly. Desert Aire Corporation. c/o Service and Warranty Department N120 W18485 Freistadt Rd Germantown, WI 53022 (800) 443-5276 Instructions • Warning — Only trained, qualified personnel should install and service Desert Aire equipment. Serious Injury or death can result from improper handling of this equipment. High voltage electrical components and refrigeration under pressure are present. • Before continuing, read the Installation and Operations manual. If you do not fully understand the manual contact the Desert Aire Service Department. Please be prepared with the model and serial numbers located on the rating plate of the unit. • Use one start up report per unit. Print or type all information. If there is not enough space available for readings or comments please attach additional pages directly to the start up report. Installation Name: Dehumidifier Model #: Location and Unit Information Serial #: Form Completed By (Print): Signed: Company Name: Company Address: Date: Telephone #: ( ) Fax #: Desert Aire - SA Manual 69 Diagnostic Summary Describe specific compressor failure type and cause. Indicate other components found to be defective and diagnostic procedures. Attach service report if available. Compressor Condition at Time of Initial Review Continuity (0 resistance) to Ground on one or more legs ❑ Continuity (0 resistance) between two or more legs (3 phase units) Cl Compressor drawing higher current than design ❑ Compressor drawing locked rotor current ❑ Other (describe): ❑ 70 Desert Aire - SA Manual Compressor Replacement Checklist Required Choose One For Test Results Showing Acid or Particulate Acid and particulate test Unit Evacuated to 500 ❑ completed ❑ microns absolute and vacuum ❑ HH Cores used decay passed ❑ Liquid Line Filter Replaced ❑ Alternate triple evacuation ❑ SF filter used process used All Filters returned to original ❑ specifications after removal of contaminants Air Flow Readings: Refer to Installation and Operations manual for correct balancing procedures. Evaporator Static Pressure Drop "WC Reheat Condenser Static Pressure Drop "WC Supply Duct Static Pressure Drop WC Return Duct Static Pressure Drop °WC Unit Power Supply Information Voltage at power block — No motors running L1-L2 L2-L3 Lt -L3 Control Voltage — No Motors running Transformer 1 Transformer Transformer 3 Temperature Readings Room Air Temperature T Room Relative Humidity T Outdoor Air Temperature T Outdoor Relative Humidity T Water Temp (main pool) T Water temp (spa or other)` T Desert Aire - SA Manual 7 Compressors and Refrigeration in Reheat Mode Circuit A Circuit B Motor # PSIG PSIG Liquid Line Pressure see wiring schematic for details At access fitting nearest TXV PSIG PSIG Suction Pressure Voltage measured with the L1-L2 L1-L2 L1-L2 L1-L2 Discharge Line Temperature 6" from compressor discharge) compressors operating L2-L3 L2-L3 L2-L3 L2-L3 At access fitting nearest TXV T °F Suction Temperature L1-L3 0-0 L1-L3 L1-L3 Refrigerant Sight Glass Condition Description (Clear, Intermittent L1 L1 L1 L1 3/4 F '/2 3/4 F '/2 3/4 F '/2 3/4 F Current L2 L2 L2 L2 L3 L3 L3 L3 Discharge Pressure PSIG PSIG Liquid Line Pressure (At access fitting nearest TXV) PSIG PSIG Suction Pressure at compressor) PSIG PSIG Discharge Line Temperature 6" from compressor discharge) F °F Liquid Line Temperature At access fitting nearest TXV T °F Suction Temperature at compressor) T °F Refrigerant Sight Glass Condition Description (Clear, Intermittent Vapor, Flashing) Compressor Oil Level Sight Glass '/z 3/A F '/z 3/4 F '/z 3/a F '/z % F Shut Down Compressors, Wait 5 Minutes Compressors and Refrigeration in Pool Water Heating Mode Circuit A Circuit B Discharge Pressure PSIG PSIG Liquid Line Pressure At access fitting nearest TXV PSIG PSIG Suction Pressure at compressor) PSIG PSIG Discharge Line Temperature 6" from compressor discharge) of of Liquid Line Temperature At access fitting nearest TXV T °F Suction Temperature at compressor) T °I= Refrigerant Sight Glass Condition Description (Clear, Intermittent Vapor, Flashing) Compressor Oil Level Sight Glassz 3/4 F '/2 3/4 F '/2 3/4 F '/2 3/4 F (Shut Down Compressors, Wait 5 Minutes) 72 Desert Aire - SA Manual Compressors and Refrigeration in Cooling Mode* (Remote Condenser Active) Superheat Minimum Values Chart Temp (°F) Circuit A Circuit B Discharge Pressure PSIG PSIG Liquid Line Pressure Temperature ff) At access fitting nearest TXV PSIG PSIG Suction Pressure 80.1 - 85.0 85.1 - 90.0 at compressor) PSIG PSIG Discharge Line Temperature 14 15 6" from compressor discharge) -F -F Liquid Line Temperature At access fitting nearest TXV F °I Suction Temperature Q �80 a� 40.1 -50.0 at compressor) F 15 Refrigerant Sight Glass Condition 16 18 Description (Clear, Intermittent 50.1 -60.0 1314 Vapor, Flashing) 15 16 Compressor Oil Level Sight Glass 3/a F '/z 3/ F '/z 3/n F '/z 3/4 F Shut Down Compressors, Wait 5 Minutes Note that superheat should be stable within 7 degrees. Minimum value for superheat at compressor in all modes: Subcooling shall be 4-14 degrees. Slight flashing in sightglass is acceptable if superheat and subcooling are within tolerance. Additional Comments: Desert Aire - SA Manual 73 Superheat Minimum Values Chart Temp (°F) Relative Air Temperature ff) 60.0 - 65.0 65.1 - 70.0 70.1 - 75.0 75.1 - 80.0 80.1 - 85.0 85.1 - 90.0 30.0-40.0 12 13 14 15 15 16 Q �80 a� 40.1 -50.0 13 14 15 15 16 18 50.1 -60.0 1314 15 16 18 18 is Cr? . 60.1 -70.0 14 15 15 16 18 19 = 70.1 -80.0 14 15 16 18 19 20 Subcooling shall be 4-14 degrees. Slight flashing in sightglass is acceptable if superheat and subcooling are within tolerance. Additional Comments: Desert Aire - SA Manual 73 DESERT /SIRE N120 W18485 Freistadt Road • Germantown, WI 53022 • E-mail: info@desert-aire.com Ph: (262) 946-7400 • Fax: (262) 946-7401 • Website: www.desert-aire.com 0322014/02