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1. Motor Sheave Blower Sheave Motor Sheave Blower Sheave 5 Sheave Browning Sheave Browning Assembly Pitch Pitch Belt No Assembly Pheh Pitch Belt No Diameter Bore Diameter Bore Diameter Bore Diameter Bore 3H35125B1 2 9 0 5 5 0 75 3H35129B1 41 0 625 10 9 1 B71 3H35125B2 29 0 625 5 0 75 A31 3H35129B2 4 1 0 875 10 9 1 71 3H35125B3 44 0 5 6 0 75 4 3H35129B3 4 1 1 125 10 9 1 70 3H35125B4 44 0 625 6 0 75 A35 3H35129B4 47 0 625 10 9 1 BX71 3H35125B5 44 0875 6 0 75 A35 3H35129B5 47 0 875 10 9 1 BX71 3H35125B6 m 0 625 15 ias ABA 3H35129B6 47 1 125 10 9 1 BX71 3512567 E ers m Tes 3H35129B7 5 5 1 375 12 4 1 BX71 3H35129B8 5 9 0 875 12 4 1 BX77 3H35125B8 5 6 0 625 5 2 0 75 5 ES Tr 919912989 ae One 92 9249 3H35129B10 5 9 1 375 12 4 1 BX75 3H35125B10 5 6 0 625 45 0 75 4 3H35129B11 53 1125 89 1 BX68 3H35125B11 5 6 0 875 4 5 0 75 A34 3H35129B12 5 5 1 375 94 1 BX68 3H35126B1 2 9 0 5 5 0 75 A33 3H35129B13 5 5 1 625 9 4 1 75 3H35126B2 2 9 0 625 5 0 75 4 3H35129B14 5 5 1 625 9 4 1 BX75 3H35126B3 44 0 5 6 0 75 A37 3H35129B15 7 1 125 10 4 1 B73 3H35126B4 44 0 625 6 0 75 A38 3H35129B16 7 1 375 10 4 1 B72 3H35126B5 4
2. Y 1 90 J Over Roof 34 49 50 37 36 68 4 B rx 2 00 Dies for Field Drilled Electrical eea 4 20 00 2 Ww poem 20 fre 05 865 34 00 34 00 Exhaust 4 1 06186 Height Y 24 00 Combustion G INSIDE 0 C Width n Inside Inside 25 3784 gregh air 264 D oc PN i Duct Connection 19 21 384 6 38 192890 _ aby l 9 21 pii A 4 24 bs 24 00 3 Np 500 4 35 3 47 304 Return 7 Inside 1 501 L Duct Connection L9 60 74 50 8 500 800 Model Shown Figure 49 2 ICS Separated Combustion Cooling Package Unit Dimensions with Blower J or 144 84 23 95 33 84 50 37 36 68 Qty 4 Drill Locator mJ Over Roof 2 00 Drilled Electrical 190 Conduit Entry Holes E epaced 2 0 apart 2 32 95 386 Exhaust Outlet Air 06 18 Duct Combustion Connection _ Air Inlet d 240 side G INSIDE rs Um Inside 26 43 19 Fresh Air 6 38 10 9 21 Connection 5 29 P 24 92 2 03 3 00 730 Se 9 80 147 26 Table 49 1 Indoor Separated Combustion Un
3. 3H36622B5 5 5 1 375 12 4 1 44 BX78 1 RAT 3H36622B6 47 1125 89 1 44 74 3H35127B14 5 2 1 375 6 2 1 A49 3H36622B7 55 1375 104 1 44 BX75 3H35127B15 5 1 125 5 2 1 45 3H36622B8 6 1 625 114 144 Qty 2 BX82 3H35127B16 5 6 1 375 5 7 1 A48 3H36622B9 6 1 625 11 4 1 44 Qty 2 BX82 3H35127B17 44 0 625 5 7 1 A43 3H36622B10 7 1 875 13 4 144 Qty 2 B86 3H35128B1 2 9 0 5 8 1 A47 3H36622B11 7 1 875 13 4 144 Qty 2 B86 3H35128B2 2 9 0 625 8 1 48 3H36622B12 5 3 1 125 8 4 1 44 B71 3H35128B3 29 0 875 8 1 A48 3H36622B13 5 9 1 375 9 4 1 44 BX74 3H35128B4 3 8 0 625 8 5 1 3H36622B14 6 1 625 9 4 1 44 Qty 2 BX79 3H35128B5 38 0 875 85 1 ABO 3H36622B15 6 1 625 9 4 144 Qty 2 BX79 3H35128B6 38 1125 85 A52 3H36622B16 7 1 875 11 4 144 Qty 2 B83 39E T6B7 5 Gees 5 1 A63 3H36622B17 7 1 875 11 4 144 Qty 2 B83 Seer TT E EE 3H36622B18 7 1 375 10 4 1 44 B77 E T128 3 36622819 7 1 625 10 4 144 Qty 2 B82 3H36622B20 7 1 625 10 4 144 Qty 2 B82 me 55 3H36622B21 7 1 875 10 4 144 Qty 2 B81 3H35128B11 5 6 1 125 8 5 1 54 3H36622B22 7 1 875 104 144 2 81 3H35128B12 5 2 1 375 8 1 54 3H36622B23 7 1 625 9 4 144 Qty 2 B80 3H35128B13 5 6 1 125 7 1 52 3H36622B24 7 1 625 9 4 144 Qty 2 B80 3H35128B14 5 2 1 375 6 5 1 52 3H36622B25 7 1 875 9 4 1 44 Qty 2 B80 3H35128B15 5 6 0 625 8 5 1 A53 3H36622B26 7 1 875 9 4 144 Qty 2 B80
4. 19 Sip PT LM 21 General Performance 30 Unit Selection si yox vx EXIT Y RR dar x 32 Performance Data 34 Blower Sheave Assembly Data 38 Electrical Data va th we ew ARE 42 Motor ee 42 Dimensions 48 52 52 Service amp Troubleshooting 54 Model Designations 56 Start Up 58 Model Nomenclature 59 Commercial Back Page AIR5 594 6 SI METRIC CONVERSION FACTORS UNIT LOCATION 10 All mechanical equipment generates some sound and 5 METRIC CONVERSION FACTORS vibration that may require attenuation Libraries private Table 3 1 offices and hospital facilities will require more attenuation and in such cases an acoustical consultant may be retained to assist in the application Locating the equipment away W C CFH 1 699 m min from the critical area is desirable within ducting limitations psig Btu ft 0 0974 Generally a unit should be located within 15 feet of a F 0 453 kg primary support beam Smaller deflections mean lesser inches 0 000293
5. oo Reset Switch High Pressure Switch only Pressure adjustment screw Top cover removed 3 High Gas Pressure Switch OPT The high gas pressure switch is factory installed in the duct furnace above the gas train The switch monitors the gas pressure downstream of all the gas controls and shuts off the electric supply to the ignition controller and combination gas valve if high gas pressure is experienced right before the manifold This will shut off all gas flow to the burner The switch has a manual reset so that if the gas pressure is too high a service person must check the unit to make sure that none of the gas controls have been damaged by the high gas pressure and then reset the switch to allow the unit to operate when gas conditions are returned to the allowable range of the pressure switch The pressure switch range is 2 to 16 W C and should be set to insure that the maximum manifold gas pressure is not exceeded 3 5 W C for natural gas 10 W C for propane gas 22 6 Ignition Controller STD The ignition controller is factory installed in the duct furnace electrical junction box with the spark ignitor and sensor located on the burner All units are supplied with intermittent pilot ignition systems For both natural and propane gas units the ignition controller is 100 shut off with
6. Return Air 435 145 gt Le Dimensions Blower Type Digit 16 F G 75 All 100 125 All 150 175 All 200 225 All 250 300 E F G or H 250 300 I J or K 350 400 E F G or H 350 400 I J 500 600 or H 500 600 I J orb 700 800 G orH 700 800 I J K orL 840 960 I J orb Table 50 2 Indoor Separated Combustion Cooling Package Units All dimensions in inches Dimensions Blower Type Digit 16 E 75 All 100 125 All 150 175 All 200 225 All 250 300 G or H 250 300 I J or K 350 400 or H 350 400 I J or K D Gas connection for 1st furnace For Models 500 800 add 41 09 for second furnace gas connection For Model 840 960 add 41 09 and 82 19 for second and third furnace gas connections 50 AIR5 594 6 DIMENSIONS COOLING COILS Figure 51 1 DX Coil Drawing All dimensions in inches Rows 2 3 4 6 J Airflow Direction 7 5 6 7 5 10 TOP VIEW 1 5 4 gt w 4 Distributor Inlet Liquid Line Connection s Coil for Right Hand Units Second Inlet on Dual Digit 9 R Circuit Coils Headers on opposite side for Left Hand Units FRONT VIEW SIDE VIEW Airflow Direction Suction Line Connections in direction of
7. Left Capillary Thermostat body Shown with cover removed Furnace IElectrical Control Box Sensor AIR5 594 6 21 OPTIONS Electronic Modulating Discharge Air Thermostat Includes a factory installed mixing tube and discharge air sensor The set point adjuster is field installed remotely and must be field set Refer to Literature 5 578 latest revision Figure 22 1 Electronic Modulating Discharge Air Thermostat Duct Furnace Electrical Control Box Mixing Tube X Discharge air Sensor Terminals Air flow 2 Low Gas Pressure Switch The low gas pressure switch is factory installed in the duct furnace above the gas train The switch monitors the gas pressure upstream of all the gas controls and shuts off the electric supply to the ignition controller and combination gas valve if low gas pressure is experienced This will shut off all gas flow to the burner The switch has an automatic reset so that if the gas pressure is interrupted and then is returned the switch will automatically allow the unit to operate when gas conditions are returned to the allowable range of the pressure switch The pressure switch range is 2 to 14 W C and should be set to insure that the minimum inlet gas pressure is available 6 W C for natural gas 11 W
8. 115 60 1 8 47 10 00 Design conforms to UL Std 1995 Certified to CAN CSA C22 2 No 236 MODINE Modine Manufacturing Company c 1500 DeKoven Ave Racine WI 53403 tiste O tiste O amp Phone 800 828 4328 9900100 9900100 5H76471B RevB Figure 57 2 IFS Serial Number Designations 09 17 09 36 10 0123 10000 SERIAL NUMBER PREFIX SPO NUMBER blank if standard lt blank gt if standard S if Special Product Order THHHHE if Special Product Order SERIES IDENTITY NUMBER SEQUENTIAL NUMBER Varies 0000 TO 9999 CONTROL SUPPLIER Each unit week has 01 Robertshaw 09 White Rodgers unique number 05 Honeywell 17 United Technologies 08 Fenwal YEAR GAS VALVE SUPPLIER PRODUCED 1 R rtsh White 09 White Rodgers WEEK PRODUCED Figure 57 3 IBS ICS Serial Number Designations Serial Number Designations 01 10 201 01 02 1000 MOTOR SEQUENCE VENDOR CODE NUMBER 01 Century 15 Marathon etc YEAR OF FAN OR BLOWER MANUFACTURE VENDOR CODE 01 2001 10 Lau 02 2002 20 Morrison etc etc __ mm SERIES IDENTITY NUMBER WEEK OF Identifies which series MANUFACTURE of controls were 01 1st week of year furnished on the unit 26 26th week of year Serial number format subject to change When contacting the factory for replacement parts always have the actual ser
9. inside Air Inlet inside Outside L 4 M 6 38 638 gl 1026 905 921 529 1 52 92 5 a xls Lit 24 92 bu 24 00 J 5e aloo 424 Insidey 4 35 7 301 Return Air Duct Connection 1 50 L K 51 09 S 500 800 Model Shown Figure 48 2 ICS Separated Combustion Cooling Package Unit Dimensions 108 94 23 95 33 84 51 15 Qty 4 Drill Locator Dimples for Field J Over Roof Drilled Electrical 2 00 Conduit Entry Holes 2 20 1 90 20 00 spaced 2 0 apart Ton 450 34 25 Outlet Air a AN Connection S Air Inlet 5 B F Height L4 24 00 X i ___ 2400 F With qp side Inside nside L 10 26 Unum 2 25i Me 98 638 goi 16 5 29 Lo 529 7 7 zg TO ZL 24 00 n a uw 4 24 24 92 Inside 4 85 sf 4 3 00 7 30 Return Air Duct Connection 150 11 111 68 Table 48 1 Indoor Separated Combustion Unit Dimensions All dimensions in inches Blower Qty of Dimensions Furnaces H J All All All All
10. G or H or H G orH G or H 87 77 85 69 87 77 85 69 87 77 85 69 87 77 85 69 87 77 85 69 87 77 85 69 128 77 126 78 128 77126 78 1 jaja For Right Hand Access Units Location of drill locator dimples for field drilled gas connection entry holes one side of unit and one on bottom For Left Hand Access Units Location of drill locator dimples for field drilled gas connection entry holes one side of unit and one on bottom For Right Hand Access Units Location of drill locator dimples for field drilled electrical connection entry holes identical sizes as side electrical connections For Left Hand Access Units Location of drill locator dimples for field drilled electrical connection entry holes identical sizes as side electrical connections Nominal vent pipe size is 4 Models 75 175 and 6 Models 200 800 Exhaust pipe installed over collar Combustion air pipe installed collar 48 AIR5 594 6 DIMENSIONS UNIT Figure 49 1 IBS Separated Combustion Blower Package Unit Dimensions with Blower Type J or L
11. 12 CHAPEAU D ADMISSION D AIR HOMOLOGUE 12PO SOLIN DE TOIT IL FAUT TENIR COMPTE DE LA COUCHE DE NEIGE PR VISIBLE CHAPPEMENT 2 in UTILISEZ UN HOMOLOGUE POUR LA TRAVERSEE DU TOIT AIR DE COMBUSTION T AVEC COLLECTEUR DE CONDENSATS ET REGARD DE NETTOYAGE Section C Horizontal 2 Pipe Vent System Installation C1 This section applies to horizontally vented 2 pipe vent Systems one combustion air inlet pipe and one vent pipe and is in addition to Section A General Instructions All Units C2 Horizontal vent systems terminate horizontally sideways C3 All horizontal vents must be terminated with a Gary Steel 1092 vent cap The cap must terminate a minimum distance from the external wall as summarized in Figure 9 1 C4 The termination of horizontally vented system must extend 12 inches beyond the exterior surface of an exterior wall C5 The combustion air pipe must be a minimum of 16 inches below the vent pipe and 24 inches from the exterior wall C6 Construct the vent system as shown in Figure 9 1 AIR5 594 6 INSTALLATION VENTING Figure 9 1 Horizontal 2 Pipe Venting MUST USE THIMBLE SUPPORT BRACKET THROUGH WALL See Fig 9 2 for detai PITCH COMBUSTION AIR PIPE DOWNWARD FROM APPLIAN
12. Dampers Fresh Air Dampers F amp RA Insulation Indoor onl Filter Spacer to be inserted non access side of unit Double Wall All Sections All All All E F G or H See Motor Data I J E F G or H I J or K D All weights in inches 52 AIR5 594 6 MAINTENANCE Figure 53 1 Filter Replacement Arrangement for Blower Size Digit 16 I J and L NON ACCESS SIDE FILTER SPACER 350 400 700 800 840 960 250 300 500 600 Duct Furnace When providing annual maintenance for the duct furnace keep the unit free from dust dirt grease and foreign matter Pay particular attention to 1 The combustion air and exhaust vent piping 2 The burner ports and pilot burner orifices avoid the use of hard sharp instruments capable of damaging surfaces for cleaning these ports To check the burner port and pilot burner orifice see Burner and Pilot Assembly Removal 3 The air shutters and main burner orifices avoid the use of hard sharp instruments capable of damaging surfaces for cleaning these orifices To check the air shutters and main burner orifices see for Manifold Assembly Removal Electrical Wiring The electrical wiring should be checked annually for loose connections or deteriorated insulation Gas Piping amp Controls The gas valves and piping s
13. 6 Slide the burner assembly out The pilot is attached to the burner assembly 7 Examine the burner and pilot assembly for cleanliness and or obstructions as necessary see Duct Furnace for cleaning instructions 8 Replace the burner assembly in reverse order In replacing the burner be certain that the rear burner slots are located properly on the burner retaining pins Do not force the burner side access panel it will not fit if the burner is not properly aligned 9 Reconnect the ignition cable and pilot gas supply line 10 Install the burner side access panel 11 Turn on the electric and gas supply Figure 53 3 Burner and Pilot Assembly Removal AIR SHUTTERS NOT SHOWN CATED AIR5 594 6 53 SERVICE amp TROUBLESHOOTING When servicing or repairing this equipment use only Modine approved service replacement parts A complete replacement parts list may be obtained by contacting Modine Manufacturing Company Refer to the rating plate on the appliance for complete appliance model number serial number and company address Any substitution of parts or controls not approved by Modine will be at the owner s risk Table 54 1 Troubleshooting 54 Trouble Power Exhauster Motor will not start Pilot does not light Main burners do not light Pilot is lit Lifting Flames See Figure 55 1 Yellow Tipping With propane gas some yellow tipping is always present Flashback A CAU
14. Figure 24 1 Minimum Positioner 20 Extended Grease Line Zerk Fittings OPT The extended grease line zerk fittings are factory installed on the exterior corner post between the electrical and blower sections The zerk fittings allow pillow block bearings to be lubricated with a grease gun Refer to Lubrication Recommendations for lubricant recommendations 21 Extended Grease Lines OPT The extended grease lines are factory installed in the blower section from the Extended Grease Line Zerk Fittings to the Pillow Block Bearings The grease lines allow the pillow block bearings to be lubricated without requiring the service personnel to remove both blower doors to access the bearings The grease lines will require filling at the time of first lubrication 22 Return Air Fire Stat OPT The return air fire stat is factory installed in the electrical section with the sensor in the return air stream In case of elevated temperatures in the return air stream the manual reset switch shuts down the entire unit If the limit temperature is exceeded a service person must inspect the unit for the cause of the high discharge temperature take corrective action and then reset the switch 23 Blower Housing STD The blower housing is factory installed in the blower section The blower housing contains a double width double inlet blower wheel so both sides of the blower must be free
15. Sheave Assembly 56 3H35126B2 3H35126B4 3H35126B6 3H35126B9 3H35126B12 143 or 145 3H35126B5 3H35126B7 3H35126B10 3H35126B13 182 or 184 3H35126B8 38 AIR5 594 6 3H35126B11 3H35126B14 BLOWER SHEAVE ASSEMBLY DATA Blower Sheave Assembly Numbers Con t Table 39 1 Digit 16 E or F 12 12 Blower Units Motor Frame Size 48 RPM Range 468 715 644 874 863 1078 1029 1332 1150 1438 1327 1659 Digit 19 Sheave Assembly 3H35127B1 Digit 19 Sheave Assembly Digit 19 Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly 56 3H35127B2 3H35127B3 3H35127B6 3H35127B17 143 to 145 3H35127B4 3H35127B7 3H35127B9 3H35127B12 182 or 184 3H35127B5 3H35127B8 3H35127B10 3H35127B13 3H35127B15 213 or 215 Motor Frame Size 48 RPM Range 3H35127B11 3H35127B14 3H35127B16 410 625 568 771 767 958 934 1136 1136 1380 Sheave Assembly 3H35128B1 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly 56 3H35128B2 3H35128B4 3H35128B7 3H35128B15 143 to 145 3H35128B3 3H35128B5 3H35128B8 3H35128B10 182 or 184 3H35128B6 3H35128B9 3H35128B11 3H35128B13 213 or 215 Motor Frame RPM
16. 1 42 F 41 F 840 960 120 F TPE End 840 105 F 120 F 7407 97 111 86 F 99 F 78 F 89 F 70 F 80 F 65 F 74 F 62 F 71 F 60 F 68 F 840 960 Barres 78 F 89 F 70 F 80 F 65 F 74 F End 840 60 F 68 F 63 F Total static pressure should include external static pressure and accessory option static pressure from Table 34 1 Unit internal resistance has been included in the unit performance tables 2 Brake Horsepower and RPM values are approximate values only Please consult the AccuSpec selection software for values at other than listed static pressures AIR5 594 6 37 BLOWER SHEAVE ASSEMBLY DATA Adjusting the Blower Drive Setting 2 Based on the Sheave Arrangement Tables 38 1 through 39 5 give the Sheave Assembly numbers used on units that include a 3 blower The Sheave Arrangement is Digit 19 and is found on the unit Model Identification Plate The Sheave Assembly describes 4 the motor and blower sheave size and bore as well as the belt provided To determine how many turns open the motor sheave should be set for 1 Follow the Selection Procedure found on pages 32 and 33 to determine what blower rpm is required to meet the job specifications Figure 38 1 Blower Section EXTENDED ADJUSTABLE FILTER GREASE MOTOR RACK LINES SHEAVE MOTOR EXTENDED T GREASE LINE ZERK FI
17. AIREDALE air conditioning for every environment AIRS 594 6 September 2010 INSTALLATION AND SERVICE MANUAL gas fired indoor separated combustion duct furnaces make up air units A WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or death and could cause exposure to substances which have been determined by various state agencies to cause cancer birth defects or other reproductive harm Read the installation operating and maintenance instructions thoroughly before installing or servicing this equipment CAUTION To prevent premature heat exchanger failure do not locate ANY gas fired units in areas where chlorinated halogenated or acid vapors are present in the atmosphere models IBS ICS US LISTED 9900100 FOR YOUR SAFETY IF YOU SMELL GAS 1 Open windows 2 Don t touch electrical switches 3 Extinguish any open flame 4 Immediately call your gas supplier FOR YOUR SAFETY The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous The use of this manual is specifically intended for a qualified installation and service agency A qualified installation and service agency must perform all installation and service of these appliances Inspection on Arrival 1 Inspect unit upon arrival In case of damage rep
18. 015 036 029 064 010 017 0 04 6500 0 07 010 046 019 017 040 034 074 012 020 0 04 7000 0 08 0 11 022 020 045 039 085 014 023 0 05 2593 0 02 0 01 002 002 002 008 003 011 0 02 003 0 01 3000 0 02 002 002 003 002 009 004 014 003 004 0 01 4000 0 03 0 03 0 04 004 0 04 014 008 022 0 05 007 0 01 5000 0 04 0 04 005 006 006 049 012 O31 007 011 0 02 6000 0 06 0 05 007 0 08 009 025 018 042 010 017 004 7000 0 07 0 07 040 0 11 012 031 024 055 014 023 0 05 8000 0 09 0 09 012 013 046 038 032 070 019 030 0 08 9000 011 012 0 15 016 020 046 040 086 024 038 0 10 10000 0 13 014 018 019 025 054 050 104 030 048 0 14 11050 0 15 017 022 023 031 0 64 0 61 124 036 058 017 12000 0 18 020 026 027 043 069 021 13000 0 20 024 030 0 31 11050 Max CFM for Evap 0 51 081 0 26 AIR5 594 6 Accessory Option static pressure losses are approximate values only Please consult the Accuspec selection Software for static pressure losses at other than listed CFM BLOWER PERFORMANCE DATA Table 35 1 Unit Performance Tables 2 Total Static Pressure W C 1 00 1 25 1 50 BHP RPM RPM RPM 100 F 80 F
19. 24 6 810 4 8 12 16 25 MILLIAMPS JOHNSON CONTROLS N S 40 Warm Up Stat A warm up stat is provided with Air Control options GK GM or GN Digits 20 amp 21 and factory installed in the electrical section with the sensor in the return air stream The warm up thermostat monitors the return air temperature to the unit and prevents the fresh air dampers from opening until the temperature of the return air has reached the desired set point typically 65 F or 5 F below the room temperature 41 Blower Supply Power Terminal Strip STD The blower supply power terminal strip is located in the electrical section The terminal strip is labeled to match the electrical wiring diagram provided with the unit Supply power labeling ranges from terminal numbers 80 to 99 All field wiring connections should be made to the bottom side of the terminals to prevent miswiring by modifying the factory wiring which is made to the top of the terminal strip 42 Service Switches The service switches are factory installed in the electrical section The service switches allow for service personnel to independently test operation of the damper blower and furnace without using jumper wires The switches override the remote monitoring panel and or thermostats to energize each compo nent directly All switches need to be reset to the OFF position after testing otherwise the compon
20. For both natural and propane gas units the ignition controller is 100 shut off with continuous retry On a call for heat the system will attempt to light the pilot for 70 seconds If the pilot is not sensed for any reason the ignition control will wait for approximately six minutes with the combination gas control closed and no spark After six minutes the cycle will begin again After three cycles some ignition controllers lockout for approximately one hour before the cycle begins again This will continue indefinitely until the pilot flame is sensed or power is interrupted to the system NOTE Factory Installed Options see page 21 could change the listed sequence of operation based on their function The descriptions given are for the basic unit Single Stage Gas Controls Utilizes a single stage combination gas control an ignition control and a single stage low voltage thermostat 1 The thermostat calls for heat 2 The power exhauster relay is energized starting the power exhauster motor Once the motor has reached full speed the differential pressure switch closes The power exhauster relay pre purge timer closes after 20 to 40 seconds energizing the gas control circuit 3 The pilot valve opens and the spark ignitor sparks in an attempt to light the pilot 4 Once the pilot is lit the flame sensor proves the pilot and stops the spark ignitor from sparking 5 The main gas valve is opened and the main burner is li
21. KW nr vibration and noise transmission feet gallons 3 785 liters CFM psig 27 7 W C Figure 3 1 Combustible Material Clearances UNIT LOCATION Model Size Access Side A 75 thru 175 1 A DANGER Appliances must not be installed where they exposed t to a potentially explosive or flammable atmosphere TAE IMPORTANT To prevent premature heat exchanger failure do not locate ANY gas fired appliances in areas where corrosive vapors i e LJ chlorinated halogenated or acid are present in the atmosphere NON ACCESS SIDE 0 Location Recommendations ACCESS 1 When locating the furnace consider general space and SIDE heating requirements availability of gas and electrical supply and proximity to vent locations 2 Unit must be installed on the positive pressure side of the circulating blower 3 Be sure the structural support at the unit location site is AN adequate to support the weight of the unit For proper BOTTOM 1 operation the unit must be installed in a level horizontal position minimum clearance to combustible material is required from the vent collar 4 Do not install units in locations where the flue products can be drawn into the adjacent building openings such as Windows Table 3 2 Recomme
22. Seller in any way so as in the judgment of Seller to affect its stability nor which has been subjected to misuse negligence or operating conditions in excess of those for which such equipment was designed This warranty does not cover the effects of physical or chemical properties of water or steam or other liquids or gases used in the equipment BUYER AGREES THAT SELLER S WARRANTY OF ITS PRODUCTS TO BE FREE FROM DEFECT IN MATERIAL AND WORKMANSHIP AS LIMITED HEREIN SHALL BE IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES EITHER EXPRESS OR IMPLIED WHETHER ARISING FROM LAW COURSE OF DEALING USAGE OF TRADE OR OTHERWISE THERE ARE NO OTHER WARRANTIES INCLUDING WARRANTY OF MERCHANTABILITY OR FITNESS FOR PURPOSE WHICH EXTEND BEYOND THE PRODUCT DESCRIPTION CONFIRMED BY BUYER AND SELLER AS OF THE DATE OF FINAL AGREEMENT This warranty is void if the input to the product exceeds the rated input as indicated on the product serial plate by more than 5 on gas fired and oil fired units or if the product in the judgment of SELLER has been installed in a corrosive atmosphere or subjected to corrosive fluids or gases been subjected to misuse negligence accident excessive thermal shock excessive humidity physical damage impact abrasion unauthorized alterations or operation contrary to SELLER S printed instructions or if the serial number has been altered defaced or removed BUYER S REMEDY FOR BREACH OF WARRANTY EXCLUSIVE OF A
23. T S P and literate to determine the BHP and rpm for 0 89 W C For this example the horsepower is 5 and the blower rpm is 1280 Following this procedure for G H blowers Using 5000 cfm and 0 71 W C T S P the horsepower is 3 hp and 870 rpm Following this procedure for the I J K blowers Using 5000 cfm and 0 69 W C T S P the horsepower is 2 hp and 642 rpm Although J blower results in a 2 hp motor this blower requires the use of the extended cabinet length As a result for purposes of this selection example G H blowers will be used Since the Bearing Type was not specified the standard spider bearings will be used Thus using Table 36 1 with spider bearings the Blower Size and Bearing Type 13 14 15 16 17 18 Determine the Motor Horsepower The motor horsepower determined in step 12 was 3 Since the supply voltage is 460V 60Hz 3Ph a motor starter will need to be provided either with the unit or by others For purposes of this selection a motor starter by others will be used so the Motor Horsepower G Determine the Motor Type The motor type was not specified so for purposes of this selection the standard open drip proof motor will be used so the Motor Type 1 Determine the Sheave Arrangement To establish the Sheave Arrangement the motor frame size must be determined The Motor Data tables on pages 42 to 46 contain the motor frame size A Using the Supply Voltage
24. above its set point Enthalpy set point scale markings located on the enthalpy controller are A B C and D See Figure 26 1 for the corresponding control point The factory installed 620 ohm jumper placed across terminals and is required for proper operation and should not be removed Refer to suppliers literature supplied with the unit for additional information Enthalpy Sensor OPT not shown and field installed An enthalpy sensor is provided with Air Control option GJ Digits 20 amp 21 and field installed in the inlet air stream The enthalpy sensor senses and combines the temperature and humidity of the outdoor air to provide the 4 20 mA input signal to the Enthalpy Controller The enthalpy sensor is used in conjunction with the Enthalpy Controller Item 29 in Figure 21 1 anda mixed air temperature sensor not shown 26 30 Damper to Damper Linkage OPT Units with fresh and return air dampers include a damper actuator that controls the fresh air damper The return air damper position is controlled by the fresh air damper through the connecting rod For adjustment refer to Damper Linkage Adjustment 31 Return Air Damper OPT When a return air damper is supplied with the unit the damper is factory installed in the blower section The return air damper is used as an air balancing damper so low leak Class leakage resistance less than 40 CFM ft2 at 1 W C dampers with self compensating st
25. are installed properly according to direction of air flow 9 Perform a visual inspection of the unit to make sure no damage has occurred during installation 10 Turn on power to the unit at the disconnect switch Check to insure that the voltage between duct furnace electrical box terminals 1 and 2 is 24V 11 Check the thermostat ignition control gas valve and supply fan blower motor for electrical operation If these do not function recheck the wiring diagram Check to insure that none of the Control Options have tripped 12 For units with a return air damper the return air damper linkage needs to be adjusted Refer to Damper Linkage Adjustment 13 Check to make sure that the damper opens properly without binding 14 Check the blower wheel for proper direction of rotation when compared to the air flow direction arrow on the blower housing Blower wheel rotation not air movement must be checked as some air will be delivered through the duct furnace with the blower wheel running backwards 15 Check the blower speed rpm Refer to Blower Adjustments for modification 16 Check the motor speed rpm 17 Check the motor voltage On three phase systems check to make sure all legs are in balance 18 Check the motor amp draw to make sure it does not exceed the motor nameplate rating On three phase systems check all legs to insure system is balanced 19 Recheck the gas supply pressure at the field installed manual shut
26. as indicated on the serial plate is not 5 less than the rated voltage Installation of wiring must conform with local building codes or in the absence of local codes with the National Electric Code ANSI NFPA 70 Latest Edition Unit must be electrically grounded in conformance to this code In Canada wiring must comply with CSA C22 1 Part 1 Electrical Code Two copies of the job specific wiring diagram are provided with each unit one located in the duct furnace electrical junction box and one in the electrical section of the unit Refer to this diagram for all wiring connections The wire gauge must be sized according to the National Electric Code or CSA code based on the power supply voltage amp draw and length of run Refer to the Table 12 1 for maximum wire lengths for the number of wires that can be wired to each low voltage terminal block Table 12 1 Low Voltage 24V Maximum Wire Length Ft Model No Digit 15 VA 18 Ga Trans 16Ga 14Ga 12Ga 10 Ga 40 75 150 250 Maximum Wires per Terminal NEC 1996 Table 310 17 Copper wire with 90 C insulation conductors in free space not in conduit 86 F ambient For other wire types refer to the NEC or CSA code 12 Make sure all multi voltage components motors transformers etc are wired in accordance with the power supply voltage The power supply to the unit must be protected with a fused o
27. electrical wiring diagram provided with the unit Low voltage labeling ranges from terminal numbers 1 to 79 All field wiring connections should be made to the right side of the terminals to prevent miswiring by modifying the factory wiring which is made to the left side of the terminal strip 16 Dead Front Disconnect Switch OPT The dead front disconnect switch is factory installed in the electrical section The disconnect switch is designed so that it must be turned OFF before entry to the electrical control cabinet can be obtained See Figure 23 1 When in the OFF position power is disconnected to all unit wiring electrically following the switch See Warning For servicing the unit the disconnect switch can be manually overridden by using a wrench and turning the disconnect switch shaft 90 clockwise See Figure 23 1 Fusible and circuit breaker switches available For fusible switches Class J time delay fuses must be field provided matching the fuse size listed on the Model Identification plate WARNING When the dead front disconnect switch is in the OFF position supply power remains energized at the blower supply power terminal strip and the top of the dead front disconnect switch When providing service on or near these terminals building supply power to the unit should be de energized Figure 23 1 Dead Front Disconnect Switch Assembly BLOWER SECTIO ELECTRICAL COMPARTMENT ACCESS D
28. option static pressure unit performance tables Brake Horsepower and RPM values are approximate values only Please consult the AccuSpec se 36 AIR5 594 6 from Table 34 1 Unit internal resistance has been included in the lection software for values at other than isted CFM static pressures BLOWER PERFORMANCE DATA Table 37 1 Unit Performance Tables 9 Total Static Pressure Inches W C 025 100 1 25 150 200 250 3 00 RPM BHP RPM BHP BHP RPM BHP RPM BHP APM 500 600 120 F 106 F Start 600 93 F 111 82 F 99 F 74 F 1 89 F 67 F 81 F 62 F 74 F 500 600 Start 600 74 F 89 F 62 F 74 F 53 F 63 F 46 F 56 F End 500 41 F 49 F 44 F 1 43 F 40 F 40 500 600 62 F 74 F 53 F 63 F 46 F 56 F Start 500 41 F 49 F 44 F 1 43 F 40 F 40 700 800 120 F TIEF Start 800 104 119 F 94 108 86 F 99 F 80 F 91 F 700 800 Start 800 65 F 74 F 58 F 66 F 52 F 59 F E ms a 1099 as 29 920 5 700 800 65 Mr 566 58 F 66 F 52 F 59 F 47 F 1 54 F 47 F 54 F 43 F 49 F End 700 40 F 46 F
29. 0 80 0 ODP 18 9 8 2 80 0 65 0 ODP 38 6 5 91 0 1812 9 2 80 0 71 0 ODP HE 37 8 93 0 TEFC ODP 18 9 40 0 17 0 1 90 2 84 0 86 5 40 0 91 0 TEFC 18 9 0 1 83 0 71 0 38 0 92 490 18 12 9 2 80 0 72 096 39 0 15 0 1 88 0 82 0 ODP 84 0 38 0 22 0 1 88 0 84 0 E 89 5 50 0 91 0 ODP 18 9 4 2 81 0 67 0 49 0 93 6 18 12 3 3 81 0 51 0 21 5 1 90 2 82 5 5 84 0 18 12 48 0 26 0 1 89 0 86 0 TE HE 85 596 TEFC 51 0 91 0 18 9 4 2 84 0 70 0 48 2 93 090 18 12 84 0 77 096 TE 18 9 52 0 18 0 1 89 0 88 0 ODP 86 576 ODP HE 89 5 ODP 18 9 6 4 82 0 72 0 ODP 18 12 5 4 5 81 0 75 0 87 5 89 5 0 3 84 0 70 0 TE 18 12 8 5 84 0 82 0 ODP i 87 5 89 5 ODP 18 9 85 0 77 0 18 12 86 0 78 0 87 5 90 2 85 0 85 0 18 12 85 0 80 0 O1 O1 O1 O1 O1 402 Po D Motors have thermal overload protection 2 Refer to page 46 for Motor Type abbreviations 44 AIR5 594 6 MOTOR DATA Table 45 1 Motor Data for
30. 100 F 62 F 77 F 53 F 66 F 41 F 51 F 34 F 42 F 28 36 EF 41 F 51 F 34 F 42 F 28 F 36 F 25 F 31 F 22 F 27 F 100 20 F 25 F 23 F 20 F 100 F 117 F 86 F 100 F 79 F 93 F 62 F 72 F 51 F 59 F 43 F 50 F 37 F 43 F 150 175 86 F 100 F 79 F 93 F 62 F 72 F 51 F 59 F 43 F 50 F 37 F 43 F 33 F 38 F 29 F 34 F 26 F 31 F 24 F 28 F 21 F 25 F 85 F 95 F 74 F 83 F 66 F 74 F 59 F 67 F 54 F 61 F 49 F 56 F 200 225 85 F 95 F 74 F 83 F 59 F 67 F 49 F 56 F 42 F 48 F 37 F 42 F 33 F 37 F 30 F 33 F 200 225 85 F 95 F 74 F 83 F 59 F 67 F 49 F 56 F 42 F 48 F 37 F 42 F 33 F 37 F 30 F 33 F 27 F 30 F 25 F 28 F Total static pressure should include external static pressure and accessory option static pressure from Table 34 1 Unit internal resistance has been included in the unit performance tables Brake Horsepower and RPM values are approximate values only Please consult AccuSpec selection software for values at other than listed static pressures AIR5 594 6 BLOWER PERFORMANCE DATA Table 36 1 Unit Performance Tables 2 E 0072 120 F 1852 Total Sta
31. 2778 0 08 0 09 015 016 023 051 045 096 012 0 15 0 06 741 0 01 0 02 0 02 002 oot 0 06 002 0 08 0 00 003 001 1000 0 02 0 02 003 004 002 008 004 012 0 01 0 05 0 01 1500 0 03 0 04 005 007 0 04 044 0 08 023 0 02 007 002 2000 005 0 06 007 010 008 021 015 036 004 040 0 03 2500 0 07 0 08 040 014 0 12 030 023 053 007 043 0 04 3000 0 09 0 1 013 019 017 040 034 073 041 016 0 05 3500 0 1 0 13 016 024 023 051 046 097 015 0 19 0 07 4000 0 14 016 020 030 030 063 060 123 019 022 0 09 4500 0 17 020 025 037 025 025 0 11 4630 0 17 0 21 0 26 0 39 4000 0 26 026 0 11 111 0 01 002 003 004 001 007 003 009 002 002 0 01 1500 0 02 003 004 005 003 010 005 015 002 003 0 01 2000 0 03 0 04 006 oos 004 015 009 024 004 005 0 02 2500 0 05 0 06 0 09 0 11 0 07 020 014 034 0 05 0 08 002 3000 0 06 0 08 0 15 010 027 020 046 007 040 0 04 3500 0 08 0 11 014 048 014 034 027 061 040 014 005 4000 0 11 013 018 0 23 048 041 035 077 043 048 0 06 4500 0 13 016 021 027 023 050 045 095 017 022 0 08 5000 0 16 019 025 032 028 059 055 115 021 027 0 10 5200 0 17 021 027 034 030
32. 4 0 875 6 0 75 A38 3H35129B17 T 1 625 10 4 1 B78 3H35126B6 3 8 0 625 4 2 0 75 A34 3H35129B18 7 1 625 104 1 878 3H35126B7 3 8 0 875 4 2 0 75 A34 3H35129B19 7 1375 94 1 70 3H35126B8 38 1125 42 0 75 A36 T 1 625 94 1 3H35126B9 56 0625 52 0 75 A38 T 1 BIT 31351266810 56 mm m m 3H35130B1 5 5 1 625 9 4 144 Qty 2 B74 anes Geen 56 455 5s 825 TS 3H35130B2 5 5 1 625 9 4 144 Qty 2 B74 3H35130B3 7 1 625 10 4 144 Qty 2 B78 SHE TED 25 242 Bor 3H35130B4 7 1 625 104 144 Qly 2 B78 3H35126B13 5 6 0 875 4 5 0 75 A37 3H35130B5 7 1 625 94 144 Qty 2 B77 3H35126B14 5 6 1 125 4 5 0 75 A39 3H35130B6 7 1 625 94 144 Qty 2 B77 3H35127B1 2 9 0 5 7 1 A42 3H35130B13 7 1 875 12 4 144 Qty 2 B82 3H35127B2 2 9 0 625 7 1 A43 3H35130B14 7 1 875 12 4 144 Qty 2 B82 3H35127B3 3 8 0 625 75 1 A46 3H35130B15 7 1 875 10 4 144 Qty 2 B79 3H35127B4 3 8 0 875 75 1 A45 3H35130B16 7 1 875 10 4 144 Qty 2 B79 3H35127B5 3 8 1 125 75 1 47 3H35130B17 7 1 875 9 4 144 Qty 2 B77 3H35127B6 5 0 625 8 1 A48 3H35130B18 7 1 875 9 4 1 44 Qty 2 B77 3H35127B7 5 0 875 8 1 A48 3H35130B19 7 1 875 8 4 144 Qty 2 B75 3 3512788 5 1125 8 1 ABO 3H35130B20 7 1 875 84 144 Qty 2 B75 3H35127B9 T 3H36622B1 4 1 0 875 10 9 1 44 B75 PEU 44 a i 3H36622B2 4 1 1 125 10 9 1 44 BX73 3H36622B3 4 1 0 875 8 9 1 44 B72 3H35127B11 5 2 1 375 6 7 1 49 3H36622B4 41 1 125 8 9 1 44 B70
33. 460V 60Hz SPh enter the correct Motor Data table Table 45 1 Using Model Nomenclature Digits 17 and 18 G1 determined in steps 13 and 14 find the motor frame size 182T Using the Motor Frame Size enter the Sheave Selection table for the selected blower determined by step 13 Table 38 2 Using the rpm calculated in step 12 870 rpm select the sheave range that contains the required rpm Find the intersection with the Motor Frame Size to determine the Sheave Selection For this example with a 182T frame with 870 rpm from Table 39 2 Sheave Arrangement Determine the Air Control The Air Control option is selected based on the required damper configuration The available damper selections are detailed on page 24 For this selection a 100 fresh air unit without return air was required so the Air Control DA Determine the Evaporative Cooler An evaporative cooler is not available so for purposes of this selection the Evaporative Cooler 0 Determine the Cooling Coil cooling coil cabinet was not specified so for purposes of this selection the Cooling Coil 0 Based on the previous steps the model number for the base unit is the following IBS400SMRLNAOF2GG1IDAOO Once the basic model has been determined the additional options and accessories outlined on page 21 to 29 can be added to the unit AIR5 594 6 33 OPTION amp ACCESSORY PRESSURE DROP DATA Table 34 1 Option amp Accessory P
34. Adjacent public walkways 7 feet all directions 3 feet above 2 Grade ground level Do not terminate the vent directly above a gas meter or regulator The vent must be at least 6 higher than anticipated snow depth A21 Vertical combustion air pipes should be fitted with a tee with a drip leg and a clean out cap to prevent against the possibility of any moisture in the combustion air pipe from entering the unit The drip leg should be inspected and cleaned out periodically during the heating season 22 addition to following these General Instructions specific instructions for Vertical and Horizontal vent systems in 2 Pipe or Concentric Vent configurations must also be followed The following outlines the differences Vertical Vent System Determination Vertical vent systems terminate vertically up an example is shown in Figure 8 1 Determine the venting configuration as follows gt For two building penetrations through the wall or roof one for the combustion air inlet pipe and one for the vent pipe proceed to Section B Vertical 2 Pipe Venting gt For a single larger building penetration through the wall or roof through which both the combustion air inlet and vent pipes will pass proceed to Section D Horizontal and Vertical Concentric Venting gt For all other cases proceed to the next section for Horizontal Vent System Determination Horizontal Vent System
35. Determination Horizontal vent systems terminate horizontally sideways an example is shown in Figure 9 1 Determine the venting configuration as follows gt For two building penetrations through the wall or roof one for the combustion air inlet pipe and one for the vent pipe proceed to Section C Horizontal 2 Pipe Venting gt For a single larger building penetration through the wall or roof through which both the combustion air inlet and vent pipes will pass proceed to Section D Horizontal and Vertical Concentric Venting INSTALLATION VENTING Section B Vertical 2 Pipe Vent System Installation B2 B3 B4 5 7 This section applies to vertically vented 2 pipe one combustion air inlet pipe and one vent pipe vent systems and is in addition to Section A General Instructions All Units Vertical vent systems terminate vertically up It is recommended to install a tee with drip leg and clean out cap as shown in Figures 8 1 or 8 2 The combustion air and vent pipes must be terminated with 2 Gary Steel Model 1092 caps Vertical vents must terminate a minimum horizontal and vertical distance from roof lines and adjacent walls or obstructions These minimum distances are outlined in Figure 8 1 and Table 8 1 or Figure 8 2 The vent must terminate at least 1 foot above and 16 inches horizontally from the combustion air inlet Once venting is complete proceed s
36. GROUND SUPPLY LINE JOINT W BRASS i gt A SEAT M e aX f MIN SEDIMENT TRAP Manual gas shut off valve is in the OFF position when handle is perpendicular to pipe Table 11 1 Gas Pipe Capacities Cu Ft per Hour Natural Gas 2 1 2 3 4 1 1 1 4 1 1 2 2 Gas pipe capacities based gas pressure up to 14 through Schedule 40 pipe with a pressure drop of 0 3 W C for Natural gas with a specific gravity of 0 60 For gas pipe capacities when using Propane gas specific gravity of 1 50 multiply the value shown for Natural gas at the applicable pipe diameter and length by 0 63 AIR5 594 6 11 UNIT INSTALLATION Electrical Connections 1 A WARNING Disconnect power supply before making wiring connections to prevent electrical shock and equipment damage All appliances must be wired strictly in accordance with wiring diagram furnished with the appliance Any wiring different from the wiring diagram could result in a hazard to persons and property Any original factory wiring that requires replacement must be replaced with wiring material having a temperature rating of at least 105 C Ensure that the supply voltage to the appliance as indicated on the serial plate is not 5 greater than rated voltage CAUTION Ensure that the supply voltage to the appliance
37. Panel GE FA amp RA Mod motor w 3 pos damper 10096 RA Variable 100 OA GF FA amp RA Mod motor w A350P Proportional Temp Controller GG FA amp RA Mod motor w Minimum Position amp Prop Temp Controller GH FA amp RA Mod motor w Remote Position amp Prop Temp Controller GJ amp RA Mod motor w FA Enthalpy Controller GK ASHRAE Cycle II with Warm up Stat GM ASHRAE Cycle with Warm up Stat GN ASHRAE Cycle III GF with Warm up Stat FA amp RA Floating motor w Space Pressure Controller JA Manual 4 RA Dampers KA Manual FA Damper with Return Air Opening 22 Evaporative Cooling 0 None 23 Cooling Coil CC 0 None 1 Factory Installed Coil AIR5 594 6 59 COMMERCIAL WARRANTY Seller warrants its products to be free from defects in material and workmanship EXCLUSIVE HOWEVER of failures attributable to the use of materials substituted under emergency conditions for materials normally employed This warranty covers replacement of any parts furnished from the factory of Seller but does not cover labor of any kind and materials not furnished by Seller or any charges for any such labor or materials whether such labor materials or charges thereon are due to replacement of parts adjustments repairs or any other work done This warranty does not apply to any equipment which shall have been repaired or altered outside the factory of
38. SITU DANS LA BO TE JUNCTION LECTRIQUE POUR REMETTRE PRESSER LE BOUTON INSTRUCTIONS D ALLUMAGE 1 DUVRIR TOUTES LES ROBINETS A GAZ DONNER LE COURANT 2 REGLER LE THERMOSTAT SUR LA POSITION DESIREE INSTRUCTIONS DE FER METURE 1 COUPER LE COURANT ET FERMER TOUTES LES ROBINETS A GAZ REFERREZ AU MANUAL D INSTALLATION ET DE SERVICE POUR PLUS D INSTRUCTIONS POUR APPAREILS AVEC DEUX PHASES MODULATION M CHANIQUE OU APPAREILS DE CONTR OLE DE GAZ LECTRIQUES MODULES UN AIR CONTROLEUR DECHARGE INSTALLE LA MANUFACTURE ET THERMOSTAT DE CHAMBRE N EST PAS INCLUS DEGAGEMENT DU COMBUSTIBLE DEGAGEMENT DE SERVICE RECOMMENDE SH76854B Rev A 56 AIR5 594 6 MODEL DESIGNATIONS Figure 57 1 Model Identification Plate MODEL IDENTIFICATION PLATE COMMON REPLACEMENT PARTS Wess Whe fing about parts ah jide mode number 1 number and part number IBS 75AFRHN10A1AA1AAA1A 01101010199 0002 pad provide ee For service contact your local qualified installation and service contractor or appropriate utility company MOTOR DATA Voltage Hertz Phase Amps Blower Motor Blower Sheave Blower Belt 115 208 230 60 1 6 6 3 0 3 3 9F20218 5H63081 20 5H76183 31 Time Delay Relay Motor Sheave SYSTEM 5H71790 5858064 3 Supply Voltage Hertz Phase Max System Amps Fuse Size Time Delay
39. connection Verify the manual shut off valve is gas tight on an annual basis See Figure 11 1 4 Provide a sediment trap before each unit in the line where low spots cannot be avoided See Figure 11 1 5 When Pressure Leak testing pressures above 14 W C 1 2 psi close the field installed shut off valve disconnect the appliance and its combination gas control from the gas supply line and plug the supply line before testing When testing pressures 14 W C 1 2 psi or below close the manual shut off valve on the appliance before testing Figure 11 1 Recommended Sediment Trap Manual Shut off Valve Installation Side or Bottom Gas GAS SUPPLY LINE GROUND e JOINT ipe UNION p W BRASS MANUAL GAS SENT SHUT OFF VALVE GAS 4 SUPPLY 5 m CAS 8 ual Y E gt o lt DN CONTROLS PLUGGED 1 8 NPT TEST 5 MIN GAGE CONNECTION o XN SEDIMENT TRAP CONTROLS PLUGGED 1 8 o NPT TEST GAGE CONNECTION 9 2 Through hole in bottom of unit 9 caulk hole to prevent MANUAL GAS water leakage o SHUT OFF VALVE GAS
40. distance of the overhang must not exceed 24 The clearance to combustibles above the exterior vent must be maintained at a minimum of 12 Consult the National Fuel Gas Code for additional requirements for eaves that have ventilation openings C12 Once venting is complete proceed section titled Installation Gas Connections Section D Concentric Vent System Installation D1 This section applies to both horizontally and vertically vented concentric vent systems as defined in Section A General Instructions All Units and is in addition to the instructions in that section D2 When utilizing the concentric vent option it should have been predetermined whether the appliance will be horizontally or vertically vented Before proceeding verify that the concentric vent kit received contains the correct components for the installation AIR5 594 6 For Vertically Vented Units Refer to Figure 9 3 Concentric adapter assembly same for horizontal and vertical kits Standard Gary Steel 1092 vent termination G Specially designed inlet terminal part 5H75154 Figure 9 3 Vertical Concentric Vent Kit Components Outlet Vent Combustion Air Termination Cap i 6 Min Inlet Terminal Size according 12 to expected snow depth E Concentric Vent Adapter T Box Building Roof Ceiling Combustion Air Pid b
41. electrical connections are made in the electrical section of the unit The low voltage thermostat and accessory control devices can be wired to either the electrical section or the duct furnace electrical junction box Refer to the wiring diagram for the terminal location of all low voltage wiring AIR5 594 6 UNIT INSTALLATION Cooling Coil Units Models with a cooling section can be provided with either a factory installed direct expansion DX evaporator a chilled fluid for use with water ethylene glycol or propylene glycol fluids coil or the coil can be field supplied and installed by others For units equipped with a factory installed cooling coil Digit 23 1 refer to the packing slip to determine the coil type provided The cooling section is located downstream of the duct furnace heat exchanger in a blow through configuration preventing condensation on the heat exchanger in the cooling mode Thus Figure 13 1 Cooling Section Optional double wall construction DX single circuit shown and dual circuit coils available Optional Factory Installed DX or Chilled Water coil Fin spacings of 6 8 10 12 or 14 fins per inch Adjustable mounting bracket for 2 3 4 and 6 row coils Full coverage 3 way sloping 409 stainless d steel drain pan Right or left hand coil 1 stubbed drain header access to connection match gas controls Table 13 1 Cooling Coil Performance Limi
42. four 4 years on certain compressors Provided a supplemental warranty has been purchased Seller extends the warranty herein for an additional four 4 years or nine 9 years on certain heat exchangers EXCLUSION OF CONSUMABLES amp CONDITIONS BEYOND SELLER S CONTROL The above referenced warranty shall not be applicable to any of the following items refrigerant gas belts filters fuses and other items consumed or worn out by normal wear and tear or conditions beyond Seller s control including without limitation as to generality polluted or contaminated or foreign matter contained in the air or water utilized for heat exchanger condenser cooling or if the failure of the part is caused by improper air or water supply or improper or incorrect sizing of power supply APPLICABLE WARRANTY PERIOD TEN YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER WITHIN Heat Exchangers Gas Fired Units except PSH BSH OCCURS FIRST TEN YEARS FROM DATE OF RESALE BY BUYER OR ANY OTHER USER WITHIN TEN YEARS FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION OR WITHIN ONE HUNDRED TWENTY SIX MONTHS FROM DATE OF SHIPMENT FROM SELLER WHICHEVER Heat Exchangers Low Intensity Infrared Units Compressors Condensing Units for Cassettes FIVE YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER WITHIN FIVE YEARS FROM DATE OF RESALE BY BUYER OR ANY OTHER USER WITHIN FIVE YEARS FROM DATE OF RESAL
43. pressure reading ____ Is flame clean and stable Does flame modulate in response to temperature control s Gas input checked Input at maximum firing rate __ Btu Hr Input at minimum firing rate Btu Hr Gas piping checked for and free of leaks Has wiring been verified to match the unit wiring diagram Have all the modes of the sequence of operation been verified and tested What optional and or accessory control devices have been set Device Setting __ ___ VF psi Inches W C etc Device Setting __ F psi Inches W C etc Device Setting __ ___ F psi Inches W C etc Customer Owner instructed in operation and maintenance of unit Yes No Name of Person s Instructed Comments Start Up Company Name Phone Signature Date 58 AIR5 594 6 MODEL NOMENCLATURE FOR SYSTEM UNITS Weatherproof Model Nomenclature 1 2 3 456 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 PT UC V MBH HE DS AS ATR GT 1 Product Type PT Indoor HVAC Unit 2 Unit Configuration UC B Blower Package Furnace amp Blower C Cooling Package Furnace Blower amp Cooling Cabinet 3 Venting V S Separated Combustion 4 5 6 Furnace Input Rating MBH Output on 840 amp 960 100 100 000 Btu Hr Input 500 500 000 Btu Hr Input 175 175 000 Btu Hr Input 600 600 000 Btu Hr Input 250 250 000 Btu Hr Input 840 1 050 000 Btu Hr Inp
44. the combination gas control is adjusted at the factory for average gas conditions It is important that gas be supplied to the duct furnace in accordance with the input rating on the serial plate Actual input should be checked and necessary adjustments made after the duct furnace is installed Over firing a result of too high an input reduces the life of the appliance and increases mainte nance Under no circumstances should the input exceed that shown on the serial plate Measuring the manifold pressure is done at the tee in the manifold See Figure 17 2 To Adjust the Manifold Pressure 1 Move the field installed manual shut off valve to the OFF position 2 Remove the 1 8 pipe plug the pipe tee and attach a water manometer of U tube type which is at least 12 high 3 Move the field installed manual gas shut off valve to the position 4 Create a high fire call for heat from the thermostat 5 Determine the correct high fire manifold pressure For natural gas 3 5 W C for propane gas 10 W C Adjust the main gas pressure regulator spring to achieve the proper manifold pressure for location see the combination gas control literature supplied with unit 6 Iftheunit has Electronic Modulation gas controls determine from the Model Identification Digit 12 the low fire gas pressure needs to be adjusted Using Figure 17 3 for item number locations this is accomplished as follows a Disconnect pow
45. the combustion air intake pipe to prevent animals and debris from entering Attach the vent cap to the vent pipe using at least 3 corrosion resistant sheet metal screws D13 Install vent pipe and combustion air pipe between unit heater and concentric vent adapter box as outlined in Section A General Instructions All Units D14 Once venting is complete proceed to the section titled Installation Gas Connections 10 AIR5 594 6 UNIT INSTALLATION Gas Connections A WAR N G Connection 1 All field gas piping must be pressure leak tested prior to operation Never use an open flame Use a soap solution or equivalent for testing 2 Gas pressure to appliance controls must never exceed 14 W C 1 2 psi 3 To reduce opportunity for condensation the minimum sea level input to the appliance as indicated on the serial plate must not be less than 5 below the rated input or 5 below the minimum rated input of dual rated units A CAUTION Purging of air from gas supply line should be performed as described in ANSI 7223 1 latest edition National Fuel Gas Code or in Canada CAN CGA B149 codes A IMPORTANT To prevent premature heat exchanger failure the input to the appliance as indicated on the serial plate must not exceed the rated input by more than 5 1 Installation of piping must conform with local building codes or in the absence of local codes with the National Fuel G
46. the pilot 4 Once the pilot is lit the flame sensor proves the pilot and stops the spark ignitor from sparking 5 The main gas valve is opened and the main burner is lit to 100 full fire 6 The time delay relay starts the blower after 30 to 45 seconds 7 The modulating gas valve can be controlled by either an electronic modulating room or duct thermostat The thermostat can modulate the firing rate between 4096 through 100 full fire The call for heat is created by a resistance signal 8000 to 12000 ohms in the thermostat The amplifier converts this resistance into a DC voltage 0 to 12 volts DC with O volts high fire and 12 volts low fire The output voltage is applied to the modulating gas valve to control the gas flow to the main burner As the temperature drops the voltage drops causing the modulating valve to open further If the discharge air temperature increases the voltage increases causing the modulating valve to close allowing less gas flow to the main burner For further information regarding the operation of the electronic modulating system consult the literature provided with the unit AIR5 594 6 19 START UP PROCEDURE 8 The unit continues to operate in this manner until the thermostat is satisfied at which time both the main and pilot valves close 100 9 The time delay relay stops the blower after 30 to 45 seconds Electronic Modulating Gas Controls Two and Three Furnaces Model Sizes 800 960 One
47. those that add internal static pressure 1 5 to the unit Once these items are determined the pressure drop curves would be used to calculate the total pressure drop T S P Total Static Pressure Internal External Static Pressure 6 Heat exchanger material The heat exchanger type is determined by the application The standard heat exchanger material is aluminized steel A 409 stainless steel heat exchanger and burner is recommended when the unit is installed downstream of a cooling coil or evaporative cooler and when the combined entering return air to the unit is below 40 F 7 Type of fuel Either natural or propane gas determined by the design engineer 8 Gas control staging method Either single stage two stage mechanical modulation or electronic modulation determined by the design engineer 9 Main power supply voltage to unit 10 Altitude at which unit is to be installed With this information a basic unit can be selected as shown in the following example 32 Selection Example Conditions Select an indirect fired 100 make up air unit to meet the following conditions 1 sea level 6 000 cfm 2 Outdoor design temp 10 F Indoor design temp 70 F 3 Heating output capacity 5000 cfm x 70 F 10 F x 1 08 324 000 Btu Hr 4 External Static Pressure 0 65 The separated combustion unit with the controls on the Right Hand Side is to be provided with the following 2 Permanent
48. to 184 3H36622B2 3H36622B4 3H36622B6 3H36622B12 213 or 215 3H36622B5 3H36622B7 3H36622B13 3H36622B18 254 3H36622B8 3H36622B9 3H36622B14 3H36622B15 3H36622B19 3H36622B20 3H36622B23 3H36622B24 3H36622B10 3H36622B16 3H36622B21 3H36622B25 3H36622B11 AIR5 594 6 3H36622B17 3H36622B22 3H36622B26 39 BLOWER SHEAVE ASSEMBLY DATA Table 40 1 Blower Sheave Assembly Settings Turns Open Sheave Assembly 2 2 5 3H35125B1 2 3H35125B3 5 3H35125B6 7 3H35125B8 9 3H35125B10 11 3H35126B1 2 3H35126B3 5 3H35126B6 8 3H35126B9 11 3H35126B12 14 3H35127B1 2 3H35127B3 5 3H35127B6 8 3H35127B9 11 3H35127B12 14 3H35127B15 16 3H35127B17 3H35128B1 3 3H35128B4 6 3H35128B7 9 3H35128B10 12 3H35128B13 14 3H35128B15 3H35129B1 3 3H35129B4 7 3H35129B8 10 3H35129B11 14 3H35129B15 18 3H35129B19 21 3H35130B1 2 3H35130B3 4 3H35130B5 6 3H35130B13 14 3H35130B15 16 3H35130B17 18 3H35130B19 20 3H36622B1 2 3H36622B3 5 3H36622B6 11 3H36622B12 17 3H36622B18 22 3H36622B23 26 40 AIR5 594 6 BLOWER SHEAVE ASSEMBLY DATA Table 41 1 Blower Sheave Assembly Settings
49. wall pipe A11 A12 A13 A14 A15 A16 A17 A18 A19 All seams and joints of the single wall pipe must be sealed with metallic tape or silastic suitable for temperatures up to 400 F Wrap the tape two full turns around the vent pipe One continuous section of double wall vent pipe may be used within the vent system Refer to instruction A12 in Section A General Instructions All Units for attaching double wall pipe to single wall pipe The following are General Instructions for Double Wall Type B Terminal Pipe Installation How to attach a single wall vent terminal to double wall type B vent pipe 1 Look for the flow arrow on the vent pipe 2 Slide the vent terminal inside the exhaust end of the double wall vent pipe 3 Drill 3 holes through the pipe and the vent terminal Using 3 4 long sheet metal screws attach the cap to the pipe Do not over tighten How to connect a single wall vent system to a double wall type B vent pipe 1 Slide the single wall pipe inside the inner wall of the double wall pipe 2 Drill 3 holes through both walls of the single and double wall vent pipes Using 3 4 sheet metal screws attach the two pieces of pipe Do not over tighten 3 The gap between the single and double wall pipe must be sealed but it is not necessary to fill the full volume of the annular area To seal run a large bead of 400 F silastic around the gap Do NOT vent this appli
50. with 1 or 2 permanent filters 2 FARR Aeropleat or 2 FARR 30 30 filters For filter replacement refer to Maintenance 27 Fresh Air Damper OPT When a fresh air damper is supplied with the unit the damper is factory installed in the blower section The fresh air damper is used as an outside air shut off damper so ultra low leak Class leakage resistance less than 10 2 at 1 W C dampers with self compensating stainless steel side seals and santoprene and galvanized steel blade seals are used 28 Direct Drive Damper Actuator OPT The direct drive damper actuator is factory installed in the blower section on the side of the fresh air damper The actuator controls the position of the fresh air damper The return air damper if provided is controlled by the damper linkage between the two dampers All damper actuators are low voltage 24V For Right Hand units Digit 9 R during operation the actuator should rotate in the counterclockwise direction when viewed from the service side of the unit For Left Hand units Digit 9 L during operation the actuator should rotate in the clockwise direction when viewed from the service side of the unit Three different types of dampers actuators can be provided Two position Modulating and Floating Two position Damper Actuator A two position damper actuator is provided with Air Control options DA EA EQ and FA Digits 20 amp 21 The two position damper
51. 0 0 27 43 192 3 80 0 23 40 216 3 90 0 20 37 240 4 100 0 25 288 7 120 0 20 37 336 5 140 0 27 43 384 6 160 0 23 40 240 4 25 42 288 7 20 37 336 5 27 43 384 6 23 40 336 5 27 43 384 6 160 0 23 a A zi A o 3 o S o o o o o A Set Screw Toward Motor Adjustable of Sheave 4 Turn outer side of motor sheave clockwise until motor sheave is fully closed 5 From fully closed position turn outer side of motor sheave counterclockwise until the proper number of turns open are achieved 6 Retighten motor sheave set screw replace belt and retighten motor base Motor base should be shifted for proper belt tension which is 3 4 deflection with about 5 16 of force Figure 18 2 Belt Tension Adjustment 3 4 deflection with 5 Ibs of force Model contains 2 furnaces Values shown are per furnace Model contains 3 furnaces Values shown are per furnace 18 7 Recheck blower rpm after adjustment NOTE Do not fire unit until blower adjustment has been made or unit may cycle on high limit control 8 Check motor amps Do not exceed nameplate amps shown on motor nameplate Lubrication Recommendations The blower can be provided with either spider or pillow block bearings Spider bearings are permanently lubricated and do not require lubrication Pillow block bearin
52. 00 225 70 250 300 63 350 400 70 A minimum 12 straight pipe is recommended from the flue outlet before turns in the vent pipe Horizontal sections of vent and combustion air pipes are to be installed with a minimum downward slope from the appliance of 1 4 inch per foot and suspended securely from overhead structures at points not greater than 3 apart Fasten individual lengths of vent together with at least three corrosion resistant sheet metal screws Keep single wall vent pipe at least 6 from combustible materials For double wall vent pipe follow the vent pipe manufacturer s clearances to combustibles The minimum distance from combustible materials is based on the combustible material surface not exceeding 160 F Clearance from the vent pipe or the top of the unit may be required to be greater than 6 if heat damage other than fire could result such as material distortion or discoloration Avoid venting through unheated space when possible When venting does pass through an unheated space or if the unit is installed in an environment that promotes condensation insulate runs greater than 5 to minimize condensation Inspect for leakage prior to insulating and use insulation that is noncombustible with a rating of not less than 400 F Install a tee fitting at the low point of the vent system and provide a drip leg with a clean out cap as shown in Figure 8 1 When the vent passes through a combustib
53. 063 060 123 023 029 011 5556 0 19 023 030 038 5200 Max for Eva 0 26 033 0 13 1481 0 01 002 003 003 002 008 004 012 002 003 001 2000 0 01 002 004 004 003 012 007 049 oos 0 05 0 01 2500 0 02 0 04 0 05 0 06 005 017 010 027 0 04 0 08 0 02 3000 0 03 0 05 0 07 0 08 008 022 045 036 0 06 040 004 3500 0 03 0 06 0 09 040 027 020 047 0 09 044 005 4000 0 05 0 08 011 0 12 043 033 0 27 060 041 018 0 06 4500 0 06 010 013 015 0 17 040 034 073 014 022 0 08 5000 0 07 0 11 016 048 021 047 042 089 048 027 0 10 5500 0 09 0 14 049 021 025 oss 050 105 021 032 0 12 6000 0 11 016 022 025 0 30 063 060 123 026 038 0 14 6500 0 13 0 18 025 028 6000 Max for 0 0 0 45 0 16 1852 0 03 0 02 005 005 002 010 0 05 045 002 007 0 02 2000 0 03 0 03 0 05 0 06 003 0 11 0 06 047 002 008 0 02 2500 0 04 0 04 007 0 09 004 045 0 09 024 0 03 009 0 03 3000 0 05 006 010 041 006 049 013 032 004 012 004 3500 0 07 0 08 012 015 009 024 047 041 006 044 0 06 4000 0 08 010 015 0 18 011 029 023 052 0 08 046 0 07 4500 0 10 013 018 022 045 035 029 064 010 049 0 09 5500 0 14 019 025 031 02
54. 110 25 33 85 100 25 All 86 37 110 25 36 36 150 175 All 86 37 110 25 40 61 All E F G or H or K or H I J or K GorH I J or K GorH or L or L AIR5 594 6 DUCT INSTALLATION UTILITY CONNECTIONS UNIT INSTALLATION DUCT CONNECTION TO UNIT 1 The furnace discharge units with Model Digit 2 B is designed to accept straight ductwork see Figure 5 1 The blower section end and bottom openings all units and cooling cabinet section discharge units with Model Digit 2 C are designed to accept 90 flanged ductwork see Figure 5 2 Provide an airtight seal between the ductwork and the furnace Seams with cracks in the ductwork should be caulked and or taped and be of permanent type All duct connections MUST be airtight to prevent air leakage 2 Provide uniform air distribution over the heat exchanger Use turning vanes where required to obtain uniform air distribution See Figure 5 3 3 Provide removable access panels on the downstream side of the ductwork See Figure 5 1 This opening should be large enough to view smoke or reflect light inside the casing to indicate leaks in the heat exchanger and to check for hot spots on heat exchangers due to poor air distribution or lack of sufficient air CFM Figure 5 1 Furnace Discharge Duct Connection Figure 5 2 Blower Section Inlet and Cooling Coil Section Discharge Duct Con
55. 18 12 18 0 9 5 86 0 81 0 ODP 89 5 TE 20 0 91 0 ODP 18 9 79 0 62 0 19 0 92 4 ODP 18 12 80 0 70 0 18 9 19 5 7 5 88 0 82 0 84 0 TE 18 12 19 5 11 0 88 0 84 0 TE HE 85 5 ODP 25 0 91 0 TEFC 18 9 84 0 70 0 ODP HE 24 5 93 6 TE 18 12 81 0 77 0 ODP 18 9 25 2 10 0 89 5 82 5 86 5 18 12 24 0 13 0 90 0 84 0 ODP HE 89 5 TEFC 25 5 91 0 ODP 18 9 80 0 66 0 TE HE 24 1 93 0 ODP 18 12 82 5 NA 18 9 26 0 8 7 89 0 88 0 87 5 89 5 18 9 84 0 70 0 18 12 82 5 75 5 87 5 89 5 ODP 18 9 84 0 73 0 ODP 18 12 78 0 71 0 OF GI 02 02 GO 02 IO PO PO PO IPO PO Motors have no thermal overload protection 2 Refer to page 46 for Motor Type abbreviations 87 5 AIR5 594 6 18 12 247140 90 0 86 0 45 MOTOR DATA Table 46 1 Motor Data for Digit 14 G 575V 60Hz 3Ph Motor Service Efficiency Size HP Factor A5 or L5 B1 or M1 B5 or M5 C1 1 C5 D1 or P1 D5 or P5 D6 or P6 E1 or Q1 E5 or Q5 E6 or Q6 F1 or R1 F5 or R5 F6 or R6 G1
56. 2 048 043 091 015 025 043 6500 0 19 026 034 042 030 063 060 123 021 031 0 18 7250 023 032 041 051 6500 for 027 0 37 023 1925 0 02 001 003 003 001 005 002 008 002 007 002 3000 0 03 0 03 0 05 005 003 010 005 015 0 04 042 0 04 4000 0 05 0 05 0 08 0 09 0 04 015 009 023 008 046 0 07 5000 0 08 008 012 007 020 014 034 012 022 0 11 6000 0 11 0 11 015 046 010 026 020 046 048 028 0 16 7000 0 15 015 049 021 014 034 027 061 025 035 0 21 8000 0 19 0 20 024 027 048 041 035 077 033 042 028 9000 0 24 025 030 033 023 050 045 095 042 051 035 10400 0 32 033 038 042 030 064 060 123 057 0 64 047 11111 0 36 0 38 043 047 10400 for Evap 0 66 071 053 2593 0 02 002 004 004 003 010 005 016 002 003 0 01 3000 0 02 002 0 05 005 004 013 007 020 003 004 0 01 3500 0 03 0 03 0 06 0 06 0 05 016 040 025 0 04 005 001 4000 0 03 0 04 007 0 08 006 019 013 032 005 007 0 01 4500 0 04 0 05 0 09 010 008 023 016 039 006 009 0 02 5000 0 05 0 06 012 040 027 020 047 0 07 01 0 02 5500 0 06 0 07 012 014 0 12 031 024 055 0 09 014 0 03 6000 0 06 008 014 017
57. 2 1852 Model Size Digits 4 6 Btu Hr Input 300 000 300 000 300 000 350 000 350 000 350 000 400 000 400 000 400 000 Btu Hr Output 240 000 240 000 240 000 280 000 280 000 280 000 320 000 320 000 320 000 Blower Style Digit 16 Letter EorF G orH I J or K EorF G orH I J or K l J or K Max Temp Rise F 100 100 100 100 100 100 100 Min Temp Rise F 37 31 20 45 37 22 25 Max CFM 6000 7250 11111 5700 7000 12000 12000 Min 2 2222 2963 2963 2963 Model Size Digits 4 6 Btu Hr Input 500 000 500 000 500 000 600 000 600 000 600 000 700 000 700 000 700 000 Btu Hr Output 400 000 400 000 400 000 480 000 480 000 480 000 560 000 560 000 560 000 Blower Style Digit 16 Letter I J or K I J or K Max Temp Rise F 120 120 Min Temp Rise F 40 40 Max CFM Min CFM 2 Model Size Digits 4 6 Btu Hr Input 800 000 800 000 800 000 1 050 000 1 050 000 1 200 000 1 200 000 Btu Hr Output 640 000 640 000 640 000 840 000 840 000 960 000 960 000 Blower Style Digit 16 Letter GorH I J or K L l J or K L I J or K L Max Temp Rise F 120 120 120 120 120 120 120 Min Temp Rise F 87 46 41 60 60 68 63 Max CFM Min CFM 2 D Ratings are shown for elevations up to 2000 ft For higher elevations the inp
58. 5 Refer to page 46 for Motor Type abbreviations ODP HE 89 5 ODP 18 9 1 4 82 0 72 0 ODP 18 12 3 4 81 0 75 0 87 5 88 5 84 0 70 0 18 12 84 0 82 096 ODP 84 0 89 5 18 9 85 0 77 0 ODP 18 12 86 0 78 0 87 5 88 5 85 0 85 0 18 12 85 0 80 0 or W1 7 1 2 ODP 4 81 5 Motors have thermal overload protection O1 C2 02 G9 Gd C2 CO C IO PO D AIR5 594 6 43 MOTOR DATA Table 44 1 Motor Data for Digit 14 E 230V 60HZ 3Ph Service Weight Efficiency i Frame ServiceWeight Efficiency Size Ibs 90 19 6 88 5 N A ODP HE 19 4 91 7 ODP 18 9 22 5 8 2 1 85 0 72 0 N A ODP 18 12 19 5 12 3 1 89 0 85 0 N A 20 0 89 5 19 2 91 7 82 5 21 0 8 8 1 87 0 75 0 84 0 18 12 20 0 12 4 1 86 0 80 0 4 1 76 0 59 0 ODP 26 8 5 89 5 ODP 18 12 4 2 74 0 60 0 25 2 91 7 TEFC N A ODP 18 9 32 4 11 6 1 88 0 77 096 TE HE 85 5 ODP 18 12 24 0 13 0 1 88 0 80 0 TEFC 18 9 4 1 76 0 58 0 26 0 89 596 TEFC 18 12 4 2 74 0 60 0 25 0 90 2 84 0 29 0 11 5 1 87 0 77 0 ODP 89 5 18 12 28 0 17 5 1 88
59. 8 Motor Starter OPT The motor starter is factory installed in the electrical section A motor starter is required for all three phase motors and single phase motors 2 Hp and greater The motor starter current set point dial is factory set to the motor full load amp draw listed on the motor nameplate The overload module of the motor starter is designed to trip to protect the motor from exceeding the nameplate amps If the motor exceeds the amp draw on the current set point dial the trip condition is indicated by a red color in the trip indicator window The motor starter can be placed in the automatic or manual reset positions Automatic reset is accomplished by depressing the RESET button and turning the button 1 4 turn When in the automatic reset position if the overload module trips the module will reset itself once the overload relay has cooled In the manual reset position if the overload module trips the RESET button must be depressed before the blower can operate The contractor module includes one 1 normally open auxiliary contact The contact rating is 10 amps 38 Variable Frequency Drive OPT The VFD controller adjusts the motor rpm to vary the unit air flow The minimum air flow may be varied between 30 and 10096 of the full speed air flow depending on the controls selection of the unit The control changeover options are two speed floating building pressure sensing and building management control If
60. AIR5 594 6 41 ELECTRICAL DATA Total Unit Amp Draw The total unit amp draw is a combination of the motor the control step down transformer and the power exhauster motor or step down transformer for 460V 3Ph or 575V 3Ph units The control step down transformer includes damper actuators ignition controllers gas valves control relays amplifiers and motor starters Motor Amp Draw Tables 42 1 to 46 1 Control Step Down Transformer Amp Draw Table 42 1 Power Exhauster Motor Amp Draw Table 42 1 Total Amp Draw Table 42 1 Control Step Down Transformer Amp Draws Control Step Down Digit 14 Transformer Amp Draw Digit 15 Transformer Model Size Supply Voltage PRI 2 4 75 175 200400 500 800 840 960 115 60 1 1 4 2 00 2 40 4 00 4 80 6 00 7 20 208 60 1 0 7 1 10 1 40 2 20 2 80 3 30 4 20 230 60 1 0 66 0 60 0 95 1 30 1 90 2 60 2 85 3 90 208 60 3 0 7 1 10 1 40 2 20 2 80 3 30 4 20 230 60 3 0 66 0 60 0 95 1 3 1 90 2 60 2 85 3 90 460 60 3 0 300 0 542 0 659 1 0891 39 1 63 2 0 575 60 3 0 249 0 432 0 529 0 879 1 1 1 304 1 69 When 2 amp draws are listed the first is for Outdoor units and the second is for Indoor Power Vented amp Separated Combustion units Amp draw is for 250 VA transformer Amp draw is for a 500 VA transformer Amp draw is for 750 VA transformer Amp draw is for a 1000 VA transformer Only include amp draw for gravity vented
61. C for propane gas Figure 22 2 Low or High Gas Pressure Switch 4 Power Exhauster Assembly STD The power exhauster is factory installed in the duct furnace section On a call for heat the power exhauster creates a combustion draft through the duct furnace prior to the pilot being energized The draft is proven through a differential pressure Switch that closes when the motor reaches full speed For information about venting refer to the Installation Venting section 5 Timed Freeze Protection The timed freeze protection system is factory installed in the duct furnace electrical junction box with the sensor 30 75 F adjustable factory installed in the discharge air stream On initial start up the timed delay in the system allows the unit to go through the normal ignition sequence The timed delay is an automatic reset switch and adjustable for 1 10 minutes In the event that the unit fails to fire after this period the discharge air sensor will sense the cold air and will shut down the entire unit Figure 22 3 Timed Freeze Protection Module 99 60 5 9 7 B Qus 65 4 8 TIME 9 g 35 39 75 2 10 1 1 3 2 MM 8 OF 82 lf nc lf Nt
62. CE 1 4 PER FOOT 24 TERMINAL ADJACENT BUILDING jj TERMINAL 16 MIN 1 24 MIN COMBUSTION AIR 7 TEE WITH DRIP LEG AND CLEANOUT CAP AT LOW POINT OF VENT SYSTEM SUPPORT BRACKET See Fig 9 2 for detail PITCH VENT PIPE DOWNWARD FROM APPLIANCE 1 4 PER FOOT C7 When horizontal vents pass through a combustible wall up to 8 inches thick the vent passage must be constructed and insulated as shown in Figure 9 2 C8 The vent must be supported as shown in Figure 9 2 C9 When condensation may be a problem the vent system shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators relief openings or other equipment Figure 9 2 Exhaust Vent Construction Through Combustible Walls and Support Bracket FIBER GLASSO INSULATIONO MIN 2 2 MIN VENT DIAMETER VENT TERMINATIONO SUPPORT BRACKETO where 0 Make from 1 x 1 steel angle C10 Maintain a 1 4 per foot downward slope away from the heater and place a drip leg with clean out near the exit of the vent as shown in Figure 9 1 or allow the condensate to drip out the end C11 For a vent termination located under an eave the
63. Digit 14 F 460V 60Hz 3Ph Frame Amp Size Draw Service Factor Weight Ibs Efficiency Digits 76 17818 6 5 Service Factor Weight Ibs Efficiency 90 2 TE N A TE 18 9 7 0 2 5 86 0 83 0 18 12 6 9 4 1 85 0 75 5 TEFC N A ODP 9 8 88 5 9 7 91 7 ODP 18 9 11 8 4 2 85 0 72 0 82 5 18 12 10 0 6 0 87 0 80 0 84 0 TE 10 0 89 5 ODP 18 9 76 0 59 0 9 6 91 7 ODP 18 12 74 0 60 0 18 9 10 0 4 1 84 0 74 0 18 12 10 3 5 6 85 0 80 0 TE HE 85 5 ODP 13 4 89 5 TEFC 18 9 73 0 58 0 ODP HE 12 6 91 7 18 12 74 0 60 0 ODP 18 9 15 0 5 3 83 0 71 0 84 0 ODP 18 12 12 0 6 3 87 0 82 0 89 5 TE 13 0 89 5 ODP 18 9 80 0 65 0 TE HE 12 5 90 2 ODP 18 12 75 0 71 0 TE 18 9 13 0 5 4 86 5 77 0 TEFC N A TE 18 12 13 5 7 5 87 0 82 0 TE HE 86 5 ODP 19 3 91 0 TEFC 18 9 83 0 71 0 ODP HE 18 9 93 0 18 12 80 0 72 0 ODP 18 9 19 3 7 8 88 5 81 5 84 0 ODP
64. E BY BUYER IN ANY UNCHANGED CONDITION OR WITHIN SIXTY SIX MONTHS FROM DATE OF SHIPMENT FROM SELLER WHICHEVER OCCURS FIRST Burners Low Intensity Infrared Units Other TWO YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER WITHIN TWO YEARS FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION OR WITHIN THIRTY MONTHS FROM DATE OF SHIPMENT FROM SELLER WHICHEVER OCCURS FIRST Components excluding Heat Exchangers Coils Condensers Burners Sheet Metal Heat Exchangers Coils Indoor and Outdoor Duct Furnaces and System Units PSH BSH Steam Hot Water Units Oil Fired Units Electric Units Cassettes Vertical Unit Ventilators Compressors Vertical Unit Ventilators Burners High Intensity Infrared Units Sheet Metal Parts All Products ONE YEAR FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER WITHIN ONE YEAR FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION OR WITHIN EIGHTEEN MONTHS FROM DATE OF SHIPMENT FROM SELLER WHICHEVER OCCURS FIRST As Modine Manufacturing Company has a continuous product improvement program it reserves the right to change design and specifications without notice AIREDALE air conditioning for every environment 2012 Modine Manufacturing Company Commercial Products Group Modine Manufacturing Company 1500 DeKoven Avenue Racine WI 53403 1 866 823 1631 toll free www airedaleusa com Litho in USA
65. Filters and Fresh Air Damper Heat exchanger and burner 409 Stainless Steel Gas Type Natural Gas Controls Electronic Modulating with Duct Sensing Supply Voltage 460V 60Hz 3Ph 10 Altitude 1000 feet With the information listed above the basic model using the Model Nomenclature shown on page 59 can be selected as shown in the following example 1 Determine the Model Configuration and Venting The Model Configuration is determined by the required sections of the unit Blower only and the venting style separated combustion that are obtained from item 5 Using the Model Nomenclature on page 59 the Model Configuration and Venting IBS 2 Determine the Furnace Input Rating MBH Using the Heating output capacity the Furnace Input Rating is determined from Table 30 1 The closest model to 324 000 Btu Hr output has an Btu Hr Input rating of 400 000 Btu Hr so the Furnace Input Rating 400 3 Determine the Heat Exchanger Burner Drip Pan Material From item Z2 in selection example conditions the Heat Exchanger and Burner required are 409 Stainless Steel Because the Drip Pan material is not specified the standard Aluminized Steel drip pan will be used Thus the Heat Exchanger Burner Drip Pan Material S 4 Determine the Development Sequence From item 8 in selection example conditions the modulating gas controls result in the Development Sequence M 5 Determine the Access Side From ite
66. LL OTHER REMEDIES PROVIDED BY LAW IS LIMITED TO REPAIR OR REPLACEMENT AT THE FACTORY OF SELLER ANY COMPONENT WHICH Applicable Models SHALL WITHIN THE APPLICABLE WARRANTY PERIOD DEFINED HEREIN AND UPON PRIOR WRITTEN APPROVAL BE RETURNED TO SELLER WITH TRANSPORTATION CHARGES PREPAID AND WHICH THE EXAMINATION OF SELLER SHALL DISCLOSE TO HAVE BEEN DEFECTIVE EXCEPT THAT WHEN THE PRODUCT IS TO BE USED BY BUYER AS A COMPONENT PART OF EQUIPMENT MANUFACTURED BY BUYER BUYER S REMEDY FOR BREACH AS LIMITED HEREIN SHALL BE LIMITED TO ONE YEAR FROM DATE OF SHIPMENT FROM SELLER FOR GAS FIRED PRODUCTS INSTALLED IN HIGH HUMIDITY APPLICATIONS AND UTILIZING STAINLESS STEEL HEAT EXCHANGERS BUYER S REMEDY FOR BREACH AS LIMITED HEREIN SHALL BE LIMITED TO TEN YEARS FROM DATE OF SHIPMENT FROM SELLER These warranties are issued only to the original owner user and cannot be transferred or assigned No provision is made in these warranties for any labor allowance or field labor participation Seller will not honor any expenses incurred in its behalf with regard to repairs to any of Seller s products No credit shall be issued for any defective part returned without proper written authorization including but not limited to model number serial number date of failure etc and freight prepaid OPTIONAL SUPPLEMENTAL WARRANTY Provided a supplemental warranty has been purchased Seller extends the warranty herein for an additional
67. Master furnace is provided with up to two Slave furnaces that utilize electronic modulating regulating gas controls combination gas valves ignition controls one multiple furnace modulating amplifier and either a modulating room thermostat or modulating duct thermostat with remote temperature adjustment The thermostat controls can modulate the gas flow of all the furnaces between 40 through 100 full fire The amplifier sends a signal to all of the gas valves so that they modulate at the same percentage When the thermostat is satisfied the amplifier cuts power to the combination gas valves which prevents gas flow to both the main and pilot burners When duct sensing is utilized a room override thermostat can be added When calling for heat the room override thermostat provides full fire operation until the space temperature is satisfied Control is then returned to the duct sensing control In this situation either the duct sensor or the room override thermostat can call for heat The sequence of operation for Electronic Modulating Gas Controls Two and Three furnaces is the same as Electronic Modulating Gas Controls Single Furnace Electronic Modulating Gas Controls Building Management Control 0 10 or 4 20 mA Signal Utilizes an electronic modulating regulating gas control combination gas valve an ignition control modulating signal conditioner and an inverted 0 Vdc or 4 mA being high fire and 10 Vdc or 20 mA be
68. OOR DISCONNECT SWITCH HANDLE OPERATION INSTRUCTION LABEL BLOWER SECTION DISCONNECT ELECTRICAL SWITCH HANDLE SHOWN IN THE POSITION COMPARTMENT STAND OFF PANEL SUPPLY POWER WIRING TERMINALS SEE WARNING DISCONNECT SWITCH HANDLE SHOWN IN THE OFF POSITION 17 Step Down Transformer Fuses OPT The transformer fuses are factory installed in the electrical section The fuses are included to protect the transformer Fuses included AIR5 594 6 23 OPTIONS 18 Step Down Transformer OPT The step down transformer is factory installed in the electrical section The transformer is only required for 460V 3Ph and 575V 3Ph When the supply power voltage is 460V 3Ph or 575V 3Ph the transformer is provided to step down from supply power voltage to 115 In this case the power exhauster motor operates at 115V 19 Factory Installed Minimum Positioner OPT The factory installed minimum positioner is installed in the electrical section and is used with a modulating damper actuator to set the minimum percentage of outside air The minimum positioner dial is manually set between 0 to 100 resulting in a 2 to 10 VDC signal being sent to the damper actuator When used in conjunction with the Proportional Temp Controller the positioner sets the minimum outside air percentage and the Proportional Temp Controller then modulates between the minimum position and 100 outside air
69. RESSION D ALIMENTATION 6 EN GAZ MIN ADMISE ANS Z83 8 TYPE GAs MANIFOLD PRESSURE 35 PRESSION ALA TUBULURE i D ALIMENTATION CGA 2 8 M86 TEMPERATURE RISE RANGE MAMM ETERNA IGN CONFORMS TO UL STD 1995 ELEVATION DE TEMPERATURE 20 100 PRESSION STATIQUE 3 IED TO CAN CSA C22 2 236 EXTERIEUR MAXIMUM D FOR USE IN BY THE WHEN EQUIPPED WITH IPI VENT CONNECTOR 6 IN CONNECTEUR DE VENTILATION 184 00 2000 IN CANADA VOLTS AIR THROUGHPUT OET 610 M 2000 TO 4500 FT 610 ET 1370 DEBIT D AIR INPUT BTU HR 1 80000 MIN 1 481 PHASE DEBIT CALORIFIQUE 200000 GPM BTU HEURE 05 OUTPUT BTU HR Listed RENDEMENT 160000 144000 7407 BTU HEURE 9900100 MIN VARIABLE GENERAL ORIFICE SIZE 23 26 SPEED CFM 1 FOR INDOOR INSTALLATIONS ONLY DIM DE LINJECTEUR 2 MINIMUM AMBIENT TEMPERATURE 40 F 2 FOR INSTALLATION DOWN STREAM OF REFRIGERATION SYSTEMS COMMON REPLACEMENT PARTS For parts ordering contact the parts wholesaler or the manufacturer s representative serving your area When inquiring about parts always provide model number serial number description and part number When ordering parts provide part number listed For service contact your local qualified installation and service contractor or utility company 5H73205 1 Comb Gas Valve 5H73696 Ignition Control Ass 3H34347 3 Pil
70. Range 3H35128B12 3H35128B14 491 649 586 744 682 821 821 1009 995 1161 1101 1285 Size 56 Sheave Assembly 3H35129B1 Digit 19 5 Assembly 3H35129B4 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly 143 or 145 3H35129B2 3H35129B5 3H35129B8 182 to 184 3H35129B3 3H35129B6 3H35129B9 3H35129B11 3H35129B15 213 or 215 3H35129B7 3H35129B10 3H35129B12 3H35129B16 3H35129B19 254 3H35129B13 3H35129B17 3H35129B20 256 3H35129B14 Table 39 4 Digit 16 2 K 18 18 Blower Units with 15 Hp motor amp up RPM Range Motor Frame Size 3H35129B18 826 1009 995 1161 1101 1285 1232 1438 Digit 19 Sheave Assembly 3H35130B1 Digit 19 Sheave Assembly 3H35130B3 Sheave Assembly 3H35130B5 Digit 19 Digit 19 Sheave Assembly 3H35130B2 3H35130B4 3H35130B6 3H35130B13 3H35130B15 3H35130B17 3H35130B19 Motor Frame 3H35130B14 3H35130B16 3H35130B18 RPM Range 3H35130B20 3H35129B21 491 649 626 765 765 901 901 1059 995 1161 1101 1285 Size 143 or 145 Sheave Assembly 3H36622B1 Sheave Assembly 3H36622B3 Sheave Assembly Digit 19 Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly 182
71. TION Do not attempt to reuse ignition controllers which have been wet Replace defective controller To check most of the Possible Remedies in the troubleshooting guide listed in Table 54 1 refer to the applicable sections of the manual Possible Cause Power supply is off No 24V power to thermostat Thermostat malfunction Defective power exhauster relay Defective power exhauster motor Main gas is off Power supply is off Air in gas line Dirt in pilot orifice Gas pressure out of proper range Pilot valve does not open a Defective ignition controller b Defective gas valve No Spark at ignitor a Loose wire connections b Pilot sensor is grounded c Defective ignition controller Safety device has cut power Defective valve Loose wiring Defective pilot sensor Defective ignition controller Improper thermostat wiring Too much primary air Main pressure set too high Orifice too large Insufficient primary air Dirty orifice Misaligned orifice Too much primary air Main pressure set too high Orifice too large 185 594 6 Possible Remedy Turn on main power Check control transformer Check replace thermostat Replace power exhauster relay Replace power exhauster motor Open manual gas valve Turn on main power Purge gas line Check for plugged pilot orifice and clean with compressed air if necessary Adjust to a maxi
72. TTINGS 1 4 PERIMETER GASKETED BLOWER CONNECTION CONVENIENCE OUTLET Locate the unit Model Identification Plate and note Digit 16 and Digit 19 of the model number Digit 16 is the Blower Size and Type and Digit 19 is the Sheave Arrangement Once the Blower Size and Type Digit 16 is known enter the proper Sheave Arrangement table Use the Sheave Arrangement Digit 19 to determine the Sheave Assembly provided Use Table 40 1 and the Sheave Assembly number to determine the required turns open to achieve the desired blower rpm Set the motor sheave as described in Blower Adjustments BLOWER DOOR SAFETY SWITCH BOTTOM SUPPORTED BLOWER AND MOTOR DIRECT DRIVE DAMPER ACTUATOR Blower Sheave Assembly Numbers Table 38 1 Digit 16 A or 9 7 Blower Units RPM Range Motor Frame 656 1001 978 1265 1150 1561 1526 1858 1763 2147 Size 48 Digit 19 Sheave Assembly 3H35125B1 Digit 19 Sheave Assembly Digit 19 3H35125B3 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly 56 3H35125B2 3H35125B4 3H35125B6 3H35125B8 3H35125B10 143 or 145 3H35125B5 3H35125B7 RPM Range 3H35125B9 3H35125B11 656 1001 978 1265 1150 1561 Motor Frame 1526 1858 1763 2147 Size 48 Digit 19 Sheave Assembly 3H35126B1 3H35126B3 Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19
73. The purpose of the air flow proving switch is to cut power to the gas controls if a positive pressure is not measured by the switch This could be caused by a lack of air movement through the heat exchanger NOTE The air flow proving switch will prevent any heat exchanger warm up because the gas controls can not be energized until air flow is proven Setting the Air Flow Proving Switch The range of the air flow proving switch is adjustable between 0 17 to 5 0 W C 1 Set the thermostat so that there is a call for heat This should fire the burner and the blower should start 2 the set screw of the pressure switch clockwise until it stops This will set the pressure at 5 0 W C 3 Turn the screw counter clockwise until the gas controls light and then one additional full turn This is approximately 0 25 W C This will allow for dirty filters or any other slight static pressure increases in the system 46 High Limit Switch Automatic STD The automatic reset high limit switch is factory installed in the duct furnace electrical junction box If the limit temperature is exceeded the gas controls are de energized until the switch is cooled Manual OPT The manual reset high limit switch is factory installed in place of the standard automatic reset high limit switch located in the duct furnace electrical junction box In case of a failure of the blower motor blockage of the inlet air etc the manual reset s
74. The unit continues to operate until the low stage thermostat is satisfied at which time both the main and pilot valves close 100 11 The time delay relay stops the blower after 30 to 45 seconds Electronic Modulating Gas Controls Single Furnace Model Sizes 75 400 Utilizes an electronic modulating regulating gas control combi nation gas valve an ignition control modulating amplifier and either a modulating room thermostat or modulating duct thermostat with remote temperature set point adjuster The thermostat controls can modulate the gas flow between 4096 through 100 full fire When the thermostat is satisfied the amplifier cuts power to the combination gas valve which prevents gas flow to both the main and pilot burners When duct sensing is utilized a room override thermostat can be added When calling for heat the room override thermostat provides full fire operation until the space temperature is satisfied Control is then returned to the duct sensing control In this situation either the duct sensor or the room override thermostat can call for heat 1 The thermostat calls for heat 2 The power exhauster relay is energized starting the power exhauster motor Once the motor has reached full speed the differential pressure switch closes The power exhauster relay pre purge timer closes after 20 to 40 seconds energizing the gas control circuit 3 The pilot valve opens and the spark ignitor sparks in an attempt to light
75. actuator provides open closed operation of the fresh air damper When the damper is energized the fresh air damper is opened to 100 outside air in 75 seconds For units with a two position damper limiter the outside air percentage would be the set by the damper limiter See Two Position Damper Limiter below All two position damper actuators are spring return so when the damper is de energized the fresh air damper will spring closed All two position dampers include auxiliary switches one normally open and one normally closed that reverse when the damper actuator is at 85 rotation adjustable Two Position Damper Limiter The two position damper limiter is factory set to prevent the outside air damper from opening 100 The outside air percentage and the actuator end switch is set based on the unit order Field adjustment of the two position damper limiter is accom plished by the following 1 Determine the amount of damper rotation required Percentage of outside air AIR5 594 6 OPTIONS 2 Locate the angle of rotation limiter on the actuator so that its edge lines up with the degree graduation on the actuator face which corresponds with the required rotation See Figure 25 1 which is shown at 50 rotation limit 3 Find the appropriate cross hair location through the slot of the limiter This is the screw mounting location 4 Pierce through the label material to allow easy fastening of the retaining screw 5 P
76. ained within the recommended values of 1 to 8 fps for Water and 1 to 6 fps for Glycol solutions Chilled fluid coils Initial Start Up 1 Open all air vents so that air is eliminated from within the coil circuitry and headers Verify that all vents and drains are not obstructed and do discharge a stream of water Fill the coil with water then close all vents Perform an initial hydrostatic leak test of all brazed threaded or flanged joints valves and interconnecting piping Recheck the coil level and correct if necessary When the setup is found to be leak free discharge and discard initial water charge It is important that all grease oil flux and sealing compounds present from the installation be removed Maintenance General 1 Filters should be inspected on a regular basis and changed as needed Maintaining clean filters is a cost effective way to help maintain maximum coil performance and service life Periodic inspection of the coil for signs of corrosion and for leaks is recommended For DX coils Small leaks can be detected using a Halide torch Repair and replacement of the coil and the connecting piping valves etc should be performed as needed by a qualified individual s Should the coil surface need cleaning caution should be exercised in selecting the cleaning solution as well as the cleaning equipment Improper selection can result in damage to the coil and or health hazards Clean the coil from the le
77. ainless steel side seals and santoprene blade seals are used 32 Proportional Temperature Controller Sensor OPT A proportional temperature controller sensor is provided with Air Control options GF GG GH GK GM or GN Digits 20 amp 21 and factory installed in the blower section The sensor provides the mixed air temperature signal to the A350P Proportional Temperature Controller which is mounted in the electrical section 33 Motor and Blower Vibration Isolation OPT The motor vibration isolation is factory installed in the blower section below the blower support bracket The four 4 13 32 neoprene vibration mount grommet provides isolation of the blower housing and motor from the blower support channels The blower vibration isolation is factory installed in the blower section between blower discharge and the blower duct connection The blower duct connection is not rigidly mechanically fastened and the 1 4 thick gasketing around the duct transition provides vibration isolation 34 Blower Support STD The blower supports are factory installed in the blower section The blower supports are used to rigidly support the weight of the blower and motor during operation and shipping 35 Convenience Outlet OPT WARNING Do not perform service on the convenience outlet without disconnecting its power supply The convenience outlet power supply is separate from main power supply to the unit When th
78. airflow Second Inlet on Dual Circuit Coils 4 1 gt Table 51 1 DX Coil Dimensions DX Single Circuit DX Dual Circuit Suction Liquid Suction Liquid 1 1 625 1 1 375 2 1 625 2 0 875 1 1 625 2 1 625 2 0 875 1 1 375 1 1 625 1 1 375 2 1 625 2 0 875 Cooling MBH 75 All 100 125 All 150 175 All Below 185 FH H te 1 1 625 1 1 375 2 1 625 2 0 875 27 345 1 2 125 1 1 375 30 37 33 1 1 625 1 1 375 250 300 28 5 38 75 31 5 2 1 625 2 0 875 375 1 2 125 1 1 375 amp Up 42 49 45 1 1 625 1 1 375 350 400 5 40 25 50 5 43 25 2 1 625 2 0 875 RA o 5 45 1 2 125 1 1375 Figure 51 2 Chilled Water Coil Drawing dimensions in inches Airflow Direction Rows 4 6 w 175 10 La TOP VIEW Eq 4 4 ae 415 15 gt 4 18 31 Water Line Connection turned 90 in 4 4 dn direction of airflow Coil for Right Hand Units Digit 5 E 2 25 4 5 ite side f SIDE VIEW leaders on opposite side for Left Hand Units FRONT VIEW H 2 25 Supply Water Line Connection turned 90 in lo 4 direction of airflo
79. ance into a masonry chimney Do NOT use dampers or other devices in the vent or combustion air pipes The venting system must be exclusive to a single appliance and no other appliance is allowed to be vented into it Precautions must be taken to prevent degradation of building materials by flue products Single wall vent pipe must not pass through any unoccupied attic inside wall concealed space or floor Uninsulated single wall vent pipe must not be used outdoors for venting appliances in regions where the 99 winter design temperature is below 32 F Long runs of horizontal or vertical combustion air pipes may require insulation in very cold climates to prevent the buildup of condensation on the outside of the pipe where the pipe passes through conditioned spaces AIR5 594 6 A20 Vent termination clearances must be maintained Table 7 1 Vent Termination Clearances Minimum Clearances for Structure Vent Terminal Location Forced air inlet within 10 feet 3 feet above Combustion air inlet of another 6 feet all directions appliance 4 feet horizontal and below 1 foot above Door window gravity air inlet or any building opening Electric meter gas meter gas regulator and relief equipment 4 feet horizontal U S 6 feet horizontal Canada 3 feet horizontal U S Gas 6 feet horizontal Canada Adjoining building or parapet wall 6 feet all directions
80. ance or hazard or could be detrimental to the operation of regulators relief openings or other equipment 9 INSTALLATION VENTING D5 The adapter box can be mounted flush to the wall for horizontal kits or to the ceiling for vertical kits The box can also be offset from the wall or ceiling by using field supplied brackets When mounting the box consider serviceability and access to the vent and combustion air pipes If the box is to be mounted using field supplied brackets these brackets must be strong enough to rigidly secure the box to the wall or ceiling and should be made from corrosion resistant material D6 Determine the length of the vent pipe and combustion air inlet pipe for the selected location THE VENT PIPE WILL PASS THROUGH THE CONCENTRIC VENT BOX THE LAST SECTION OF VENT PIPE IS A CONTINUOUS LENGTH OF DOUBLE WALL B VENT See section A12 for attaching and terminating double wall pipe Begin with pipe lengths on the concentric pipe side of the adapter box referring to Figure 10 1 These pipes will extend through the building wall or roof as well as any added length for the thickness of the wall and the offset from any field installed brackets For Vertical Concentric Vent Kits refer to Figure 9 3 The bottom of the combustion air intake pipe must terminate above the snow line or at least 12 inches above the roof whichever distance is greater The bottom of the vent cap must terminate at lea
81. arts list may be obtained by contacting Modine Manufacturing Company Refer to the rating plate on the appliance for complete appliance model number serial number and company address Any substitution of parts or controls not approved by Modine will be at the owners risk A CAUTION 1 The concentric vent adapter box must be installed inside of the structure or building Do not install this box on the exterior of a building or structure 2 Purging of air from gas lines should be performed as described in ANSI 7223 1 latest edition National Fuel Gas Code or in Canada in CAN CGA B149 codes 3 Ensure that the supply voltage to the appliance as indicated on the serial plate is not less than the rated voltage 4 Do not attempt to reuse ignition controllers which have been wet Replace defective controller IMPORTANT 1 To prevent premature heat exchanger failure do not locate ANY gas fired appliances in areas where corrosive vapors i e chlorinated halogenated or acid are present in the atmosphere 2 To prevent premature heat exchanger failure the input to the appliance as indicated on the serial plate must not exceed the rated input by more than 5 3 To prevent premature heat exchanger failure observe heat exchanger tubes by looking at the heat exchanger through the field installed access openings in connecting ductwork in cooling package units or the unit access doors in blower package units If the b
82. as Code ANSI Z223 1 NFPA 54 Latest Edition In Canada installation must be in accordance with CAN CGA B149 1 for natural gas units and CAN CGA B1 49 2 for propane units 2 Piping to units should conform with local and national requirements for type and volume of gas handled and pressure drop allowed in the line Refer to Table 18 1 to determine the cubic feet per hour cfh for the type of gas and size of unit to be installed Using this cfh value and the length of pipe necessary determine the pipe diameter from Table 11 1 Where several units are served by the same main the total capacity cfh and length of main must be considered Avoid pipe sizes smaller than 1 2 Table 11 1 allows for a 0 3 W C pressure drop in the supply pressure from the building main to the unit The inlet pressure to the unit must be 6 7 W C for natural gas and 11 14 W C for propane gas When sizing the inlet gas pipe diameter make sure that the unit supply pressure can be met after the 0 3 W C has been subtracted If the 0 3 W C pressure drop is too high refer to the Gas Engineer s Handbook for other gas pipe capacities 3 The gas piping to the unit can enter the unit from the side of the unit or from below Install a ground joint union with brass seat and a manual shut off valve external of the unit casing and adjacent to the unit for emergency shut off and easy servicing of controls including a 1 8 NPT plugged tapping accessible for test gauge
83. astening 4 5 6 7 5 8 5 and 10 deep coils When obtaining the specifications from a coil manufacturer it is important to obtain the pressure drop through the coil so that the proper motor horsepower can be selected For Both Chilled Water and Direct Expansion Coils The condensate drain line needs to include a P trap immediately downstream of the connection to the unit This trap should extend at least two inches below the connection to prevent air pressure from forcing air into the unit The trap should be primed with a water glycol solution to prevent freezing All points where refrigerant water or condensate lines enter the structure should be sealed and vibration dampened Include shut off valves to isolate the cooling coil from the system in order to remove the coil for service or replacement without draining the entire system For additional guidelines refer to the ASHRAE Fundamentals Handbook section of piping recommendations DX Single Circuit DX Dual Circuit Chilled Water Coil Area CFM Sq Ft Coil Area CFM Sq Ft Coil Area Sq Ft Max CFM Max Cooling Tons 2 3 DX Chilled Coils Water Coils Min CFM All Units D Based on 550 feet per minute FPM coil face velocity 2 1 12 000 Btu Hr 8 Based on 95 F Entering Dry Bulb 75 F Entering Wet Bulb Model Size 75 listed for Chilled Water DX Single C
84. aving air side so that foreign material will be washed out of the coil rather than pushed further in Be sure to carefully read and follow the cleaning fluid manufacturer s recommendations before using any cleaning fluid For DX coils the use of filter dryers in the system piping is recommended along with a sight glass that has a moisture indicator Replace the filter dryer s as needed For chilled fluid coils A Maintain the circulated fluid free of sediment corrosive products and biological contaminants Periodic testing of the fluid followed by any necessary corrective measures along with maintaining adequate fluid velocities and proper filtering of the fluid will help to satisfy this goal B Automatic air vents must be utilized to remove accumulated air AIR5 594 6 C Freeze Protection During the winter chilled water coils need to be protected against freezing The two predominant protective measures are 1 Blowing out the coils with air or 2 Flushing coils with inhibited glycol It is recommended to use inhibited glycol designed for HVAC applications for corrosion protection Select an inhibited glycol solution that will protect the coil from the lowest possible temperatures that can occur at the particular coil s locality 15 START UP PROCEDURE START UP PROCEDURE IMPORTANT 1 To prevent premature heat exchanger failure observe heat exchanger tubes by looking at the heat exchanger through the field installed ac
85. cess openings in connecting ductwork in blower package units or the unit access doors in cooling package units If the bottom of the tubes become red while blower and duct furnace are in operation check to be sure the blower has been set to the proper rpm for the application Refer to page 18 for Blower Adjustments 2 Start up and adjustment procedures should be performed by a qualified service agency 1 Turn off power to the unit at the disconnect switch Check that fuses or circuit breakers are in place and sized correctly Turn all hand gas valves to the OFF position 2 Remove the duct furnace and blower exterior panels and open the electrical compartment door 3 Check that the supply voltage matches the unit supply voltage listed on the Model Identification plate Verify that all wiring is secure and properly protected Trace circuits to insure that the unit has been wired according to the wiring diagram 4 Check to insure that the venting system is installed and free from obstructions 5 Check to see that there are no obstructions to the intake and discharge of the unit 6 Check the belt tension and sheave alignment Refer to Blower Adjustments for proper belt tension 7 Check bearings for proper lubrication For units provided with pillow block bearings See Model Nomenclature refer to Lubrication Recommendations for lubrication requirements 8 Check to make sure that all filters are in place and that they
86. continuous retry On a call for heat the system will attempt to light the pilot for 70 seconds If the pilot is not sensed for any reason the ignition control will wait for approximately six minutes with the combination gas control closed and no spark After six minutes the cycle will begin again After three cycles some ignition controllers lockout for approximately one hour before the cycle begins again This will continue indefinitely until the pilot flame is sensed or power is interrupted to the system 7 Differential Pressure Switch STD The differential pressure switch is factory installed in the duct furnace electrical junction box The differential pressure switch monitors the pressure differential between the duct furnace vent discharge and the atmosphere The purpose of the differential pressure switch is to cut power to the gas controls if a positive vent pressure is not measured by the switch This could be caused by a blocked combustion air inlet vent pipe 8 Control Relay OPT The control relay is factory installed in the duct furnace electrical junction box The relay has a 24V coil with double pole double throw DPDT contacts Refer to the unit wiring diagram for the AIR5 594 6 OPTIONS function of the switching operation of the relay The two normally open and two normally closed contacts are rated for a maximum of 30 amps 115V 1Ph 9 Time Delay Relay STD The time delay relay is factory in
87. cy G Single phase motors 1 1 2HP and smaller feature integral thermal overload protection 2HP and larger require external protection The optional motor starter for those sizes provides overcurrent protection Table 43 2 Motor Data for Digit 14 D 208V 60Hz 3Ph Digits Frame ServiceWeight Efficiency igi i Frame Weight 96 Factor AlorL1 1 3 22 3 91 7 5 15 1 3 48 1 2 1 00 15 N A ODP 18 9 23 0 9 3 85 0 72 0 1 1 2 87 0 75 0 86 0 80 0 ODP 18 9 51 76 0 59 096 ODP 18 12 4 2 74 0 60 0 N A TE HE 84 5 TEFC 18 9 76 0 58 0 18 12 271 74 0 60 0 29 0 11 5 87 0 77 0 80 0 18 12 30 0 17 0 _1 88 0 80 0 ODP 3 89 5 ODP 45 6 3 87 5 ODP 18 9 0 2 80 0 65 0 ODP HE 43 4 3 93 0 ODP 18 12 0 2 80 0 71 0 18 9 42 5 16 5 1 90 2 84 0 TEFC N A 42 0 i 91 0 TE HE 5 84 0 40 3 91 7 TEFC 18 9 83 0 71 0 44 0 16 0 A 88 0 82 0 TEFC 18 12 10 2 80 0 72 0 TE 18 12 i 88 0 84 0 ODP 82 0 87 5 ODP 89 5 93 6 ODP 18 9 2 2 81 0 67 096 ODP 18 9 90 2 82 5 ODP 18 12 5 3 81 0 NA ODP 18 12 89 0 86 0 i 84 0 86 5 TE 18 9 TEFC 18 9 4 2 84 0 70 096 TE 18 12 4 3 84 0 77 0 81
88. e dampers to maintain between 50 F and 56 F at the sensor The enthalpy controller contains a minimum position adjustment and an enthalpy changeover set point that must be field set Figure 25 2 Enthalpy Controller ENTHALPY CHANGEOVER SETPOINT MINIMUM DAMPER POSITION SETTING W7210 A 1001 LED LIGHTS WHEN OUTDOOR AIR IS SUITABLE FOR FREE COOLING M11162A AIR5 594 6 25 OPTIONS Minimum Position Adjustment The minimum position adjustment keeps the outdoor air damper from closing completely during system operation to provide ventilation in both the heating and cooling modes To set the minimum position adjustment 1 Disconnect mixed air sensor from terminals T and T1 on the enthalpy controller 2 Make sure the factory installed jumper is in place across terminals P and P1 3 Connect 24 Vac across terminals TR and TR1 4 Adjust the minimum position adjustor with a screwdriver for the desired minimum position Figure 26 1 Enthalpy Changeover Set Point Control Points 85 90 95 100 105 110 29 32 35 38 41 43 90 9 2 4 7 10 13 16 18 21 24 27 29 32 35 38 41 43 APPROXIMATE BULB TEMPERATURE F T 11160 HIGH LIMIT CURVE FOR W6210D W7210D Qutdoor Enthalpy Changeover Set Point The outdoor enthalpy changeover set point returns the outdoor air damper to the minimum position when the enthalpy rises
89. e main disconnect switch is de energized the convenience outlet power supply remains energized The convenience outlet is factory installed in the blower section for providing power for 115V service equipment trouble light power tools etc The 115V ground fault circuit interrupter GFCI is rated for 15 amps and includes test and reset switches A separate field supplied 115V 1Ph power supply must be routed through the electrical section wall into the back of the convenience outlet junction box 36 Blower Door Switch OPT The blower door switch is factory installed inside the blower section door on the access side of the unit When the blower section door is removed the momentary switch is released and interrupts power to the low voltage circuit For single phase units 1 1 2 Hp and less the door switch de energizes a relay that controls blower motor operation For three phase units and single phase units 2 Hp and greater the door switch de energizes the motor starter that controls blower motor operation AIR5 594 6 OPTIONS For servicing the switch is equipped with an override position that can be manually pulled out to override the switch See Figure 27 1 Figure 27 1 Blower Door Switch with Manual Override REST POSITION OVERRIDE POSITION OPERATING POINT COM NC NO 37 Dirty Filter Switch OPT The dirty filter pressure switch is factory installed in the electrical sect
90. ection titled Installation Gas Connections Figure 8 1 Vertical Venting 2 Pipes Sloped Roof 16 PO MIN CHAPEAU CHAPEAU D ADMISSION HOMOLOGUE D AIR HOMOLOGUE H MIN VOIR TABLEAU 8 1 POUR LA DIMENSION H l H MIN E MERO IE SOLIN PENTE DU TOIT X 12 DE TOIT UTILISEZ UN MANCHON IL FAUT TENIR COMPTE HOMOLOGUE POUR DE LA COUCHE DE TOUTE TRAVERS E DE NEIGE PR VISIBLE PLAFOND OU DE TOIT DAS 5 6 gt o o 5 a lt Nod ao TE AVEC COLLECTEUR DE CONDENSATS ET REGARD DE 12 PO RECOMMAND Table 8 1 Minimum Height from Roof to Lowest Discharge Opening Rise X in Roof Pitch Min Height H ft 0 6 Flat to 6 12 1 00 6 7 6 12 to 7 12 1 25 7 8 7 12 to 8 12 1 50 8 9 8 12 to 9 12 2 00 9 10 9 12 to 10 12 2 50 10 11 10 12 to 11 12 3 25 11 12 11 12 to 12 12 4 00 12 14 12 12 to 14 12 5 00 14 16 14 12 to 16 12 6 00 16 18 16 12 to 18 12 7 00 18 20 18 12 to 20 12 7 50 20 21 20 12 to 21 12 8 00 Size according to expected snow depth Figure 8 2 Vertical Venting 2 Pipes Flat Roof CHAPEAU HOMOLOGUE 24 PO MIN 16 PO MIN JUSQU AU MUR OU N AU B TIMENT ADJACENT
91. ents will remain energized Figure 28 2 Service Switches SYSTEM OVERRIDE SWITCH POSITIONS DAMPERS ONLY ON OFF OFF qq DAMPERS amp BLOWER ONLY ON OFF 58 DAMPERS BLOWER amp FURNACE ONLY ON ON ON 09 RESET SWITCHES OFF POSITION AFTER TESTING 28 43 Electronic Modulating Gas Valve OPT An electronic modulating gas valve is provided factory installed in the duct furnace gas train when the unit is equipped with Electronic Modulating Gas Controls Digit 12 4 5 6 7 or 8 The gas valve modulates the firing rate between 40 to 100 full fire based on the input signal from the Electronic Modulation Amplifier or Signal Conditioner For additional information refer to Control Operating Sequence 44 Electronic Modulation Amplifier OPT An electronic modulation amplifier is provided factory installed in the duct furnace electrical junction box when the unit is equip ped with Electronic Modulating Gas Controls Digit 12 4 or 5 The amplifier processes the thermostat temperature and set point signals to modulate the firing rate between 40 to 100 full fire For additional information refer to Control Operating Sequence 45 Air Flow Proving Switch OPT The air flow proving switch is factory installed in the duct furnace electrical junction box The air flow proving switch monitors the pressure differential between the duct furnace and the atmosphere
92. er b Remove all wires from duct furnace terminal 43 and remove cover plate 2 c Turn on power at the disconnect switch d Remove the maximum adjustment screw 4 spring b and plunger 8 A small magnet is useful for this purpose CAUTION The plunger is a precision part Handle carefully to avoid marring or picking up grease and dirt Do not lubricate e Using minimum adjusting screw 9 adjust low fire manifold pressure to 0 56 W C for natural gas and 1 6 W C for propane gas f Replace plunger and spring retainer spring and maximum adjusting screw in proper order g Using maximum adjustment screw 4 adjust high fire manifold pressure to 3 5 W C for natural gas and 10 W C for propane gas h Disconnect power i Replace cover plate 2 and re install all wires from duct furnace terminal 43 7 After adjustment move the field installed manual shut off valve to the OFF position and replace the 1 8 pipe plug 8 After the plug is in place move the field installed manual shut off valve to the ON position and recheck pipe plugs for gas leaks with soap solution Figure 17 2 Checking Manifold Pressure with U Tube Manometer TOP HOUSING COVER PLATE SEAL GASKET MAXIMUM ADJUSTMENT SCREW MAXIMUM ADJUSTMENT SPRING SOLENOID MINIMUM ADJUSTMENT SPRING PLUNGER MINIMUM ADJUSTMENT SCREW MINIMUM ADJUSTMENT SCREW STOP 23 Air Shutt
93. er Adjustment Proper operation provides a soft blue flame with a well defined inner core A lack of primary air will reveal soft yellow tipped flames Excess primary air produces short well defined flames with a tendency to lift off the burner ports For both natural and propane gas the air shutters can be adjusted to control the burner flame height The air shutters can be accessed by reaching behind the manifold tee shown in Figure 17 2 The larger models may require the removal of the manifold see Manifold Assembly Removal AIR5 594 6 17 START UP PROCEDURE Natural Gas Flame Control Control of burner flames on duct furnaces utilizing natural gas is achieved by resetting the primary air shutters See Figure 53 2 to either increase or decrease primary combustion air Prior to flame adjustment operate duct furnace for about fifteen minutes The main burner flame can be viewed after loosening and pushing aside the gas designation disc on the side of the burner box To increase primary air loosen the air shutter set screws and move the air shutters closer to the manifold until the yellow tipped flames disappear See Figure 53 2 for air shutter and heat exchanger support locations To decrease primary air move the air shutters away from the manifolds until flames no longer lift from burner ports but being careful not to cause yellow tipping Retighten set screws after adjustment Propane Gas Flame Control An optimum flame wi
94. er Bearings under 15 Hp D 9 9 Pillow Block Bearings J 18 18 Pillow Block Bearings under 15 Hp E 12 12 Spider Bearings 18 18 Pillow Block Bearings for 15 Hp amp up F 12 12 Pillow Block Bearings 20 18 Pillow Block Bearings 17 Motor Horsepower HP 1 3 Hp L 1 3 Hp with Motor Starter 1 2 Hp M 1 2 Hp with Motor Starter 3 4 Hp 3 4 Hp with Motor Starter D 1Hp P 1Hp with Motor Starter E 1 1 2 Hp Q 1 1 2 Hp with Motor Starter F 2Hp R 2 Hp Hp with Motor Starter G 3 Hp 5 3 Hp with Motor Starter H 5 Hp T 5 Hp with Motor Starter 7 1 2 Hp W 7 1 2 Hp with Motor Starter J 10 Hp X 10 Hp with Motor Starter K 15 Hp 15 Hp with Motor Starter V 20 Hp 2 20 Hp with Motor Starter 18 Motor Type MT 1 ODP 5 TE 2 ODP High Eff 6 High Eff 3 ODP 1800 900 RPM 7 TE 1800 900 RPM 4 ODP 1800 1200 RPM 8 TE 1800 1200 RPM 19 Sheave Arrangement SA See Sheave Tables 20 21 Air Control AC AA RA Opening BA FA Opening CA FA amp RA Openings DA FA Dampers w 2 pos motor No RA EA FA amp RA Dampers w 2 pos motor EQ ASHRAE Cycle EA with Warm up Stat FA FA Damper amp RA Opening w 2 pos motor GA 8 motor w 0 10 External Input GB FA amp RAMod motor w 4 20 mA External Input GC FA amp RA Mod motor w Minimum Position GD FA amp RA Mod motor w Remote Position On Remote
95. fier Air Flow Proving Switch High Limit Switch Main Gas Valve Supply Air Fire Stat Burner Box All units include the standard STD features The unit must be reviewed to determine the optional OPT features that may have been supplied with the unit 1 Discharge Thermostat OPT The discharge thermostat is factory installed in the discharge air stream of the unit For additional information refer to the thermostat vendor literature provided in the literature packet with the unit Note Model Sizes 500 960 contain multiple furnaces so multiple thermostats sensors may be included Figure 21 2 Two Stage Capillary Type Thermostat The thermostat s provided can be one of the following a Two stage Capillary Type Thermostat The thermostat includes a thermostat body that is factory installed below the unit junction box The thermostat body contains the b discharge air set point adjuster that must be field set Two stage Electronic Thermostat Includes a factory installed discharge air sensor The thermostat body is field installed remotely and includes the discharge air set 5 577 point adjuster that must be field set Refer to Literature Figure 21 3 Two Stage Electronic Thermostat Box Setpoint Adjuster Duct Furnace Electrical Control KE Right 9
96. from obstructions for proper operation For Right Hand units Digit 9 R during operation the blower wheel should rotate in the clockwise direction when viewed from the service side of the unit For Left Hand units Digit 9 L during operation the blower wheel should rotate in the counterclockwise direction when viewed from the service side of the unit If necessary interchange supply power wiring to reverse blower rotation 24 24 Pillow Block Bearings OPT The blower bearings are factory installed in the blower section The blower can be provided with either spider or pillow block bearings Spider bearings are permanently lubricated and do not require lubrication Pillow block bearings are shipped non greased from the factory and require lubrication before start up For lubrication recommendations see Lubrication Recommendations 25 Blower Motor STD The blower motor is factory installed in the blower section The blower motor can be provided in a variety of supply voltages frame types and motor horsepowers Refer to the model nomenclature to determine the type of motor provided The blower motor is supplied with an adjustable sheave that can be used to increase decrease the blower RPM For instructions on changing the blower RPM refer to Blower Adjustments 26 Filters OPT When filters are supplied with the unit a rack and the filters are factory installed in the blower section The unit can be supplied
97. gnal conditioner converts the input signal into a DC voltage 0 to 12 volts DC with O volts high fire and 12 volts low fire The output voltage is applied to the modulating gas valve to control the gas flow to the main burner As the temperature drops the voltage drops causing the modulating valve to open further If the discharge air temperature increases the voltage increases causing the modulating valve to close allowing less gas flow to the main burner For further information regarding the operation of the electronic modulating system consult the literature provided with the unit 20 m 8 The unit continues to operate in this manner until the thermostat is satisfied at which time the BMS heat contact opens resulting in both the main and pilot valves closing 100 If the unit was not provided with a time delay relay the blower stops at this time 9 The time delay relay stops the blower after 30 to 45 seconds Variable Air Movement Applications Units may be supplied with variable frequency drives for applications where variable air volume is required The minimum air flow may be varied between 30 and 100 of the full speed air flow depending on the controls selection of the unit Due to the extra restrictions of the controller all selections must be performed with Accuspec configuration software Within Accuspec three variable frequency drive speed control changeover options are available 1 Two speed which
98. gs are shipped greased from the factory but will require lubrication The bearings should be checked and lubricated before each heating season but a more frequent lubrication schedule may be required based on the environment in which the unit is installed and the frequency of the equipment operation Shell Alvania 2 lubricant is recommended AIR5 594 6 START UP PROCEDURE Damper Linkage Adjustment If the unit is provided with a return air damper to prevent shipping damage the return air damper linkage is disconnected and the damper closed Before operating the unit the fresh and return air dampers must be connected This is accomplished by the following 1 The damper actuator should be de energized and the fresh air damper in a fully closed position 2 Open the return air damper in a fully open position 3 Slide the connecting rod into the ball joint on the blade arm with the return air damper fully open See Figure 19 1 4 Tighten the 5 16 hex head screw on the ball joint Figure 19 1 Damper Linkage Adjustment Connecting Rod Ball Joint Blade Arm Damper Blade Control Operating Sequence Indoor separated combustion units are supplied with intermittent pilot ignition systems These systems are offered with 100 shut off with continuous retry for operation on natural gas and propane gas On all systems both the main burner and pilot burner are turned off 100 when the thermostat is satisfied
99. gure 14 1 General Chilled Fluid Piping Air Vent d Vent Plug Gate Valve Tee Supply Drain Plug Dirt Union Cap 1 Onceinstalled the coil should be pressurized to 100 psig with dry nitrogen or other suitable gas The coil should be left pressurized for a minimum of 10 minutes If the coil holds the pressure the hook up can be considered leak free If the pressure drops by 5 psig or less re pressurize the coil and wait another 10 minutes If the pressure drops again there is more than likely one or more small leaks which should be located and repaired Pressure losses greater than 5 psig would indicate a larger leak that should be isolated and repaired If the coil itself is found to be leaking contact your local factory representative AIR5 594 6 UNIT INSTALLATION All field brazing and welding should be performed using high quality materials and an inert gas purge such as nitrogen to reduce oxidation of the internal surface of the coil All field piping must be self supporting System piping should be flexible enough to allow for thermal expansion and contraction of the coil Operation General All coils 1 Proper air distribution is vital to coil performance Air flow anywhere on the coil face should not vary by more than 20 Air velocities should be maintained between 200 and 550 feet per minute For chilled fluid coils fluid velocities should be maint
100. he system is ready to be charged or refrigerant pumped down in another portion of the system can be opened to the coil 14 A steady rise in microns would indicate that moisture is still present and that the coil should be further vacuumed until the moisture has been removed 9 Failure to obtain a high vacuum is indicative of a great deal of moisture or a small leak Break the vacuum with a charge of dry nitrogen or other suitable gas and recheck for leaks soapy water works well If no leaks are found continue vacuuming the coil until the desired vacuum is reached 10 All field piping must be self supporting Chilled Fluid Piping To prevent noise within a system an air vent is necessary to bleed off the accumulated air in the system The vent should be located on the top of the inlet manifold where the air collects This vent should be opened twice a year Air in the system will generate noise and may cause water hammer than can damage the joints of the piping and the cooling coil The outlet manifold should have a drain installed on the bottom of the manifold to allow for periodic flushing of the system to remove sediments and corrosion products from the cooling coil This drain should be opened to allow some fluid to drain twice a year Check coloration and viscosity of the effluent for indications of corrosion in the system The lines between the unit and the structure should be insulated to prevent freezing of the water Fi
101. hen gas controls are energized Adjust belt tension Check correct blower drive settings for proper rpm Check correct venting system g Replace air distribution baffle h Replace high limit switch Adjust main gas pressure Minimum for Natural Gas 6 W C Minimum for Propane Gas 11 W C Adjust outside air damper to decrease outside air percentage if possible Check replace thermostat Check unit wiring against the wiring diagram Check design conditions If unit is undersized an additional unit s or other heat source must be added Check replace thermostat a Check unit wiring against the wiring diagram b Check for loose or worn wires Adjust to a maximum of 14 W C Replace gas valve Figure 55 1 Lifting Flame Condition 0990000000000 during normal operation refer to the Not Enough Heat section of Service amp Troubleshooting Figure 55 2 Figure 55 3 Floating Flame Condition Flame Rollout Appearance AIR5 594 6 55 MODEL DESIGNATIONS Model Identification Indoor duct furnace make up air units contain CSA and ETL ETL Canada certified indoor separated combustion duct furnace s This duct furnace is combined with either a blower section or a blower and cooling section to make a complete make up air or heating ventilating cooling unit that is ETL ETL Canada certified For this reaso
102. hould be checked annually for general cleanliness and tightness The gas control should be checked to insure that the unit is operating properly Manifold Assembly Removal To remove the manifold 1 Shut off gas and electric supply 2 Remove the burner side access panel 3 Disconnect gas manifold at ground union joint 4 Remove the two screws holding the manifold to the heat exchanger support Slide the manifold through the manifold bracket Clean the orifices and adjust the air shutters as necessary 7 Follow steps 3 6 in reverse order to install the manifold assembly Turn on the electric and gas supply 9 Check the ground union joint for leaks with a soap solution Tighten if necessary 10 Install the burner side access panel Figure 53 2 Manifold Assembly Removal SERIAL PLATE ON OUTSIDE OF DOOR NOT SHOWN BURNER SIDE ACCESS PANEL HEAT EXCHANGER SUPPORT MANIFOLD Burner and Pilot Assembly Removal To remove the burner 1 Shut off gas and electric supply 2 Remove the burner side access panel 3 Disconnect the pilot supply line from the gas valve 4 Disconnect the ignition cable from the ignition controller located in the electrical junction box Feed the cable through the bushing in the bottom of the electrical junction box 5 Remove the screws holding the burner side access panel Attached to the panel are the burner retaining pins that align the burner
103. i Exhaust OY CX For Horizontally Vented Units Refer to Figure 9 4 Concentric adapter assembly same for horizontal and vertical kits Special vent termination cap part 5H75150 Special inlet air guard Figure 9 4 Horizontal Concentric Vent Kit Components Concentric 14 Min Outlet Vent Vent Adapter Termination Cap N Combustion Air Intake Guard 4 amp Building Side Wall A CAUTION The concentric vent adapter box must be installed inside of the structure or building Do not install this box on the exterior of a building or structure D3 Once the kit contents have been verified as correct for the direction of venting the concentric vent adapter box is to be installed Determine the location of the box Be sure to maintain all clearances as listed in these instructions D4 The adapter box is to be mounted on the interior side of the building It must not be mounted outside the building The adapter box has integral mounting holes for ease of installation When horizontal venting multiple units the minimum spacing between any sides of the adapter boxes must be 18 and boxes must not overlap in the vertical plane above or below When condensation may be a problem the vent system shall not terminate over public walkways or over an area where condensate or vapor could create a nuis
104. ial number ready from the unit s AIR5 594 6 57 START UP CHECKLIST INDIRECT GAS FIRED HEATING EQUIPMENT Job Name Date Address Model No City amp State Order No Start Up Check List ALL ITEMS MUST BE CHECKED Serial No All shipping straps braces tie downs removed Unit installed level and secure Gas burner properly located and aligned Blower and motor alignment okay Bearings aligned and tight on shaft bearing supports Electrical connections checked and secure Gas piping checked and tightened if necessary Any visible damage to unit Describe If damaged was the damage repaired Air inlet and discharge checked for obstructions Bearings checked for proper lubrication Filters in place and correct to direction of air flow Belt tension checked Electric supply to unit Volts Hz Phase Gas supply to unit _ Natural Propane gy Gas supply pressure to unit W C PSIG Inlet and or discharge dampers operating correctly Blower rotation correct Blower speed ______ Lo Speed RPM Motor speed Hi Speed RPM Lo Speed Is unit noisy Excessive vibration Motor 1 ______ 12 V L3 V Motor amps L1 _ 2 Ampl3 Amp High temperature limit control continuity checked Burner light off Low Fire Does entire burner light off Hi Fire Burner
105. ing low fire 0 10 or 4 20 mA input signal provided by a Building Management System BMS The signal conditioner can modulate the gas flow between 40 through 100 full fire When the BMS thermostat field supplied is satisfied the BMS heat contact field supplied opens to cut power to the combination gas valve which prevents gas flow to both the main and pilot burners 1 The BMS thermostat field supplied calls for heat and closes the BMS heat contact field supplied 2 The power exhauster relay is energized starting the power exhauster motor Once the motor has reached full speed the differential pressure switch closes The power exhauster relay pre purge timer closes after 20 to 40 seconds energizing the gas control circuit The pilot valve opens and the spark ignitor sparks in an attempt to light the pilot Once the pilot is lit the flame sensor proves the pilot and stops the spark ignitor from sparking The main gas valve is opened and the main burner is lit to 100 full fire The time delay relay starts the blower after 30 to 45 seconds The modulating gas valve is controlled by the BMS thermostat The thermostat can modulate the firing rate between 40 through 100 full fire by modulating the input signal between either 0 10 Vdc or 4 20 mA The signal conditioner can accept a 0 10 Vdc signal when all the dip switches are in the OFF position and 4 20 mA signal when all the dip switches are in the ON position The si
106. ion The dirty filter pressure switch monitors the pressure differential between the two sides of the filters When the filters become dirty the differential pressure increases and trips the pressure switch which energizes a light on the remote monitoring panel The pressure differential switch must be field Set because setting the switch requires the blower to be in operation and the ductwork to be installed Setting the Dirty Filter Switch The range of the dirty filter pressure switch is adjustable between 0 17 to 5 0 W C 1 Ensure that the unit filters are clean Clean or replace if necessary 2 Connect the leads of a continuity tester to the NO and C terminals of the dirty filter pressure switch See Figure 27 2 3 Setthe thermostat so that there is a call for heat This should fire the burner and the blower should start 4 Turn the set screw of the pressure switch clockwise until it stops This will set the pressure at 5 0 W C and the continuity tester should be sensing an open circuit 5 Begin turning the screw counterclockwise until the continuity tester senses a closed circuit This determines the base pressure of the system 6 Turn the screw clockwise until the continuity tester senses an open circuit and then one additional full turn This is approximately 0 25 W C This will allow for the increase in static pressure due to dirty filters Figure 27 2 Dirty Filter Pressure Switch and Air Flow Proving Switch 3
107. ircuit minimum is 688 and DX Dual Circuit min is 621 amp Model Size 100 CFM listed for Chilled Water DX Single Circuit CFM minimum is 802 and DX Dual Circuit CFM min is 745 AIR5 594 6 13 UNIT INSTALLATION Direct Expansion DX Piping The refrigerant lines should be insulated to prevent warming or cooling of the refrigerant If the suction line is allowed to be cooled liquid will condense in the line and can severely damage the compressor If the liquid line is warmed the refrigerant can flash into a gas This will cause erratic operation of the expansion device and impair the heat transfer ability of the cooling coil Long runs of piping need to be periodically supported to prevent excess vibration that can damage the piping and joints It is recommended to provide dampening supports at intervals of length equivalent to 15 tube diameters Figure 14 1 General DX Piping Suction Header Distributor Equalizer Line Coil Expansion Valve By Others Suction Line Straps Remote Sensing Bulb Suction Connection 1 Inspectthe refrigerant distributor and verify that the nozzle is in place 2 Allfield brazing and welding should be performed using high quality materials and an inert gas purge such as nitrogen to reduce oxidation of the internal surface ot the coil 3 Connect the suction line and suction connection 4 Install the expansion valve By Others Follow
108. is determined by entering the bottom of the curve at the desired cfm and reading up the graph until the cfm intersects the desired item For this example in Table 34 1 the 2 Permanent Filter line is used At the point of intersection read the table to get the pressure drop in inches of water column for the filters For this example the pressure drop is 0 06 W C As a result For the Model Size 400 with Digit 16 E F G or H 2 Permanent Filters 0 06 W C Internal Static Pressure Drop 0 06 W C The Total Static Pressure for the system is determined by Internal Static External Static Total Static Pressure For this example 0 06 0 65 0 71 W C T S P From page 34 for the Model Size 400 with Digit 16 J or K 2 Permanent Filters 0 04 W C Internal Static Pressure Drop 0 04 W C The Total Static Pressure for the system is determined by Internal Static External Static Total Static Pressure For this example 0 04 0 65 0 69 W C T S P B Using the total static pressure T S P calculated in step 12a use blower performance tables for the Model Size 400 Tables 36 1 Using Table 36 1 enter the table at the required 5000 for E F blowers and follow the line to the right until it intersects with the T S P line of 0 75 W C which is shown at the top of the table At the point of intersection of these two columns read the required horsepower and blower rpm repeat the process for 1 00
109. it Dimensions with Blower I J or L All dimensions in inches Blower Qty of Dimensions Size Digit 16 Furnaces J S 06 250 300 I J orK 123 63 350 400 1 J orK 123 63 500 600 1 J 164 63 700 800 I or L 164 63 840 960 1 J or 205 77 For Right Hand Access Units Location of drill locator dimples for field drilled gas connection entry holes one side of unit and one on bottom For Left Hand Access Units Location of drill locator dimples for field drilled gas connection entry holes one side of unit and one on bottom For Right Hand Access Units Location of drill locator dimples for field drilled electrical connection entry holes identical sizes as side electrical connections For Left Hand Access Units Location of drill locator dimples for field drilled electrical connection entry holes identical sizes as side electrical connections 5 Nominal vent pipe size is 4 Models 75 175 and 6 Models 200 800 Exhaust pipe installed over collar Combustion air pipe installed collar Applies to units with Digit 16 L only AIR5 594 6 49 DIMENSIONS UNIT Figure 50 1 Unit Base Dimensions lt gt end of unit 0 75 Suspension Hanging Locations Typical 4 Corners E Inside Suspension Point 24 00 Inside Suspension Point TT Lifting Poin Point
110. l screws Seal the joint and seam using sealant suitable for temperatures up to 400 F D10 Place this assembly the adapter box vent pipe and combustion air pipe through the wall or roof and verify that the distance requirements as defined in Step D7 are met Securely attach the assembly building D11 From outside the building caulk the gap between the combustion air intake pipe and the building penetration D12 Attach the combustion air intake and vent pipe terminations as follows Figure 10 1 Adapter Box with Combustion Air Intake Pipe Attached Combustion Air Pipe Attached Outlet Vent Pipe Extended Through Box Model Sizes A B 75 175 13 33 18 84 200 400 17 00 15 27 For Vertical Concentric Vent Kits refer to Figure 9 3 Slide the combustion air cap down over the vent pipe and fasten it to the combustion air pipe with at least 3 corrosion resistant sheet metal screws Attach the vent cap to the vent pipe using at least 3 corrosion resistant sheet metal screws Refer to instruction A12 for connecting terminal to double wall pipe Caulk the gap between the combustion air cap and the vent pipe with silicone sealant or other appropriate sealants suitable for metal to metal contact and for temperatures up to 400 F For Horizontal Concentric Vent Kits refer to Figure 9 4 Attach the combustion air intake guard using corrosion resistant screws at the end of
111. le INTERIOR wall or floor a metal thimble 4 greater than the vent diameter is necessary If there is 6 or more of vent pipe in the open space between the appliance and where the vent pipe passes through the wall or floor the thimble need only be 2 greater than the diameter of the vent pipe thimble is not used all combustible material must be cut away to provide 6 of clearance Where authorities have jurisdiction type B vent may be used for the last section of vent pipe to maintain clearance to combustibles while passing through wall or floor See Figure 7 1 Any material used to close the opening must be noncombustible AIR5 594 6 INSTALLATION VENTING Figure 7 1 Venting Through Combustible Roof or Wall Vertical Venting 5 gt 5 N LISTED p ROOF FLASHING NV ROOF I DOUBLE WALL FLASHING PIPE LISTED THIMBLE CLEARANCE SPECIFIED BY TYPE B VENT MANUFACTURER SINGLE WALL PIPE 4 sne WALL PIPE MODINE SPECIFIED SINGLE WALL PIPE CAP SINGLE WALLA PIPE MODINE SPECIFIED CAP 22 CLEARANCE SPECIFIED BY TYPE B VENT MANUFACTURER 51 LISTED 7 THIMBLE DOUBLE WALL PIPE D See Instruction A12 for attaching single wall pipe to double
112. ll show a slight yellow tip Prior to flame adjustment operate furnace for at least fifteen minutes Loosen air shutter set screws and move the air shutters away from the manifold to reduce the primary air until the yellow flame tips appear Then increase the primary air until yellow tips diminish and a clean blue flame with a well defined inner cone appears Table 18 1 Manifold Pressure and Gas Consumption Blower Adjustments If blower fan speed changes are required adjust motor sheave as follows 1 Refer to page 38 to determine correct blower speed according to job requirements then proceed with steps 2 through 8 2 Loosen motor base and take belt off of motor sheave 3 Loosen set screw on outer side of adjustable motor sheave Figure 18 1 Motor Sheave Adjustment Model Size Type of Gas Btu Cu Ft Specific Gravity High Fire Manifold Pressure Inches of Water Column Cfh Orifice Drill Size Cfh Orifice Drill Size Cfh Orifice Drill Size Propane 2500 1 58 Natural 72 1 30 0 20 37 96 1 40 0 30 45 120 2 50 0 25 42 No of Orifices Cfh Orifice Drill Size Cfh Orifice Drill Size Cfh Orifice Drill Size Cfh Orifice Drill Size Cfh Orifice Drill Size Cfh Orifice Drill Size Cfh Orifice Drill Size Cfh Orifice Drill Size Cfh Orifice Drill Size Cfh Orifice Drill Size Cfh Orifice Drill Size Cfh Orifice Drill Size Drill Size Orifice Drill Size 144 2 60 0 30 45 168 3 7
113. lose the electrical compartment door 26 Replace all exterior panels Refer to page 58 for the Start up Checklist Pilot Burner Adjustment The pilot burner is orificed to burn properly with an inlet pressure of 6 7 W C on natural gas 11 14 W C on propane gas but final adjustment must be made after installation If the pilot flame is too long or large it is possible that it may cause soot and or impinge on the heat exchanger causing failure If the pilot flame is shorter than shown it may cause poor ignition and result in the controls not opening the combination gas control A short flame can be caused by a dirty pilot orifice Pilot flame condition should be observed periodically to assure trouble free operation To Adjust the Pilot Flame 1 Create a call for heat from the thermostat 2 Remove the cap from the pilot adjustment screw For location see the combination gas control literature supplied with unit 3 Adjust the pilot length by turning the screw in or out to achieve a soft steady flame 3 4 to 1 long and encompassing 3 8 1 2 of the tip of the thermocouple or flame sensing rod See Figure 17 1 4 Replace the cap from the pilot adjustment screw 16 AIR5 594 6 START UP PROCEDURE Figure 17 1 Correct Pilot Flame Z 3 4 to 1 Main Burner Adjustment The gas pressure regulator integral to
114. m 5 in selection example conditions the Right Hand Gas controls result in the Access Side 6 Determine the Air Temperature Rise From item Z2 in selection example conditions the Air Temperature Rise is 60 F 70 F 10 F However using the output capacity of the IFS400 5000 cfm the resulting temperature rise is 59 3 F 320 000 5000 x 1 08 Since the rise is less than 60 F the Air Temperature Rise L 7 Determine the Gas Type From item 7 in selection example conditions the Natural Gas results in the Gas Type N 8 Determine the Gas Valve From item 8 in selection example conditions the Electronic Modulating with Duct Sensing results in the Gas Valve 4 9 Determine the Additional Safety Switches Since no additional safety switches were specified the Additional Safety Switches 0 AIR5 594 6 UNIT SELECTION 10 11 12 Determine the Supply Voltage From item 9 listed above the 460V 60H2 3Ph results in the Supply Voltage F Determine the Transformer For IBS ICS models a 75VA Transformer is required Thus the Transformer 2 Determine the Blower Size and Bearing Type Using Table 30 1 the Model Size 400 has three available blowers for which the performance table are shown on page 36 Since all of the blower performance curves can provide the required 5000 cfm the total static pressure for each blower performance curve must be determined A The Pressure Drop of the filters
115. maximum allowable total static pressure of 3 0 W C AIR5 594 6 31 UNIT SELECTION Selection Procedure In order to properly select an indirect fired heating ventilating cooling or make up air unit it is necessary to have the following basic information 1 Required air handling capacity The air capacity of the unit is usually determined by the ventilation air requirements exhaust load of the building infiltration losses or the air turns changes of the space 2 Outdoor and indoor design temperature The outdoor design temperature is determined by using the ASHRAE Guide design temperatures for the city where the equipment is to be installed For heating and ventilating units the desired room temperature would be used as the indoor design temperature In the case of 100 make up air units the discharge air temperature should be at least equal to the temperature of the air being exhausted 3 Required heating output capacity Btu Hr The heating output capacity of the unit is determined by using the formula BTU HR CFM x Temp Rise F x 1 08 4 External static pressure to unit The external static pressure E S P is determined using the ASHRAE Guide for duct losses or may be provided by the design engineer 5 Unit configuration with options and accessories Filters or dampers The unit configuration is determined by the location where the unit is to be installed The critical options and accessories are
116. may be controlled by a manual high low switch which may be factory mounted on the control panel or shipped loose for field installation or by exhaust fan interlocks 2 Floating building pressure sensing which utilizes a photohelic pressure controller to adjust the building pressure by varying the amount of makeup air supplied to the space 3 Building management control which allows for an external signal of 0 10VDC of 4 20mA to adjust the unit air flow Additionally when the unit is equipped with a two speed motor the allowable minimum CFM of the duct furnace can be 6696 of the minimum listed CFM in Table 30 1 if the unit is applied as follows 1 The unit is provided with 2 stage or electronic modulating gas controls see Model Identification 2 The unit is provided with a factory installed discharge air controller 3 The system does not include a room thermostat The factory installed discharge air thermostat will prevent the unit from firing above the allowable 100 F rise when the unit is at or above the minimum CFM by monitoring the discharge air and going to low fire A room thermostat because it is located remote from the unit could cause the unit to over fire AIR5 594 6 OPTIONS FACTORY INSTALLED Figure 21 1 Factory Mounted Option Locations AN Oar m NY OMAN OAR TODA AN DAP Discharge Thermostat Low Gas P
117. models For power vented models the step down transformer amp draw is included in the Power Exhauster Motor Amp Draw Amp draw is for 250 VA step down transformer Power Exhauster Amp Draw Table 42 2 Motor Data for Digit 14 A 115V 60Hz 1Ph _ Table 42 3 Motor Data for Digit 14 B 208V 60Hz 1Ph Digits Motor Frame Service Weight Efficiency Digits Motor Frame Service Weight Efficiency 17818 Size Size Factor Ibs 96 2 17818 Size HP Size Factor Ibs 2 F1 or R1 F1 or R1 F5 R5 F5 or R5 Hi or T1 G1 or 51 H5 or T5 G5 or S5 Refer to page 46 for Motor Type abbreviations Motors manufacturers do not rate single phase motors for efficiency Single phase motors 1 1 2HP and smaller feature integral thermal overload protection 2HP and larger require external protection The optional motor starter for those sizes provides overcurrent protection 42 AIR5 594 6 MOTOR DATA Table 43 1 Motor Data for Digit 14 C 230V 60Hz 1Ph Digits Motor Service Efficiency 17 amp 18 Size HP Factor A1 A5 B1 B5 C1 C5 D1 D5 E1 E5 F1 or R1 F5 or R5 G1 or S1 G5 or S5 H1 or T1 H5 or T5 Refer to page 46 for Motor Type abbreviations 0 Motors manufacturers do not rate single phase motors for efficien
118. mum of 14 W C Minimum for Natural Gas 6 W C Minimum for Propane Gas 11 W C Check wiring for 24 volts to valve a Replace ignition controller b Replace gas valve a Check all ignition controller wiring b Replace sensor if cracked or worn c Replace ignition controller Check all safety devices High limit air flow proving switch differential pressure switch gas pressure switches etc Determine and correct problem Reset if necessary Replace valve Check wiring to gas valve Replace pilot sensor Replace ignition controller Verify wiring compared to wiring diagram Reduce primary air Adjust to a maximum of 14 W C Check orifice size with those listed on the serial plate Increase primary air Check orifices and clean with compressed air if necessary Check manifold replace if necessary Reduce primary air Adjust to a maximum of 14 W C Check orifice size with those listed on the serial plate SERVICE amp TROUBLESHOOTING Table 55 1 Troubleshooting continued Trouble Floating Flames See Figure 55 2 Flame Rollout See Figure 55 3 Not Enough Heat Too Much Heat Automatic Reset High Limit The duct furnace comes standard with an automatic reset high limit switch that will shut off the gas should the discharge air temperature become excessive See Figure 21 1 indicator 46 for the location of either the standard automatic or optional manual reset high limit s
119. must not be installed where they may be exposed to a potentially explosive or flammable atmosphere A WARNING 1 Gas fired heating equipment must be vented do not operate unvented 2 A built in power exhauster is provided additional external power exhausters are not required or permitted 3 All field gas piping must be pressure leak tested prior to operation Never use an open flame Use a soap solution or equivalent for testing 4 Gas pressure to appliance controls must never exceed 14 W C 1 2 psi 5 Disconnect power supply before making wiring connec tions to prevent electrical shock and equipment damage 6 All appliances must be wired strictly in accordance with wiring diagram furnished with the appliance Any wiring different from the wiring diagram could result in a hazard to persons and property 7 Any original factory wiring that requires replacement must be replaced with wiring material having a temperature rating of at least 105 C 8 To reduce the opportunity for condensation the minimum sea level input to the appliance as indicated on the serial plate must not be less than 5 below the rated input or 5 below the minimum rated input of dual rated units 9 Ensure that the supply voltage to the appliance as indicated on the serial plate is not 5 greater than the rated voltage 10 When servicing or repairing this equipment use only Modine approved service replacement parts A complete replacement p
120. n two identification plates are used on these models The Serial Plate is used to identify the duct furnace and its components The Model Identification Plate is used to identify the complete model including blower and cooling sections Ordering When servicing repairing or replacing parts on these units locate the model identification plate of the unit and always give the complete Model Number and Serial Number from the model identification plate The model identification plate is located on the door of the electrical control box See Figure 56 1 The part numbers for some common replacement parts are listed on the serial plate See Figure 56 2 and the model identification plate See Figure 57 1 For a complete description of the model number see Model Identification Figure 56 2 Serial Plate Modine Manufacturing Company 1500 DeKoven Ave Racine WI 53403 Figure 56 1 Serial Plate and Model Identification Plate Locations SERIAL PLATE MODEL IDENTIFICATION PLATE SEPARATED COMBUSTION DUCT FURNACE FOR INDUSTRIAL COMMERCIAL USE CHAUDIERE AGA DUIT SEPARE Phone 800 828 4328 POUR USAGE INE COMMERCIAL MADE MODEL NUMBER MIN INPUT BTU HR P NUMERO DE MODELE IFS200AFRHN10A1 DEBTCALORFIQUE 160000 SERIAL NUMBER MIN INLET PRESS FOR PURPOSE DESIGN COMPLIES OF INPUT ADJUSTMENT NUMERO DE SERIE 1010700 0001 P
121. nded Service Clearances 5 Be sure that the minimum clearances to combustible Non Access materials and recommended service clearances are Side maintained Units are designed for installation on non combustible surfaces with the minimum clearances shown 75 in Figure 3 1 and Table 3 2 100 125 6 Units installed downstream of refrigeration systems or 150 175 exposed to inlet air temperatures of 40 F or less may experience condensation therefore provisions should 200 225 be made for disposal of condensate Means have been 250 300 provided in the bottom pan of the unit to accommodate a 350 400 condensate drain line connection flange 7 When locating units it is important to consider that the combustion air and exhaust vent piping must be connected 700 800 to the outside atmosphere The maximum equivalent lengths are listed in Table 6 1 on page 6 8 In garages or other sections of aircraft hangars such as offices and shops which communicate with areas used for servicing or storage keep the bottom of the unit at least 7 above the floor In public garages the unit must be installed in accordance with the Standard for Parking Structures NFPA 88A and the Standard for Repair Garages NFPA 88B In Canada installation of unit heaters in airplane hangars must be in accordance with the requirements of the enforcing authority and in public garages in accordance with the current CAN CGA B149 codes 9 Do not install units in loca
122. nections Figure 5 3 Recommended Field Installed Discharge Duct Configurations for Blower Package Units Dimension B should never be 550 than 1 2 of dimension A Provide leak tight access Turning discharge duct for heat inspection 3 53 Dimension B should never be 1 550 than 1 2 of dimension A Yn Turning Pu 3 Provide leak tight access 5 in discharge duct for heat inspection Utility Connections Utility and control connections can be made to the unit from the bottom or through the fixed side panels for floor mounted units Holes can be made in fixed side panels to accommodate utility connections for any model or as specified according to the unit dimensional drawings Seating of holes cut in the unit casing for utility connections should be done with care to prevent air leaks Unit Installation Follow site preparation instructions for Unit Mounting for applicable unit suspension or floor mounted units before installation Check Model Identification Plate of unit with plans to be sure unit is properly located See page 57 Also inspect damper motors and dampers for proper type e g two position modulating fresh air only fresh and return air etc Although units may look outwardly similar their function capacities options and accessories will of
123. never possible to reduce compressor operation of the mechanical cooling system The economizer functions as a true first stage of cooling and provides maximum fuel economy during the cooling cycle HEATING and VENTILATING MODE When the space thermostat calls for heat or it is in the fan ON position without a call for cooling ventilation mode the economizer is automatically locked out It holds the outdoor air damper at the minimum position setting COOLING MODE When the space thermostat calls for cooling the system operates as follows Outdoor Air Enthalpy is Below Changeover Set Point 1 The outdoor air damper is proportioned open and the return air damper is proportioned closed to maintain between 50 F and 56 F at the mixed air temperature sensor 2 During economizer operation mechanical cooling is operated by the second stage of the cooling on the space thermostat Outdoor Air Enthalpy is Above Changeover Set Point 1 The outdoor air damper is closed to its minimum position 2 Acall for cooling from the space thermostat brings on mechanical cooling The enthalpy controller is used in conjunction with the Enthalpy Sensor not shown and field installed and a mixed air temper ature sensor not shown The mixed air temperature sensor is factory installed in the blower section to sense the combined temperature of the fresh and return air streams The sensor is non adjustable and when in the free cooling mode modulates th
124. off valve The minimum inlet pressure should be 6 W C on natural gas and 11 W C on propane gas The maximum inlet pressure for either gas is 14 If inlet pressure exceeds 14 W C a gas pressure regulator must be added upstream of the combination gas valve 20 Open the field installed manual gas shut off valve 21 Open the manual main gas valve on the combination gas valve Call for heat with the thermostat and allow the pilot to light On a call for heat the power exhauster relay will energize the power exhauster motor Once the power exhauster motor reaches full speed a differential pressure switch will close before the pilot can light If the pilot does not light purge the pilot line If air purging is required disconnect the pilot line at outlet of pilot valve In no case should line be purged into heat exchanger Check the pilot flame length See Pilot Flame Adjustment 22 Once the pilot has been established check to make sure that the main gas valve opens Check the manifold gas pressure See Main Gas Adjustment and flame length See Air Shutter Adjustment while the supply fan blower is operating 23 Check to insure that gas controls sequence properly See Control Operating Sequence Verify if the unit has any additional control devices and set according to the instructions in the Control Options 24 Once proper operation of the unit has been verified remove any jumper wires that were required for testing 25 C
125. or S1 G5 or S5 G6 or S6 H1 or T1 H5 or T5 H6 or T6 or W1 15 W5 16 W6 J1 or X1 J5 or X5 J6 or X6 K1 or Y1 K5 or Y5 K6 or Y6 V1 or Z1 V5 or Z5 V6 or Z6 Motors have no thermal overload protection Motor Type Abbreviations ODP Open Drip Proof ODP HE Open Drip Proof High Efficiency ODP 18 9 Open Drip Proof 2 speed 1800 900 RPM 18 12 Open Drip Proof 2 speed 1800 1200 RPM TE Totally Enclosed TEFC Totally Enclosed Fan Cooled TE HE Totally Enclosed High Efficiency TE 18 9 Totally Enclosed 2 speed 1800 900 RPM TE 18 12 Totally Enclosed 2 speed 1800 1200 RPM TENV Totally Enclosed Non Ventilating 46 AIR5 594 6 PAGE INTENTIONALLY LEFT BLANK AIR5 594 6 47 DIMENSIONS UNIT Figure 48 1 IBS Separated Combustion Blower Package Unit Dimensions 34 49 51 15 Qty 4 Drill Locator gt Over Roof Dimples for Field Drilled Electrical 1 90 r 2 00 Conduit Entry Holes 2 20 spaced 2 0 apart 21 i 9NO 34 25 Exhaust f x Height 5 3458 GPO H Combustion G INSIDE 24 00 Width
126. ort it immediately to transportation company and your local factory sales representative 2 Check rating plate on unit to verify that power supply meets available electric power at the point of installation 3 Inspect unit upon arrival for conformance with description of product ordered including specifications where applicable THIS MANUAL IS THE PROPERTY OF THE OWNER PLEASE BE SURE TO LEAVE IT WITH THE OWNER WHEN YOU LEAVE THE JOB SPECIAL PRECAUTIONS TABLE OF CONTENTS SPECIAL PRECAUTIONS THE INSTALLATION AND MAINTENANCE INSTRUCTIONS IN THIS MANUAL MUST BE FOLLOWED TO PROVIDE SAFE EFFICIENT AND TROUBLE FREE OPERATION IN ADDITION PARTICULAR CARE MUST BE EXERCISED REGARDING THE SPECIAL PRECAUTIONS LISTED BELOW FAILURE TO PROPERLY ADDRESS THESE CRITICAL AREAS COULD RESULT PROPERTY DAMAGE OR LOSS PERSONAL INJURY OR DEATH THESE INSTRUCTIONS ARE SUBJECT TO ANY MORE RESTRICTIVE LOCAL OR NATIONAL CODES HAZARD INTENSITY LEVELS 1 DANGER Indicates an imminently hazardous situation which if not avoided WILL result in death or serious injury 2 WARNING Indicates a potentially hazardous situation which if not avoided COULD result in death or serious injury 3 CAUTION Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury 4 IMPORTANT Indicates a situation which if not avoided MAY result in a potential safety concern A DANGER Appliances
127. osition the limiter back to the desired position making sure the locating teeth on the limiter are engaged into the locating holes on the actuator 6 Fasten the limiter to the actuator using the self tapping Screw provided 7 Testthe damper rotation either manually with the manual crank or apply power and if required a control signal Re adjust if necessary Figure 25 1 Two position Damper Actuator and Limiter Lock down with screw as shown Adjustable end switch set to angle of rotation Actuator clamp at 50 rotation limit Modulating Damper Actuator A modulating damper actuator is provided with Air Control options GA GB GC GD GE GF GG GH GJ GK GM and GN Digits 20 amp 21 The modulating damper actuator provides incremental operation of the fresh air damper The return air damper is controlled by the fresh air damper position Full 90 rotation of the modulating actuator requires 150 seconds All modulating damper actuators operate using a 0 10 input signal Air Control GB utilizes a resistor to convert from a 4 20 mA to 0 10 Vdc from a damper controller All modulating damper actuators are spring return so when the damper is de energized the fresh air damper will spring closed Floating Damper Actuator A floating damper actuator is provided with Air Control option HP Digits 20 amp 21 The floating damper actuator provides forward and reversing damper opera
128. ot Assy Kit T non 5H74976 1 Limit Control 5H74977 1 Transformer 5H76776 1 Wiring Diagram 3H35628 6 Burner Kit 3H35747 6 Heat Exch Kit 5 75745 1 uster FROM OUTSIDE SURFACE OF VENT PIPE 1 LA DISTANCE MINIMUM DE MATERIAU COMBUSTIBLE CONDUIT DE VENTILATION CLEARANCE TO COMBUSTIBLE MATERIALS INSTALL ON THE POSITIVE PRESSURE SIDE OF AIR CIRCULATING BLOWER FOR UNITS WITH MANUAL RESET HIGH LIMIT BWITCH RESET BUTTON LOOATED IN ELECTRICAL 6 USA INSTALLATIONS ABOVE 2000 FEET DERATE 4 PERCENT FOR EACH 1000 FEET ELEVATION ABOVE SEA LIGHTING INSTRUCTIONS 1 OPEN ALL GAS VALVES TURN ON POWER 2 SET THERMOSTAT TO DESIRED SETTING SHUT DOWN INSTRUCTIONS 1 TURN OFF POWER amp CLOSE ALL GAS VALVES REFER TO INSTALLATION AND SERVICE MANUAL FOR MORE INSTRUCTIONS FOR UNITS WITH TWO STAGE MECHANICAL MODULATION OR ELECTRONIC MODULATING GAS CONTROLS A FACTORY DISCHARGE AIR CONTROLLER AND NO ROOM THERMOSTAT INCLUDED ACCES 1 3 MINIMUM CLEARANCE TO COMBUSTIBLE MATERIAL IS DE 3 PO EST DETERMINEE PARTIR DE 1 EXT RIEUR DU RECOMMENDED SERVICE CLEARANCE GENERAL 1 SEULEMENT POUR INSTALLATION INT RIEURE 2 LATEMPERATURE MINIMUM DE L AIR DEHORS EST 40 3 POUR L INSTALLATION QUE LES SYSTEMS REFRIGERANTS 4 INSTALLER DU C T DE LA PRESSION POSITIVE DU VENTILATEUR 5 POUR APPAREILS AVEC INTERRUPTEUR REMIS MANUEL HAUT LIMITE REMISE EST
129. ottom of the tubes become red while blower and duct furnace are in operation check to be sure the blower has been set to the proper rpm for the application Refer to page 18 for Blower Adjustments 4 Start up and adjustment procedures should be performed by a qualified service agency 5 To check most of the Possible Remedies in the trouble shooting guide listed in Tables 54 1 and 55 1 refer to the applicable sections of the manual Table of Contents Inspection on Arrival ee qn RR RE 1 Special Precautions 2 SI Metric Conversion 3 Unit Eocatiloni sued sawed peu cer exem rh ay em en ee 3 Combustible Material and Service Clearances 3 Unit Lifting and Unit Mounting 4 Duct Installation 5 5 bem Lp 6 Gas 11 Electrical 12 Cooling Coil Specifications and Installation 13 Start Up 16 Pilot Burner and Main Burner Adjustment 16 Blower 18 Lubrication Recommendations 18 Damper Linkage 19 Control Operating
130. perating steps Lights will come on as a point of electrical operation is passed and proven If any light is not lit that is the point where failure occurred Figure 29 1 Circuit Analyzer Circuit analyzer tagging will vary based on the unit ordered Circuit analyzer shown is for reference only oO 52 AIR5 594 6 29 GENERAL PERFORMANCE DATA Table 30 1 General Performance Data Models With Blower Model Size Digits 4 6 Btu Hr Input 75 000 75 000 100 000 100 000 125 000 125 000 150 000 150 000 175 000 175 000 Btu Hr Output 60 000 60 000 80 000 80 000 100 000 100 000 120 000 120 000 140 000 140 000 Blower Style Digit 16 Letter AorB CorD CorD or F CorD CorD EorF CorD EorF Max Temp Rise F 100 100 100 85 100 100 100 100 100 100 Min Temp Rise F 28 20 21 20 27 20 33 20 39 23 Max CFM 1980 2778 3450 3450 4630 3350 5556 3350 5556 Min 2 556 556 741 926 926 1111 1111 1296 1296 Model Size Digits 4 6 Btu Hr Input D 200 000 200 000 200 000 225 000 225 000 225 000 250 000 250 000 250 000 Btu Hr Output D 160 000 160 000 160 000 180 000 180 000 180 000 200 000 200 000 200 000 Blower Style Digit 16 Letter Cor D EorF G or H Cor D EorF G or H I J or K Max Temp Rise F 100 85 85 100 95 95 96 Min Temp Rise F 44 28 23 49 32 26 20 6000 7250 Min CFM 185
131. r circuit breaker disconnect switch Refer to the Factory Mounted Option Locations Figure 21 1 for the factory mounted disconnect switch location and then review the unit to determine if a factory installed dead front disconnect switch was provided Accessory field installed disconnect switches should be mounted where shown in Figure 12 1 For fusible disconnect switches refer to the Model Identification plate for the fuse size and type Figure 12 1 Recommended Accessory Field Installed Disconnect Switch Mounting Locations DISCONNECT SWITCH WIRING AND CONNECTOR SUPPLY ELECTRIC SUPPLY COMPONENTS MUST BE CLEAR OF SERVICE DOORS BLOWER LEFT HAND ACCESS ELECTRIC UNIT SHOWN The power supply must be within 5 of the voltage rating and each phase must be balanced within 2 percent of each other If not advise the utility company External electrical service connections that must be installed include a Supply power connection 120 208 240 480 or 600 volts b Connection of thermostats remote monitoring panels building pressure sensors CO detectors time clocks or any other accessory control devices that may be supplied 24 volts All outdoor electrical connections must be weatherized to prevent moisture from entering the electrical compartment Refer to the unit dimensional drawings on Figures 48 1 through 49 1 for the electrical knock out locations All supply power
132. ressure Drop Tables W C 2 Unit Size 75 100 125 150 175 200 225 250 300 500 600 350 400 700 800 840 960 34 Digit 16 A B C D C D E F C D E F C D E F G H E F G H LJ K L E F G H LJ K L nits eatherproof Unit Only 5 5 8 5 5 5 5 E E E 5 555 98 885 Be E Eo 99 oge 63 25 55 95 25 265 55 622 ST e a 2 25 de gos 55 82 85 88 556 0 01 001 002 003 001 005 002 007 000 001 000 600 0 01 0 01 002 003 001 005 002 007 000 001 0 01 800 0 02 001 003 004 002 008 004 012 0 01 0 02 0 01 1000 0 02 0 02 004 0 05 0 03 011 0 06 047 0 01 0 03 0 01 1200 0 03 0 02 005 006 004 044 0 08 022 0 02 003 0 01 1400 0 03 0 03 006 007 006 017 029 003 004 0 02 1600 0 04 0 04 007 009 0 08 021 015 036 0 04 0 06 002 1800 0 04 0 04 008 010 0 10 025 019 044 005 007 0 03 2000 0 05 0 05 040 041 012 030 023 053 006 008 0 03 2300 0 06 007 013 016 037 031 068 008 0 04
133. ressure Switch High Gas Pressure Switch Power Exhauster Assembly Timed Freeze Protection Ignition Controller Differential Pressure Switch Control Relay Time Delay Relay Power Exhauster Relay Furnace Low Voltage Terminal Strip Furnace Supply Power Terminal Strip Control Step Down Transformer Control Relay Blower Low Voltage Terminal Strip Dead Front Disconnect Switch Step Down Transformer Fuses Step Down Transformer Factory Installed Minimum Positioner Extended Grease Line Zerk Fittings Extended Grease Lines Return Air Fire Stat Blower Housing Pillow Block Bearings Blower Motor Filters Fresh Air Damper Direct Drive Damper Actuator Enthalpy Controller 30 31 32 33 34 35 36 37 38 39 0 2 8 O 09 Q4 ORO 9142 2 69 9 gt 22 25 22 2 22 26 CS 8 6 100 G2 9 G9 69 N 9 V G2 V GO d 0 9 9 9 9 6 9 9 Damper to Damper Linkage Return Air Damper Proportional Temp Controller Sensor Motor and Blower Vibration Isolation Blower Support Convenience Outlet Blower Door Switch Dirty Filter Switch Motor Starter VFD Control Proportional Temp Controller 40 41 42 43 44 45 46 47 48 49 Warm Up Stat Blower Supply Power Terminal Strip Service Switches Electronic Modulating Gas Valve Electronic Modulating Ampli
134. rosion and other deficiencies which could cause an unsafe condition A2 The combustion air and vent pipes should be galvanized steel or other suitable corrosion resistant material Follow the National Fuel Gas Code for minimum thickness of vent material The minimum thickness for connectors varies depending on the pipe diameter Do not vent unit with PVC or other forms of plastic venting material 4 AS 9 10 All heaters come with factory installed vent and combustion air adapters for attaching the pipe to the heater The pipe diameters are 4 for model sizes 75 175 and 6 for model sizes 200 400 All units are classified as Category vented appliances which defined by ANSI is positive pressure non condensing and requires the vent system to be gastight Attach the vent pipe to the adapter with 3 corrosion resistant screws Drill pilot holes through the vent pipe and adapter prior to screwing in place Vent pipe must not be smaller than the connector size Limit the total equivalent vent pipe length to a minimum of 5 and a maximum as shown in Table 6 1 making the vent system as straight as possible Total equivalent vent pipe length must include elbows The equivalent length of a 4 elbow 15 5 and for a 6 elbow is 7 Table 6 1 Individual Total Equivalent Lengths for Combustion Air and Exhaust Vent Pipes Model Size Minimum ft Maximum ft 75 48 100 125 150 175 55 2
135. st 6 inches above the top of the combustion air intake cap For Horizontal Concentric Vent Kits refer to Figure 9 4 The combustion air intake pipe must terminate at least 1 inch from the wall to prevent water from running down the wall and into the pipe The back of the vent cap must terminate at least 14 inches from the combustion air intake pipe D7 the concentric side vent and combustion air pipes to the proper length as determined in the previous step Note that the vent pipe diameter is 4 and the combustion air intake pipe diameter is 6 for model sizes 75 175 and 6 and 8 respectively for model sizes 200 400 The pipes must be single wall galvanized or stainless steel material except for the last section of vent pipe which must be one continuous length of double wall B vent extended through the concentric vent box and combustion air inlet pipe on the concentric side of the box D8 Allow the concentric side vent pipe to pass through the concentric vent adapter box as shown in Figure 10 1 Attach the double wall vent pipe to the single wall vent pipe that goes to the unit Be sure to seal the joint and the open area around the double wall vent Seal all joints and seams using sealant suitable for temperatures up to 400 F D9 Slide the combustion air pipe over the vent pipe and attach to the air inlet of the concentric adapter box as shown in Figure 10 1 using at least 3 corrosion resistant sheet meta
136. stalled in the duct furnace electrical junction box The time delay relay allows the gas controls to operate for approximately 30 seconds before the blower starts This allows the heat exchanger a warm up period so that the initial delivered air coming out of the ductwork is not cool The time delay relay also keeps the motor running for approximately 30 seconds after the call for heat has been satis fied to remove the residual heat from the heat exchanger For single phase units below 2 Hp the time delay relay controls the motor directly For single phase units 2 Hp and greater and all three phase units the time delay relay controls the motor starter 10 Power Exhauster Relay STD The control relay is factory installed in the duct furnace electrical junction box The relay has a 24V coil with single pole single throw SPST contacts On a call for heat the relay coil is energized resulting in the contacts energizing the power exhauster motor 11 Furnace Low Voltage Terminal Strip STD The furnace low voltage terminal strip is located in the duct furnace electrical junction box The terminal strip is labeled to match the electrical wiring diagram provided with the unit Low voltage labeling ranges from terminal numbers 1 to 79 All field wiring connections should be made to the top side of the terminals to prevent miswiring by modifying the factory wiring which is made to the bottom of the terminal strip 12 Furnace Suppl
137. t 7 Venting of Equipment of the National Fuel Gas Code ANSI 7223 1 NFPA 54 latest edition In Canada installation must be in accordance with CSA B149 1 Model IFS duct furnaces must be vented with the proper passageway as described in these instructions to convey flue gases from the unit or the vent connector to the outside atmosphere The heaters must also have a separate combustion air intake pipe to bring in fresh air for combustion from the outside atmosphere The venting instructions are organized in sections based on installation type The sections are identified as follows Section Installation Instructions by Vent System Type General Instructions for ALL installations VERTICAL 2 PIPE vent systems HORIZONTAL 2 PIPE vent systems HORIZONTAL AND VERTICAL CONCENTRIC vent systems The differences between Vertical and Horizontal vent systems 2 Pipe or Concentric Vent configurations will be identified in Section A General Instructions All Units Section A General Instructions All Units A1 If the heater being installed is replacing existing equipment and using the existing vent system from that equipment inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code ANSI 2223 1 or CSA B149 1 Installation Code latest edition and these instructions Determine that there is no blockage or restriction leakage cor
138. t to 100 full fire 6 Thetime delay relay starts the blower after 30 to 45 seconds 7 The unit continues to operate until the thermostat is satisfied at which time both the main and pilot valves close 100 8 The time delay relay stops the blower after 30 to 45 seconds Two Stage Gas Controls Utilizes a two stage combination gas control an ignition control and a two stage low voltage thermostat The unit fires at 5096 fire on low stage and 100 fire on high stage 1 The thermostat calls for low stage heat 2 The power exhauster relay is energized starting the power exhauster motor Once the motor has reached full speed the differential pressure switch closes The power exhauster relay pre purge timer closes after 20 to 40 seconds energizing the gas control circuit 3 The pilot valve opens and the spark ignitor sparks in an attempt to light the pilot 4 Oncethe pilot is lit the flame sensor proves the pilot and stops the spark ignitor from sparking 5 The main gas valve is opened and the main burner is lit to 50 fire 6 The time delay relay starts the blower after 30 to 45 seconds 7 Ifthe temperature at the thermostat continues to fall the thermostat will call for high stage heat 8 The main gas valve is opened completely and the main burner is lit to 100 full fire 9 Theunit continues to operate until the high stage of the thermostat is satisfied at which time the main valve closes to 50 fire 10
139. ten vary Check dimensions Orient unit to its ductwork and suspend or floor mount unit For proper operations the unit must be installed in a level horizontal position Refer to the applicable sections to make Venting Gas Connec tions Electrical Connections and Cooling Coil Connections Make final unit connections to the electric power supply and remote control circuits Connect the gas lines to the unit heating compartment in accordance with the submittal drawings and architect plans Caulk all utility line clearance holes on the unit after connections are completed AIR5 594 6 5 INSTALLATION VENTING WARNING Gas fired heating equipment must be vented do not operate unvented A built in power exhauster is provided additional external power exhausters are not required or permitted If you are replacing an existing heater it may be necessary to resize the venting systems Improperly sized venting systems can result in vent gas leakage or the formation of condensate Refer to the National Fuel Gas Code ANSI 7223 1 or CSA B149 1 latest edition Failure to follow these instructions can result in serious injury or death Under no circumstances should two sections of double wall vent pipe be joined together within one horizontal vent system due to the inability to verify complete seal of inner pipes A CAUTION Installation must conform with local building codes or in the absence of local codes with Par
140. the expansion valve manufacturer s recommendations for installation to avoid damaging the valve 5 The expansion valve s remote sensing bulb should be securely strapped to the horizontal run of the suction line at the 3 or 9 o clock position and insulated 6 Connectthe liquid line to the expansion valve Pressurize the coil expansion valve assembly and suction connection to 100 psig with dry nitrogen or other suitable gas The coil should be left pressurized for a minimum of 10 minutes 7 coil holds pressure the hook up be considered leak free If the pressure drops by 5 psi or less repressurize the coil and wait another 10 minutes If the pressure drops again there are more than likely one or more small leaks which should be located and repaired Pressure losses greater than 5 psi would indicate a larger leak which should be isolated and repaired Be sure to check valves and fittings as potential sites for leakage or bleed If the coil is found to be leaking contact your local Modine representative 8 Use vacuum pump to evacuate the coil and any interconnecting piping that has been open to atmosphere Measure the vacuum in the piping using a micron gauge located as far from the pump as possible the vacuum at the pump will be greater than the rest of the system Evacuate the coil to 500 microns or less then close the valve between the pump and the system If the vacuum holds to 500 microns or less for one minute t
141. the bearings drive sheaves and belts Blower bearings should be checked and lubricated based on the blower manufacturer s recommendations Bearings should also be checked for any unusual wear and replaced if needed Drive sheaves should be checked at the same time the bearings are inspected Check to make sure the sheaves are in alignment and are securely fastened to the blower and motor shafts Belt tension should be rechecked shortly after the unit has been installed to check for belt stretching After the initial start up monthly checks are recommended Filters If the unit is supplied with a dirty filter switch and light clean or replace the filters any time the dirty filter light comes on Units which do not have a dirty filter warning light should have the filters checked monthly Clean or replace if necessary In dirty atmospheres filter maintenance may be required more often Figure 52 2 Filter Replacement Arrangement for Blower Size Digit 16 A B C D E F Gand H E FILTER SPACE J Double Wall All Sections All 150 175 All FILTER SPACE All E F G or H I J E F G or H I J See Motor Data GorH 220 225 250 300 500 600 350 400 I J orb 700 800 GorH 20 X 25 FILTER B 16 X 25 FILTER I J orb 15 X 25 FILTER I J orb Blower Type Size Digit 16 All
142. the factory installed motor starter option or a VFD was not ordered with a unit that has a three phase motor or single phase motor 2 Hp or greater it must be field supplied and installed Figure 27 3 Motor Starter Negative pressure Positive pressure connector connector Pressure adjustment set screw Screener amp 1 18 m C 69 CO CONTACTOR MODULE TRIP CURRENT 1 SET POINT 4 DIAL RESET 14 lal OVERLOAD x MODULE i 8 Be 2 amp L 39 Proportional Temperature Controller OPT A proportional temperature controller is provided with Air Control options GF GG GH GK GM or GN Digits 20 amp 21 and factory installed in the electrical section The controller compares the mixed air temperature set point and the mixed air temperature from the Proportional Temperature Controller Sensor The controller sends a 2 10 Vdc signal to the modulating damper actuator in order to maintain the set point The controller includes a set point dial that must be field set to the desired mixed air temperature typically 55 F AIR5 594 6 27 OPTIONS Figure 28 1 Proportional Temperature Controller 4 N Set Point A350 VOLTS
143. tic Pressure Start 300 83 F 100 F 2222 74 F 89 F 2500 62 F 74 F 13000 53 F 63 F 3500 46 F 56 F 4000 41 F 49 F 4500 37 F 44 F 5000 34 F 40 F 5500 Start 300 __ 83 F 100 F 2222 74 F 89 F 2500 62 F 74 F 13000 53 F 63 F 3500 46 F 56 F 4000 41 F 49 F 14500 37 F 44 F 5000 34 F 40 F 5500 31 F 37 F 6000 28 F 34 F 6500 250 300 J 46 F 56 F 46 F 56 F 37 F 44 F 5000 31 F 37 F 6000 26 F 32 F 7000 23 F 28 F 8000 End 250 20 F 24 F 9259 100 96 87 F 100 F 2963 74 F 85 F 3500 65 F 74 F 4000 58 F 66 F 4500 52 F 59 F 5000 ETA 1549 5500 350 400 G H 100 F 1 Start 400 gt 872 100 F 74 F 85 F 65 F 74 F 58 F 66 F 52 F 59 F 47 F 54 F 43 F 49 F 40 F 46 F 350 400 1 J K _100 F Start 400 gt 87 F 100 F 65 F 74 F 52 F 59 F 43 F 49 F 37 F 42 F 32 F 37 F 29 F 33 F 26 F 30 F 24 F 27 F 23 F 26 F D Total static pressure should include external static pressure and accessory
144. tion in response to contact closures from the space pressure controller When the space pressure is above the desired set point a high pressure contact on the space pressure controller energizes the damper to drive the fresh air damper closed When the space pressure is below the desired set point a low pressure contact on the space pressure controller energizes the damper to drive the fresh air damper open When the space pressure is between the high and low set points the damper floats at the fresh air percentage that satisfied the space pressure controller Full 90 rotation of the floating actuator requires 150 seconds For additional information on the space pressure controller refer to Literature 5 585 latest revision The damper actuator is designed to float and therefore it is not spring return When the unit is de energized under normal operation the fresh air damper is closed by a relay contact closure which electrically drives the damper closed If the supply power to the unit is interrupted before the damper actuator can drive closed the fresh air damper will remain open The damper can be manually closed through the use of the manual override Switch on the floating damper actuator 29 Enthalpy Controller OPT An enthalpy controller is provided with Air Control option GJ Digits 20 amp 21 and factory installed in the blower section The purpose of the enthalpy controller is to use outside air for cooling whe
145. tions where gas ignition system is exposed to water spray rain or dripping water 500 600 AIR5 594 6 3 UNIT LIFTING UNIT MOUNTING UNIT LIFTING All standard blower system units are shipped fully crated with skid supports below the unit The unit may be lifted from the bottom by means of a fork lift or other lifting device only if the shipping support skids are left in place DO NOT attempt to lift the unit from the bottom unless the shipping skid supports are still in place When lifting units make sure the load is balanced All extended cabinet systems are shipped without a crate and cannot be lifted with a fork truck Use a crane or other overhead lifting device in conjunction with the lifting holes refer to page 50 for base rail lifting hole locations for safe unit relocation If the unit must be lifted from the bottom for final installation of the unit be sure to properly support the unit over its entire length to prevent damage UNIT MOUNTING Be sure the method of unit support Suspension or floor mounting is adequate to support the weight of the unit see Weights for base unit and factory installed option weights For proper operation the unit must be installed in a level horizontal position Combustible material and service clearances as specified in Figure 3 1 and Tables 3 2 and 3 3 must be strictly maintained To assure that flames are directed into the center of the heat exchanger tubes the unit must be le
146. ts a stainless steel heat exchanger is not required when a cooling section is used However a stainless steel heat exchanger is still recommended when the combined entering return air to the unit is below 40 F The cooling section includes a full coverage 3 way sloping 409 stainless steel drain pan to remove condensate from coil headers thermal expansion valves and refrigerant piping Insulation is standard on outdoor units and optional on indoor units and double wall construction is optional on all units The cabinet includes two doors a removable upper door for service access to the coil once the plumbing has been installed and a lower door which includes a factory supplied 1 stubbed drain connection to the exterior of the cabinet Field connections for coil inlet and outlet piping can be made through the cabinet corner post or back of the unit The cooling section duct transition includes 1 1 2 flanges for fastening the sides of the coil The bottom duct transition is angled to remove any condensation that may be entrained in the supply air stream For field supplied coils do not exceed the maximum coil dimensions listed in Literature 82 135 The dimensions listed are for the maximum coil dimensions If the coil supplied is smaller than the listed dimensions field supplied blank off plates are required to prevent air bypass around the coil The coil is supported by two 14 gauge support rails which contain mounting provisions for f
147. ut 400 400 000 Btu Hr Input 960 1 200 000 Btu Hr Input 7 Heat Exchanger Burner Drip Pan Material HE A Aluminized Steel S 409 Stainless Steel Heat Exchanger Burner T 409 Stainless Steel Heat Exchanger Burner Drip Pan 8 Development Sequence Designation DS F Single Stage 2 stage or Modulating 9 Access Side AS R Right Hand L Left hand 10 Air Temperature Rise ATR H High 60 100 F L Low 20 60 F 11 Gas Type GT N Natural with ignition controller P Propane with ignition controller 12 Gas Valve GV 1 Single Stage 6 Electronic Modulation Slave 2 Two Stage 7 Electronic Modulation 0 10 4 Electronic Modulation Input 5 Electronic Modulation Master 8 Electronic Modulation 4 20 mA External Input 13 Additional Safety Switches SS 0 No Switches Standard 1 Low Gas Pressure Switch Premium 2 High Gas Pressure Switch Premium 3 High and Low Gas Pressure Switch Premium 14 Supply Voltage SV 115 60 1 230 60 3 208 60 1 460 60 3 230 601 G 575 60 3 D 208 60 3 15 Transformer TR 1 40 4 250 2 75 0 None 3 150 VA GV SV TR HP 16 Blower Size amp Bearing BB A 9 7 Spider Bearings G 15 15 Spider Bearings 9 7 Pillow Block Bearings 15 15 Pillow Block Bearings C 9 9 Spider Bearings 18 18 Spid
148. ut rating should be reduced at the rate of 4 for each 1000 feet above sea level For Canada in elevations between 2000 and 4500 feet the unit must be derated to 90 of the rating listed above 2 For Variable Air Movement Applications see page 20 30 AIR5 594 6 GENERAL PERFORMANCE DATA Table 31 1 Air Temperature Rise Btu Hr Air Temperature Rise through Unit F Input Output 40 45 50 55 75 000 60 000 100 000 80 000 2963 2469 125 000 100 000 3704 3086 150 000 120 000 4444 3704 175 000 5185 4321 200 000 5926 4938 225 000 6667 5556 250 000 7407 6173 300 000 8889 7407 350 000 ir Temperature Rise through U es 70 75 80 105 110 CFM 9259 8230 5291 11111 9877 6349 12963 11523 7407 14500 13000 8466 12698 D Ratings are shown for elevations up to 2000 ft For higher elevations the input rating should be reduced at the rate of 4 for each 1000 feet above sea level For Canada in elevations between 2000 and 4500 feet the unit must be derated to 90 of the rating listed above 0 For Variable Air Movement Applications see page 20 Air Temperature Limits The maximum allowable discharge air temperature is 150 F The maximum allowable air temperature rise per furnace for Low Air Temperature Rise Units is 60 F All system units are designed for a
149. vel in a horizontal position Use a spirit level to ensure that the unit is suspended or floor mounted correctly Unit Suspension Four 3 4 diameter suspension hanging locations are provided in the base rail assembly of the unit Refer to Figure 50 1 for Suspension Hanging Locations and Figure 4 1 demonstrates how the unit should be suspended and fastened to the unit base rail If required vibration isolators may be added Figure 4 1 Unit Suspension Method 5 8 SUSPENSION RODS BY OTHERS BLOWER SECTION 1 3 4 NUT amp LOCKWASHER 7 i i Y 2 3 4 NUTS amp LOCKWASHER Floor Mounted Units For floor installations the floor structure must be adequately designed to support the live weight load of the unit and any other required support structure Additional reinforcement should be provided if necessary The floor should include threaded 5 8 inch anchor bolts spaced according to Figure 4 2 and Table 4 1 for securing the unit in place Anchor bolts should extend at least 1 1 2 above the surface of the floor to allow clearance for mounting washers nuts and bolts mounting washers nuts and bolts by others Figure 4 2 Floor Mounted Units 5 8 Dia 4 S Table 4 1 Floor Mounted Unit Anchor Bolt Dimensions inches Model Blower Type IBS Units ICS Units All Units IBS Units Size Digit 16 A A B 75 All 86 27
150. w v ar M 1 8 Table 51 2 Chilled Water Coil Dimensions Model Size Supply Line Return Line 75 1 50 100 125 1 50 150 175 1 50 200 225 1 50 250 300 1 50 350 400 1 50 1 50 1 50 1 50 1 50 1 50 1 50 AIR5 594 6 DIMENSIONS WEIGHTS MAINTENANCE Figure 52 1 Remote Panel Dimensions 5 1 LHoles visable on right side are also on left side in the same location 2 LHoles on top are also on the in the same location horizontally O 0 1 down vertically Table 52 1 Remote Panel Dimensions All dimensions in inches Remote Panel Type Light and Switch Panels Only Light and Switch Panels with Single Stage Thermostat or Electronic Set Point Adjustor Light and Switch Panels with Two Stage Thermostat Table 52 2 Blower Package Unit Operating Weights Model Blower Type Digit 16 Unit Filters All Dampers Fresh Air F amp RA Dampers Insulation Maintenance heating equipment should be serviced before each heating Season to assure proper operations The following items may be required to have more frequent service schedule based on the environment in which the unit is installed and the frequency of the equipment operation Blower Assembly The blower assembly includes
151. witch The switch should operate only when something is seriously wrong with the unit operation Anytime the switch operates correct the difficulty immediately or serious damage may result If the switch cuts off the gas supply Possible Cause Insufficient primary air Main pressure set too high Orifice too large Blocked vent Main pressure set too high Orifice too large Blocked vent Unit cycling on high limit a Obstructions leaks in duct system b Main pressure set too high c Blower motor not energized d Loose belt e Blower speed too low f Blocked damaged venting system g Air distribution baffle removed high temperature rise units only h Defective high limit switch Main pressure set too low Too much outside air Thermostat malfunction Gas controls wired incorrectly Unit undersized Thermostat malfunction Gas controls do not shut off a Gas controls wired incorrectly b Short circuit Main gas pressure set too high Defective gas valve Possible Remedy Increase primary air Adjust to a maximum of 14 W C Check orifice size with those listed on the serial plate Clean correct venting system Adjust to a maximum of 14 W C Check orifice size with those listed on the serial plate Clean correct venting system Clean correct duct system Adjust to a maximum of 14 W C Check correct to insure blower motor operates within 45 seconds of w
152. witch prevents the unit from cycling on the high limit If the limit temperature is exceeded a service person must inspect the unit for the cause of the high discharge temperature take corrective action and then reset the switch AIR5 594 6 OPTIONS 47 Main Gas Valve STD The main gas valve is factory installed in the duct furnace gas train The main gas valve provides the pilot regulator main gas and manual shutoff functions For additional information see the supplier literature included with the unit 48 Supply Air Fire Stat OPT The supply air fire stat is factory installed in the duct furnace electrical junction box with the sensor in the discharge air stream In case of elevated temperatures in the supply air stream the manual reset switch shuts down the entire unit If the limit temperature is exceeded a service person must inspect the unit for the cause of the high discharge temperature take corrective action and then reset the switch 49 Burner Box STD The burner box is located in the duct furnace section and contains the burner and pilot assembly The burner box includes an access panel for removal of the burner for inspection and servicing Not Shown Circuit Analyzer OPT The circuit analyzer is factory installed on the door of the electrical section The circuit analyzer is used to quickly assist service personnel in troubleshooting by monitoring the unit firing sequence and vital o
153. y Power Terminal Strip STD The furnace supply power terminal strip is located in the duct furnace electrical junction box The terminal strip is labeled to match the electrical wiring diagram provided with the unit Supply power labeling ranges from terminal numbers 80 to 99 All field wiring connections should be made to the bottom side of the terminals to prevent miswiring by modifying the factory wiring which is made to the top of the terminal strip 13 Control Step Down Transformer STD The control step down transformer is located in the duct furnace electrical junction box The transformer is used to step down the supply power 115V 208V 230V 460V 575V to 24V This transformer is used to control the gas controls damper actuator motor starter etc Refer to the unit model number to determine the volt amp VA capacity of the duct furnace The 15th digit indicates the VA See Model Nomenclature 14 Control Relay OPT The control relay is factory installed in the electrical section The relay has a 24V coil with double pole double throw DPDT contacts Refer to the unit wiring diagram for the function of the switching operation of the relay The two normally open and two normally closed contacts are rated for a maximum of 30 amps 115V 1Ph 15 Blower Low Voltage Terminal Strip STD The blower low voltage terminal strip is located in the electrical section The terminal strip is labeled to match the

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