Installation Manual IOM-HEPA-TLF-00 HEPALERT LED LIGHT Kit Installation, Operation, and Maintenance Manual for the TLF Diffuser Contents Page Introduction...1 General...1 Safety...1 Inspection...1 Product Description...1 Tools and Equipment...1 Preparation...1 Installation...2 Startup and Operation...5 Calibration...5 Maintenance...5 Abbreviations...6 Appendix - Bill of Materials...7 Introduction This document provides installation, operation, and maintenance information for the Titus HEPALERT LED Light Kit installed on TLF diffusers, specifically. Additional information may be found at the Titus website, www.titus-hvac.com. General The following information is to be used by the installer as a guide. Since each installation is unique unto itself, only general topics are covered. Topic order may not be the same as required by actual installation. This guide is not intended to supersede or circumvent any applicable national, state, or local codes. The installation is to be performed only by individuals whose experience meets or exceeds the requirements of the work involved. The installer MUST read the entire contents of this guide and develop a thorough understanding before beginning installation. Due to a continuing program of product research, Titus reserves the right to discontinue or change without notice, any or all specifications or designs without incurring obligations. Safety The installation and / or servicing of comfort conditioning equipment can be hazardous due to system pressures and electrical devices. Caution: Only trained and qualified personnel should perform service and/or installation. Observe all precautions and warnings in product data or attached to the unit. Follow all safety codes. Wear eye protection and gloves. Have a fire extinguisher readily available. Caution: Disconnect all power supplies before accessing equipment. Disconnecting more than one power supply may be required to de-energize some equipment. DANGER ELECTRIC SHOCK CAN CAUSE DEATH. Inspection Thoroughly inspect all packages upon receipt. Ensure carton(s) have not been dropped, crushed or punctured. Inspect all contents for damage. If damage is found, immediately file a claim with the delivering carrier. Product Description The HEPALERT LED Light Kit provides an easy and visible verification for HEPA filter cleanliness from the occupied space. The kit uses pressure sensors and light emitting diodes (LED) indicators to alert clean room users when filter replacement is needed. Tools and Equipment In addition to the HEPALERT LED light kit the following items (supplied by others) assist the installation process. Transformer (Class 2 120 Vac to 24 Vac transformer, rated for 40 VA) Power cord for transformer Silicon sealant Rubber tubing /8-inch OD Screw drivers (various sizes of Phillips and flat blades) Drill and drill bits (sizes needed are /16-, ¼-, /8-, and 5/8-inch) Preparation Unpack HEPAlert LED Light Kit and check contents against Bill of Materials. Sort contents, especially wire, screws, nuts according to color, size, and type as listed on the Bill of Materials. Keep Bill of Materials readily available for reference. Remove HEPA filter and back pan before attempting installation. 605 Shiloh Road Plano, Texas 75074 972-212-4800 All rights reserved. No part of this work may be reproduced or transmitted in any form or any means, electronic or mechanical, including photocopying and recording, or by any information storage retrieval system without permission in writing from Air Distribution Technologies.
Installation 1. Determine and mark hole locations in back pan (see Figure 1). Before drilling holes, position the base bracket on back pan to verify alignment of marked holes to bracket openings. Drill holes and insert grommet into the 5/8-inch diameter hole. 2. Determine and mark hole locations on HEPA filter frame (see Figure 2). Before drilling frame holes, verify the marked holes align directly under the back pan holes in final installation. Insert grommet into the 5/8-inch diameter hole.. Determine LED bracket placement on the back pan. Drill mounting holes on the side of back pan (see Figure ). The holes should be on the side of the back pan adjacent to the holes drilled in Steps 1 and 2. 4. Secure the pressure switch and terminal barrier strip to base bracket using pan head screws and hex nuts (see Figure 4). 5. Secure base bracket to back pan using self-tapping screws (see Figure 5). Figure. Hole Placement for LED Bracket Figure 1. HEPALERT Kit Hole Placement Figure 4. Base Bracket with Pressure Switch and Terminal Barrier Attached Figure 2. HEPA Filter Frame Hole Locations Figure 5. HEPALERT Base Attached to Back Pan 2 of 7
6. Secure LED bracket to inside of back pan using selftapping screws (see Figure 6). 7. Secure the LED assemblies to LED bracket using self-tapping screws (see Figure 6). 8. Feed quick-connect terminals of LED assemblies through the grommets on HEPA filter frame and back pan (see Figure 6). 9. Insert 9-inch rubber tube through the /8-inch diameter holes in back pan and HEPA filter frame. Connect tube to the high-pressure port of the pressure switch (see Figure 7). 10. Insert -inch rubber tube through the hole on back pan and connect tube to the low-pressure port of pressure switch (see Figure 7). Use silicon sealant to seal both sides of the back pan hole to prevent leakage. 11. Connect spade-tongue terminal on the white LED assembly wire to the terminal barrier strip (see Figure 8). 12. Connect the quick-connect terminal on the blue LED assembly wire to the low-pressure terminal on the pressure switch (see Figure 8). 1. Connect the quick connect terminal on the red LED assembly wire to high-pressure terminal on the pressure switch (see Figure 8). 14. Ensure all drilled holes and gaps in grommets and tubing ports in back pan and HEPA filter frame are sealed with silicon sealant. 15. Connect quick-connect terminal of 8-inch red wire assembly to pressure sensor power terminal. Connect spade-tongue terminal to the terminal barrier strip adjacent to white wire (see Figure 9). Figure 6. HEPAlert Base Bracket and LED Bracket Placement Figure 8. LED to Pressure Switch Wiring Connections Note: Seal inside and outside of backpan with silicon sealant. Figure 7. Rubber Tube and Pressure Port Connections Figure 9. LED to Pressure Switch Wiring Connections of 7
16. Secure a Class 2 120 Vac to 24 Vac transformer (rated for 40 VA. Transformer supplied by others) to back pan using self-tapping screws (see Figure 10). 17. Connect spade-tongue terminal of 14-inch red wire assembly to terminal barrier strip across from previously connected red wire (see Figure 11). 18. Connect spade-tongue terminal of 14-inch white wire assembly to terminal barrier strip across from previously connected white wire (see Figure 11). 19. Feed quick-connect terminals of red and white wire assemblies through grommet in side of base bracket. Connect to transformer (see Figure 11). NOTE: A single transformer may be used to power multiple HEPAlert Kits. Each kit includes the 60-inch red and white wire assemblies to interconnect terminal barrier strips on adjacent diffusers. 20. Place and align top cover to base bracket and secure using self-tapping screws to secure (see Figure 12). 21. Connect AC supply power wires to transformer (see Figure 1). 22. Install clean HEPA filter with wing nuts. Restore the face screen to diffuser. Figure 11. HEPALERT Kit and Transformer Wiring Figure 12. Securing Top Cover Note: Use a Class 2 120 Vac to 24 Vac transformer (rated for 40 VA). Figure 10. Transformer Placement Figure 1. Power Cord Connection 4 of 7
HEPALERT Kit Installation Manual Startup and Operation When power is supplied, the green LED comes on, indicating the system is functioning. The red LED comes on when a pressure differential of 50% is reached, indicating that filter needs to be replaced. Once a clean filter is inserted in the filter frame, the green LED comes on. Calibration Each HEPAlert kit sensor must be set based on the module and inlet size. Use the information in the following steps to calibrate the setscrew. 1. Turn the setscrew clockwise to ensure it is in the fully closed position. See Figure 14. 2. Based on the module and inlet size, twist the setscrew counter-clockwise the prescribed number of turns from the fully closed position. See Table 1. Figure 15 shows the setscrew at the fully open position. Figure 16 is a chart showing the pressure from supply side of the HEPA filter. Figure 14. Setscrew at Fully Closed Position Table 1. TLF, TLF-AA, and TLF-SS Calibration Settings Module and Inlet Size 24 x 24 7-inch inlet 48 x 24 8-inch inlet 48 x 24 10-inch inlet 48 x 24 12-inch inlet 1- or 2-way Pattern CFM Number of CCW Turns from Fully Closed Position (50% Full Filter Setting) 100 4 160 220 2-/4 00 100 4 160 220 2-/4 00 215 295 2-/4 400 515 2-1/4 215 295 2-/4 400 515 2-1/4 Figure 15. Setscrew at Fully Open Position Maintenance Components of the HEPAlert require no regular maintenance. However, if neither LED is on, check the following items. Power supplied to unit. Wiring and tubing connections are secure. Transformer is operational (use a voltmeter). Contact a Titus representative if service or replacement is required. Note: Replace filter when filter is 50% full. 5 of 7
# of CCW Turns on Setting Screw from the Closed (Bottomed-Down) Position 4 1/2 4 1/2 2 1/2 2 1 1/2 1 1/2 0 y =.0026674924016900000000000x -0.18708940776940000000000 R 2 = 0.9927654985160000000000 0 1 2 4 5 6 7 8 Ps, in. wg. (HEPA-Supply Side) # of CCW Turns from the bottomed-down position Power (# of CCW Turns from the bottomed-down position) Figure 16. Setscrew Position Versus Filter Pressure Abbreviations The following abbreviations were used in this document. Abbrev. AC CCW DP HEPA ID LED OD Vac Vdc Term Alternating Current counter-clockwise Differential Pressure High Efficient Particulate Air Inside Diameter Light Emitting Diode Outside Diameter Volts Alternating Current Volts Direct Current 6 of 7
Appendix - Bill of Materials The following table provides a bill of materials list for the HEPALERT kit. HEPALERT Kit Installation Manual Part / Assembly No. Table 1. Bill of Materials Description Unit of Measure Quantity 72499-01 Base EA 1 724940-01 Cover EA 1 724809-01 Bracket, LED Indicator EA 1 105-01 Switch, DP Air EA 1 10519-01 LED Assembly EA 1 10520-01 Wire Assembly, Red, 14-inch EA 1 10520-02 Wire Assembly, White, 14-inch EA 1 10520-0 Wire Assembly, Red, 8-inch EA 1 10520-04 Wire Assembly, Red, 60-inch EA 1 10520-05 Wire Assembly, White, 60-inch EA 1 1054-01 Terminal Barrier Strip, 2 Position EA 1 102215-01 Rubber Tube, 0.16 ID, /8 inch OD, 9-inch IN 1 102215-01 Rubber Tube, 0.16 ID, /8 inch OD, -inch IN 1 00TCBE Screw, Self-Tapping, #8 X 0.50 EA 10 10574-01 Screw, Pan Head, 6-2 X 0.75 EA 10 10569-01 Nut, Hex, 6-2 EA 10 101796-01 Grommet, 0.50 ID EA 4 HEPALERT LED Light Kit Installation Manual EA 1 7 of 7