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for your safety for your safety important caution warning

1. Duct Connection 5 29 6 28 ehe 1 Spaced 2 0 apart Le ZR 34 00 nk 2 g t 9 50 I L 7 1 1 45 2 446 22 98 Height mn N PEL 2400 2 F 24 00 F Width F 300 4 Ca Inside 22 K Inside inside ae Inside i CS 37 85 p ji rape ondi E all yi UM ii als mam i Dus Connection 2 a cu _ WV ug 16 73 24 00 435 inside 1150 d mon rr T sm 1 1 om 6 28 5 500 800 Model Shown Figure 42 2 HDG HDP Outdoor Downturn Package Unit Dimensions with Blower Type I J K or L 2 P Over Root 29 32 47 27 36 58 2 4162 s D p200 Qty 4 Drill Locator Max Dimples for Field 1 Optional Rainhood 6 Drilled Electrical 232 amp Birdscreen E E x Se oF 145 Y Sch E 4 x zem l 24 00 2 2400 a inside 16 K Inside inside m 37 85 43 23 SL NF S mL DE Du 41 lownturn cu Fresh Air Connection lh OM Ab NEN 921 Duct Connection
2. 33 34 35 36 37 38 39 40 Mild Temperature Thermostat 42 41 59 9 9079 9 D 08 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 ORORO 44 45 46 47 48 49 50 51 52 53 3a Blower Supply Power Terminal Strip Service Switches Electronic Modulating Amplifier Electronic Modulating Gas Valve Air Flow Proving Switch High Limit Switch Supply Air Fire Stat Main Gas Valve Burner Box Direct Drive Damper Actuator Damper to Damper Linkage 43 Warm Up Stat 54 Discharge Damper 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 Not Shown The discharge thermostat is field 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 Model Sizes 500 960 contain multiple furnaces so multiple thermostats sensors may be included The thermostat s provided can be one of the following a Two stage Capillary Type Thermostat The thermostat includes a thermostat body and c
3. 14 5 572 8 START UP PROCEDURE Main Burner Adjustment The gas pressure regulator integral to 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 maintenance 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 or at the pressure tap of the gas valve for standard gas string See Figure 15 1 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 in the pipe tee or gas valve 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 ON 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 Ifthe unit has Electronic Modulation ga
4. 1 TOP HOUSING 2 COVER PLATE 3 SEAL GASKET 4 MAXIMUM ADJUSTMENT SCREW 5 MAXIMUM ADJUSTMENT SPRING 6 SOLENOID 7 MINIMUM ADJUSTMENT SPRING 8 PLUNGER 9 MINIMUM ADJUSTMENT SCREW 10 MINIMUM ADJUSTMENT SCREW STOP Air Shutter 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 in Figure 15 1 The larger models may require the removal of the manifold see Manifold Assembly Removal Adjusting the primary combustion air is achieved by resetting the primary air shutters See Figure 51 2 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 1 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 and a clean blue flame with a well defined inner cone appears 2 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
5. For HDG HDP and HPG HPP Downturn Discharge 1 The blower section back and bottom and the downturn plenum bottom is designed to accept 90 flanged ductwork on both the supply and return air openings Refer to the roof curb Figure 46 1 or the unit base Figure 45 1 dimensional drawings to determine the location of the openings 2 Acoustic duct liners are recommended on all internal supply and return air ducts 3 When ductwork is installed prior to unit arrival flexible connections should be included to make connections easier and to simplify possible future service 4 When a roof curb is used in conjunction with factory supplied discharge and or return air connectors the ductwork can be fastened to the connectors prior to the unit installation The connectors will accept 90 flanged ductwork See Figure 6 2 Figure 6 2 Discharge and or Return Air Connectors UNIT BASE 90 FLANGED DUCTWORK By Installer BEFORE UNIT INSTALLATION CAULK ALL MATING SURFACES Caulk by installer RETURN AIR CONNECTOR DISCHARGE AIR CONNECTOR Utility Connections Utility and control connections can be made to the unit from the bottom for roof curb mounted units or through the fixed side panels for horizontal supply and return units Holes can be made in fixed side panels to accommodate utility connections as specified according to the unit dimensional drawings Sealing of holes cut in the unit casing for ut
6. MODINE 5 572 8 5H0762330001 August 2015 INSTALLATION AND SERVICE MANUAL gas fired weatherproof duct furnaces make up air units power vented models HBP HCP HDP HPP gravity vented models HBG HCG HDG HPG 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 Installing starting up and servicing heating ventilation and air conditioning equipment poses significant hazards and requires specialized knowledge of Modine products and training in performing those services Failure to have any service properly performed by or making any modification to Modine equipment without the use of qualified service personnel could result in serious injury to person and property including death Therefore only qualified service personnel should work on any Modine products K Listed Intertek All models approved for use in California by the CEC A 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 FOR YOUR SAFETY IF YOU SMELL GAS 1 Op
7. side for Direction SIDE VIEW Left Hand Units FRONT VIEW V 225 Supply Water Line Connection turned 90 in Y direction of airflow Y t gt 1 8 Table 47 2 Chilled Water Coil Dimensions Model Size Supply Line Return Line 75 1 50 MPT 1 50 MPT 100 125 1 50 1 50 150 175 1 50 MPT 1 50 MPT 200 225 1 50 1 50 250 300 1 50 MPT 1 50 MPT 350 400 1 50 MPT 1 50 MPT 5 572 8 47 DIMENSIONS RAINHOOD REMOTE PANEL EVAPORATIVE COOLER Figure 48 1 Rainhood and Birdscreen Dimensions Table 48 1 Rainhood and Birdscreen 1 09 42 66 Approx 1 14 Dimensions All dimensions in inches Rainhood amp Birdscreen Model Size A 75 100 125 32 71 150 175 200 225 250 300 350 400 500 600 700 800 840 960 Figure 48 2 Evaporative Cooling Module Figure 48 3 Remote Panel Dimensions Top View J Box Pump m a 1 2 NPT Drain x 1 2 NPT Overflow mw ef 7_ t Optional 1 Pre Filter Rack Side View Blower Section 36 00 ____ Media 1 2 NPT Water Inlet 6 or1 2 le Y 4 N 3 t 450 00
8. 3H35129B14 Table 36 4 Digit 16 K 18 18 Blower Units with 15 Hp motor amp up Motor Frame Size RPM Range 3H35129B18 826 1009 995 1161 1101 1285 1232 1438 Digit 19 Sheave Assembly 3H35130B1 Digit 19 3H35130B3 Sheave Assembly Digit 19 3H35130B5 Sheave Assembly Digit 19 Sheave Assembl y 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 Digit 19 3H36622B3 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly 182 to 184 3H36622B2 3H36622B4 3H36622B6 3H36622B12 213 or 215 3H36622B5 3H36622B7 3H36622B13 3H36622B18 254 3H36622B8 3H36622B14 3H36622B19 3H36622B23 256 3H36622B9 3H36622B15 3H36622B20 3H36622B24 36 5 572 8 X Y Z 284 3H36622B10 3H36622B16 3H36622B21 3H36622B25 286 3H36622B11 3H36622B17 3H36622B22 3H36622B26 BLOWER SHEAVE ASSEMBLY DATA Table 37 1 Blower Sheave Assembly Settings Turns Open Sheave Assembly 2 2 5 3 Blower RPM 3H35125B1 2 3H35125B3 5 3H35125B6 7 3H3
9. 0 34 0 73 0 46 0 97 0 60 1 23 4000 0 04 0 12 0 07 0 19 0 10 0 27 0 15 0 36 0 20 0 47 0 27 0 60 0 34 0 73 0 42 0 89 0 50 1 05 0 60 1 23 6000 0 17 0 41 0 23 0 52 0 29 0 64 0 43 0 91 0 60 1 23 6500 0 03 0 11 0 04 0 14 0 08 0 22 0 12 0 31 0 18 0 42 0 24 0 55 0 32 0 70 0 40 0 86 0 50 1 04 0 61 1 24 11050 Accessory Option static pressure losses are approximate values only Please consult the Accuspec selection software for static pressure losses 5 572 8 at other than listed CFM 31 BLOWER PERFORMANCE DATA Table 32 1 Unit Performance Tables 100 F 79 F 69 F 56 46 F 40 35 31 100 F 80 F 100 F 62 F 77 F 53 F 66 F 41 F 51 F 34 F 42 28 F 36 25 F 31 F 51 F 42 F 36 F 31 F 27 F 25 F 23 F 20 F 00 86 F 100 F 79 F 93 F 62 F 72 51 F 59 F 43 F 50 37 F 43 86 F 100 F 79 F 93 F 62 F 72 F 51 F 5
10. 43 F 40 F 40 F 62 F 74 F 53 F 63 F 46 F 56 F Start 500 41 F 49 F 44 48 F 40 700 800 40 F 120 F Start 800 115 500 600 5000 94 F 108 F 5500 86 F 99 F 6000 700 800 80 F 91 F 120 F Start 800 104 F 119 F 86 F 99 F 65 F 74 F 58 F 66 F 52 F 59 F 47 F 54 F 43 F 49 F 700 800 40 F 46 F 65 F 74 F 58 F 66 F 52 F 59 F 47 F 54 F 47 F 54 F End 700 43 F 49 F 40 F 46 F 42 F 8 18 994 19 1019 19 1045 2 3 685 736 3 785 419 14500 02 968 61 21 82 E 840 960 120 F 6481 72 630 3 09 3 48 88 4 30 832 4 72 876 5 60 960 6 52 1038 7 48 1112 111 F 7000 3 36 672 3 76 723 4 17 772 4 60 818 5 04 863 5 49 905 642 986 7 38 1061 8 39 1133 End 840 05 F 120 7407 3 93 705 4 35 754 4 79 800 5 23 845 5 69 888 6 16 929 7 13 1007 8 13 1081 9 17 1151 926 97 F 111 F 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 86 F 99 F 78 F 89 F 70 F 80 F 65 F 74 F End 840 Total static pressure should include external static pressure and accessory option static pre
11. 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 Turn on main power Check control transformer Check replace thermostat Replace power exhauster relay Replace power exhauster motor The duct furnace comes standard with an automatic reset high Lifting Flame Condition limit switch that will shut off the gas should the discharge air temperature become excessive See Figure 19 1 indicator for the location of either the standard automatic or optional manual reset high limit switch 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 during normal operation refer to the Not Enough Heat section of Service amp Troubleshooting Figure 53 2 Figure 53 3 Floating Flame Condition Flame Rollout Appearance 4 pez x 5 572 8 53 MODEL DESIGNATIONS Model Identification Modine weather
12. 56 5 572 8 MODEL NOMENCLATURE FOR SYSTEM UNITS Weatherproof Model Nomenclature 1 2 3 456 7 8 9 10 16 17 18 19 2021 22 23 UC V MBH HE DS AS ATR 1 Product Type PT H Outdoor HVAC Unit 2 Unit Configuration UC B Blower Package Furnace amp Blower C Cooling Package Furnace Blower amp Cooling Cabinet D Downturn Package Furnace Blower amp Downturn P Packaged Unit Furnace Blower Cooling Cabinet amp Downturn 3 Venting V G Gravity 4 5 6 Furnace Input Rating MBH Output on 840 amp 960 P Power 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 Input 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 M 2 stage or Modulating 9 Access Side AS R Right Hand 10 Air Temperature Rise ATR H High 60 100 F L Low 20 60 F L Left hand 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 Vdc 4 Electronic Modulation External Input 5 Electr
13. Determine the Additional Safety Switches Since no additional safety switches were specified the Additional Safety Switches 0 29 UNIT SELECTION 10 11 12 30 Determine the Supply Voltage From item 9 listed above the 460V 60Hz 3Ph results in the Supply Voltage F Determine the Transformer With the selected Unit Type HDP the Transformer 2 Determine the Blower Size and Bearing Type Using Table 27 1 the Model Size 400 has three available blowers for which the performance tables are shown on page 32 Since all of the blower performance tables can provide the required 5000 cfm the total static pressure for each blower performance curve must be determined A The Pressure Drop of an option or accessory is determined by entering the right of the table at the desired cfm and reading across the table until the cfm intersects the desired item For this example in table 31 1 the 2 Permanent Filter is used At the point of intersection read across the table to the right and read the pressure drop in inches of water column for the filters For this example the pressure drop is 0 06 W C This method is used to determine the pressure drop for the other options and accessories As a result For the Model Size 400 with Digit 16 E F G or H 2 Permanent Filters 0 06 W C Rainhood 0 11 W C Downturn 0 07 W C Internal Static Pressure Drops 0 24 W C The Total Static Pressure for the sys
14. HCG HCP Outdoor Cooling Package Unit Dimensions with Blower Type J or 141 34 24 00 mE 47 27 36 58 P Over Roof eu ver Hoo 1 P 2 Qty 4 Drill Locator D Max Dimples for Field Drilled Electrical 8 l Conduit Entry Holes 2 32 Optional Rainhood Poo spaced 2 0 apart amp Birdscreen Duet Air i 7 gt PECs seme 2 56 Connection n 28 00 Height 00 M MS 5100 x i K Inside Width Inside 2 Inside Inside pM N 1 2 Em Re Fresh Air 9 21 Duct Connection IN 2 03 Fi Return Air 24 00 4 35 1 50 1 50 3 00 Duct Connection Inside 5 29 5 29 16 73 a 3 24 94 6 28 6 28 229 143 98 Figure 44 2 Outdoor Packaged Unit Dimensions with Blower Type I J or K 170 66 29 32 24
15. P 921 H _ WV H 2 03 1 eT 24 00 2400 3 00 427 Inside mm 985 4 35 IS 4 19 1 2 500 800 Model Shown Table 42 1 HBG HPG HDG HDP Outdoor Unit Dimensions with Blower I J K or L All dimensions in inches 250 300 l J or K Qty of Furnaces Dimensions 350 400 l J or K 500 600 I J K orL 700 800 I J K orb 840 960 For Right Hand Access Units Location of drill locator dimples for field dril For Left Hand Access Units Location of drill locator dimples for field drille G For Right Hand Access Units Location of drill locator dimples for field dril I J K led gas connection entry holes one side of unit and one on bottom d gas connection entry holes one side of unit and one on bottom ed electrical connection entry holes identical as side electrical connections amp For Left Hand Access Units Location of drill locator dimples for field drilled electrical connection entry holes identical as side electrical connections For Gravity Vented Models the combustion air vent cap is required so only dimensions B C and D apply For Power Vented Models the power exhauster discharge cover and inlet louvers are included so only dimensions Q and R apply Applies to units with Digit 16 L only 42 5 572 8 DIMENSIONS UNIT Figure 43 1 HCG HCP Outdoor Cool
16. Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly 143 to 145 3H35127B2 3H35127B3 3H35127B4 3H35127B7 3H35127B9 3H35127B12 F 3H35127B6 Q 3H35127B17 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 Sheave Assemb ly 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 Size 143 145 3H35128B12 3H35128B14 491 649 586 744 682 821 821 1009 995 1161 1101 1285 Sheave Assembly 3H35129B1 3H35129B2 Sheave Assembly 3H35129B4 3H35129B5 Sheave Assembly 3H35129B8 Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly 182 to 184 3H35129B3 3H35129B6 3H35129B9 3H35129B11 3H35129B15 213 or 215 3H35129B7 3H35129B10 3H35129B12 3H35129B16 3H35129B19 254 3H35129B13 3H35129B17 3H35129B20 256
17. 1 1 4 Capacities in Cubic Feet per Hour through Schedule 40 pipe with maximum 0 3 W C pressure drop with up to 14 W C gas pressure Specific gravity is 0 60 for Natural gas and 1 50 for Propane gas For Pipe Capacity with Propane Gas divide Natural gas capacity by 1 6 Example What is the Propane gas pipe capacity for 60 feet of 1 1 4 pipe The Natural gas capacity is 400 CFH Divide by 1 6 to get 250 CFH for Propane gas 8 5 572 8 INSTALLATION Table 9 1 Burner Orifice Sizing and Gas Consumption Gas Type Orifice Natural Propane Qty Cfh Orifice Drill Size Cfh Orifice Drill Size Cfh Orifice Drill Size Cfh Orifice Drill Size Cfh Orifice Drill Size Cfh ifice Drill Size Cfh ifice Drill Size Cfh ifice Drill Size Cfh ifice Drill Size Cfh ifice Drill Size Cfh ifice Drill Size Cfh ice Drill Size Cfh ice Drill Size Cfh ice Drill Size Cfh ifice Drill Size Cfh ifice Drill Size Cfh ice Drill Size 175 9 9 9 Q Q 500 es eS Q 95 Q Based on natural gas properties of 1040 Btu Cu Ft and specific gravity of 0 60 Q Based on propane gas properties of 2500 Btu Cu Ft and specific gravity of 1 53 Model sizes 500 800 contain 2 furnaces Values shown are per furnace Model sizes 840 960 co
18. 120 120 Min Temp Rise F 53 40 40 63 40 40 76 40 40 Max CFM Min 2 Model Size Digits 4 6 Btu Hr Input 3086 800 000 800 000 800 000 1 050 000 3704 1 050 000 3704 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 G or H LJ 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 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 For Variable Air Movement Applications see page 18 5 572 8 1296 27 GENERAL PERFORMANCE DATA Table 28 1 Air Temperature Rise Btu Hr Air Temperature Rise through Unit F 60 65 70 CFM Output 60 000 100 000 80 000 125 000 100 000 150 000 120 000 175 000 140 000 200 000 160 000 225 000 180 000 250 000 200 000 300 000 240 000 350 000 280 000 Btu Hr Air Temperature Rise throug
19. 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 the AccuSpec configuration software Within AccuSpec three variable frequency drive speed control changeover options are available 1 Two speed which 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 the space 3 Building management control which allows for an external signal of 0 10VDC of 4 20mA to adjust the unit airflow The allowable minimum CFM of the system can be 66 of the minimum listed CFM in Table 27 1 if the unit is applied as follows 1 The unit is provided with 2 stage or electronic modulating gas controls 2 The unit is provided with a discharge air thermostat 3 The system does not include a room thermostat The 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 t
20. b Freeze Protection During the winter chilled water coils need to be protected against freezing Two common methods are 1 blowing out the coils with air or 2 flushing coils with inhibited glycol designed for corrosion protection in HVAC applications Select an inhibited glycol solution that will protect the coil from the lowest possible temperatures that can occur at that locality 50 5 572 8 Electrical Wiring The electrical wiring should be checked annually for loose connections or deteriorated insulation 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 For HBG HCG HDG HPG units the combustion air intake and exhaust vent cap louvered openings For HBP HCP HDP HPP units the power exhauster discharge opening and the combustion air inlet louvers 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 The heat exchanger should be checked annually for cracks and discoloration of the tubes If a crack is det
21. 3 P SIDE VIEW FRONT VIEW Minimum clearance to combustible for HBP HCP HDP HPP is 1 0 from rooftop 5 572 8 3 UNIT LOCATION ROOF CURB INSTALLATION Sound and Vibration Levels All mechanical equipment generates some sound and vibration that may require attenuation Libraries private offices and hospital patient rooms will require more attenuation and in such cases an acoustical consultant may be retained to assist in the application Locating the equipment away from the critical area is desirable within ducting limitations Frequently units can be located above utility areas corridors restrooms and other non critical areas Generally a unit should be located within 15 feet of a primary support beam Smaller defections mean lesser vibration and noise transmission Roof curb must be installed level If roof is pitched it will be necessary to construct a sub base on which to install the curb Install the unit over roof decking with 2 acoustic fiberglass lining within curb area for sound attenuation The return air duct should be acoustically lined and should be installed with a flexible connection If the ceiling space is used as a plenum the acoustically lined return intake duct should form an inverted tee with five foot minimum legs in each direction The discharge duct should be acoustically insulated and should have a flexible connection as illustrated Figure 4 1 Suggested Sound Attenuation 2 Acous
22. 300 To prevent premature heat exchanger failure do not locate 350 400 ANY gas fired appliances in areas where corrosive vapors i e 500 600 chlorinated halogenated or acid are present in the atmosphere 100 125 150 175 200 225 Location Recommendations 1 When locating the furnace consider general space and heating requirements and availability of gas and electrical supply Non Access Side 2 Unit must be installed on the positive pressure side of the i i A circulating blower 3 Be sure the structural support at the unit location site is adequate to support the weight of the unit and any other 100 125 required support structure For proper operation the unit 150 175 must be installed in a level horizontal position 200 225 4 Do not install units in locations where the flue products can be drawn into the adjacent building openings such as 250 300 windows fresh air intakes etc 350 400 5 Be sure that the minimum clearances to combustible 500 600 materials and recommended service clearances are 700 800 maintained For HBG HCG HDG HPG units be sure 840 960 Figure 3 1 Combustible Material amp Service Clearances 2 SSS Se Combustion Air Vent 36 00 Cap on Models with 27 00 Digit 3 G Bes Power Exhauster _ AE Discharge Cover A eel on Models with Digit
23. 54 Latest Edition In Canada installation must be in accordance with CAN CGA B149 1 for natural gas units and CAN CGA B149 2 for propane units 2 For HBG HCG HDG HPG units do not operate duct furnaces without the factory supplied vent cap shipped loose fastened securely in place HBP HCP HDP HPP units are shipped with the power exhauster discharge cover factory installed 3 For HBG HCG HDG HPG units do not modify or obstruct the vent cap in any manner For HBP HCP HDP HPP units do not modify or obstruct the combustion air inlet louvers or the power exhauster discharge cover 4 Do not add any vents other than those supplied by the manufacturer 6 5 572 8 THIS PAGE INTENTIONALLY LEFT BLANK 5 572 8 UNIT INSTALLATION Gas Connections A WARNING 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 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 CAUTION Purging of air from gas supply line should be performed as described in ANSI Z223 1 latest edition National Fuel Gas Code or in Canada in CAN CGA B149 codes IMPORTANT To prevent premature h
24. 840 960 add 33 50 and 67 00 for second and third furnace gas connections 5 572 8 45 DIMENSIONS ROOF CURBS Figure 46 1 Roof Curb Dimensions SS 5 24 00 INSIDE GAS LINE CONN LH ASSY ONLY E lt 24 00 INSIDE SLN OPENING D US 4 1 79 5555 GAS LINE CONN RH ASSY ONLY ELECT BOTT PAN CONN AS o X We Ww YL d Discharge Air Opening is for HDG HDP HPG HPP models only Table 46 1 HBG HBP amp HDG HDP Roof Curb Dimensions All dimensions in inches Dimensions Blower Type HDG HDP HBG HBP HDG HDP Digit 16 A B F G H 75 100 125 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 or K 500 600 GorH 500 600 I J K or L 700 800 GorH 700 800 I J K or L 840 960 I J K or L Dimensions Blower Type HPG HPP HCG HCP HPG HPP Digit 16 A B G H 75 100 125 150 175 200 225 250 300 250 300 350 400 350 400 136 59 105 98 Gas connection for 1st furnace For Models 500 800 add 33 5 for second furnace gas connection For Model 840 960 add 33 50 and 67 00 for second and third furnace gas connections 46 5 572 8 DIMENSIONS COOLING COILS Figure 47 1 DX Coil Drawing dimensions in inches J Airflow Directi
25. Frame Size to determine the Sheave Selection For this example with a 182T frame with 920 rpm the Sheave Arrangement I 16 Determine the Air Control The Air Control option is selected based on the required damper configuration The available damper selections are detailed on page 21 For this selection a 10096 fresh air unit without return air was required so the Air Control DA 17 Determine the Evaporative Cooler An evaporative cooler was not specified so for purposes of this selection the Evaporative Cooler 0 18 Determine the Cooling Coil A 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 HDP400SMRLN40F2GG1IDA00 Once the basic model has been determined the additional options and accessories outlined on page 19 to 26 can be added to the unit 5 572 8 OPTION amp ACCESSORY PRESSURE DROP DATA Table 31 1 Option amp Accessory Pressure Drop Tables in W C 100 125 150 175 200 225 250 300 500 600 350 400 700 800 840 960 Filters Evap Cooler 12 Media Other 1 Permanent 2 Permanent 2 Farr Aeropleat 2 Farr 30 30 Without Pre Filters With Pre Filters Downturn Plenum Rainhood and Birdscreen Discharge Damper 0 02 0 08 0 04 0 12 0 08 0 23 0 15 0 36 0 23 0 53
26. SERVICE DOORS lt gt DISCONNECT ALTERNATE LOCATION with each unit one located in the duct furnace electrical DISCONNECS junction box and one in the electrical section of the unit ALTERNATE Refer to this diagram for all wiring connections ud 3 wire gauge must be sized according to the National i Electric Code or CSA code based on the power supply voltage amp draw and length of run Refer to Table 11 1 i for maximum wire lengths and the number of wires that can li be wired to each low voltage terminal block DISCONNECT Table 11 1 Low Voltage 24V Maximum Wire Length ft SWITCH WIRING AND CONNECTOR SUPPLY NEC 1996 Table 310 17 Copper wire with 90 C insulation conductors in free space not in conduit 86 F ambient For saa a rt other wire types refer to the NEC of CSA code Transformer Wire Gauge Evaporative Cooler Installation Size VA 14Ga 12Ga For units equipped with an evaporative cooler Digit 22 refer to Installation and Service Manual Evaporative Coolers Literature 5 588 4 250 26 4 per Terminal 4 Make sure all multi voltage components motors transformers etc are wired in accordance with the power supply voltage 5 The power supply to the unit must be protected with a fused or circuit breaker disconnect switch Refer to the Factory Mounted Option Locations Figure 19 1 for the factory mounted disconnect sw
27. Table 10 1 Gas Heating Values at Altitude Btu ft3 20909 0 2 000 2 001 3 000 3 001 4 000 4 001 4 500 4 501 5 000 5 001 6 000 6 001 7 000 7 001 8 000 8 001 9 000 9 001 10 000 Values shown for 3 5 W C manifold pressure for Natural Gas and 10 0 W C for Propane Gas If the local utility supplies gas with a different Btu ft3 value use Equation 10 1 to calculate the required manifold pressure Gas heating values shown are derated 4 per 1 000 of elevation 10 between 2 000 and 4 500 elevation in Canada in accordance with ANSI Z223 1 and CSA B149 respectively G 945 Btu ft for Canada 2 250 Btu ft for Canada When installed at altitudes above 2 000 a pressure switch may need to be changed Refer to Tables 10 2 and 10 3 to determine if a switch change is required If the utility is supplying gas with heating values SAME as shown in Table 10 1 the manifold pressure should remain set to 3 5 W C for natural gas and 10 0 W C for propane gas and you may proceed to the section on this page titled Selection of the Proper High Altitude Kit If the utility is supplying gas with heating values DIFFERENT than shown in Table 10 1 use Equation 10 1 to determine the appropriate manifold pressure for the elevation and gas heating value being supplied Note what that value is as it will be needed later for Start Up Proceed to the section on this page titled Selection of the Prop
28. 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 Figure 22 2 Minimum Positioner Belimo 20 21 Extended Grease Lines OPT The extended grease lines 21 are factory installed in the blower section and include Zerk grease fittings 20 factory installed on the exterior corner post between the electrical and blower sections This option allows the pillow block bearings to be lubricated with a grease gun without requiring the service personnel to remove both blower doors to access the bearings Refer to Lubrication Recommendations for lubricant recommendations 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 DWDI blower wheel so both sides of the blower must be free fr
29. box when the unit is equipped with Electronic Modulating Gas Controls Digit 12 4 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 47 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 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 48 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 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 S
30. dimensions Q and R apply 44 5 572 8 DIMENSIONS UNIT BASE Figure 45 1 Unit Base Dimensions A C To end of Unit 6 28 Drill Locator Dimple for Field Drilled Gas Inside Connection Entry Hole 1 E Left Hand Access Units Inside E 6 28 Drill Locator Dimple for Field Drilled Gas _ Connection Entry Hole Right Hand c Access Units Supply Air Opening Return Air Opening 4 29 24 00 Inside 24 00 Inside 4 85 Table 45 1 HBG HBP amp HDG HDP Outdoor Unit Base Rail Dimensions All dimensions in inches Dimensions Blower Type HBG HBP HDG HDP HBG HBP HDG HDP Digit 16 A B FO GO H 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 l J or K 500 600 GorH 500 600 I J 700 800 GorH 700 800 I J K 840 960 I J K orL Table 45 2 HCG HCP amp HPG HPP Outdoor Unit Base Rail Dimensions All dimensions in inches Dimensions Blower Type HCG HCP HCG HCP HPG HPP Digit 16 A C B F G H 75 100 125 150 175 200 225 250 300 250 300 350 400 350 400 Gas connection for 1st furnace For Models 500 800 add 33 5 for second furnace gas connection For Model
31. not approved by the factory will be at the owner s risk A CAUTION Do not reuse any mechanical or electrical component which has been wet Such component must be replaced IMPORTANT To check most of the Possible Remedies in the troubleshooting guide listed in Table 52 1 refer to the applicable sections of the Table 52 1 Troubleshooting Trouble Pilot does not light Main burners do not light Pilot is lit Lifting Flames See Figure 53 1 Yellow Tipping With propane gas some yellow tipping is always present Flashback Floating Flames See Figure 53 2 52 manual Possible Cause 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 Insufficient primary air Main pressure set too high Orifice too large Blocked vent cap 5 572 8 Possible Remedy Open ma
32. 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 A 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 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 21 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 21 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 Figure 21 1 Dead Front Disconnect Switch Assembly BLOWER SECTIO ELECTRICAL COMPARTMENT ACCESS DOOR DISCONNECT SWITCH HANDLE OPERATION INSTRUCTION LABEL BLOWER SECTION DISCONNECT LECTRICAL SWITCH HANDLE COMPARTMENT SHOWN IN THE STAND
33. yellow tipping 3 Re tighten set screws after adjustment 5 572 8 15 START UP PROCEDURE Blower Adjustments If blower fan speed changes are required adjust motor sheave as follows 1 Refer to page 32 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 16 1 Motor Sheave Adjustment Set Screw Toward Motor 4 57 _ Adjustable Half 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 Ibs of force Figure 16 2 Belt Tension Adjustment 3 4 deflection with 5 Ibs of force 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 lubricatio
34. 00 p 87 F 100 74 F 1 85 65 F 7 74 F 58 F 66 F 52 F 59 F 47 F 54 F 350 400 GH 100 Start 400 gt 87 F 100 F 74 F 785 65 F 74 F 58 F 7 66 F 1 50 F 4T FT 54F 43 F 7 40 F 40 F 7 46 F 100 F 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 Total static pressure should include external static pressure and accessory option static pressure from Table 31 1 Unit internal resistance has been included in the unit performance tables Brake Horsepower and RPM values are approximate values only Please consult the AccuSpec selection software for values at other than listed CFM static pressures 5 572 8 33 BLOWER PERFORMANCE DATA Table 34 1 Unit Performance Tables 2 2 Total Static Pressure Inches W C 025 oso 075 100 125 150 200 250 300 120 F 7 106 F Start 600 93 F 111 82 F 99 F 74 F 89 F 67 F 81 F 62 F 74 F 57 F 68 F 500 600 Start 600 93 F 111 F 74 F 89 F 62 F 74 F 53 F 63 F 46 F 56 F End 500 41 F 49 F 44 F
35. 00 3850 47 27 36 58 Over Root Prey 2 Qty 4 Drill Locator Dimples for Field Drilled Electrical D Max Conduit Entry Holes 2 32 Optional Rainhood 2 00 spaced 2 0 apart AE Birdscreen 2 1 x 9 50 z 2102 56 24 53 19 23 1 45 N 32 68 nS K Inside 24 00 Downturn 1 45 T Duct f 4111 13 00 Connection nd rd MN 10 26 24 00 3 i 24 00 4 27 Return Air 4 35 Inside Duct Connection Inside 429 1 16734094 6 28 76 28 173 22 Model Blower Size Digit 16 250 300 Dimensions H K 350 400 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 as side electrical connections For Left Hand Access Units Location of drill locator dimples for field drilled electrical connection entry holes identical as side electrical connections For Gravity Vented Models the combustion air vent cap is required so only dimensions B C and D apply For Power Vented Models the power exhauster discharge cover and inlet louvers are included so only
36. 100 full fire c Modulating Thermostat Room or Duct The main gas valve is opened 10096 and the burner firing rate is modulated between 40 and 100 full fire A resistance signal 8000 to 12000 ohms in the thermostat is converted 5 572 8 by the modulating amplifier to an inverted DC voltage OVDC for high fire to 12 VDC for low fire The output voltage is applied to the modulating gas valve to control the gas flow to the main burner The modulating valve is modulated open or closed based on the voltage from the amplifier less gas flow required higher voltage more gas flow required lower voltage Note When modulating duct sensing is utilized a room override thermostat can be added When the room override calls for heat the burner modulates to full fire operation until the room override is satisfied The unit then reverts back to duct sensing control When equipped with both either the duct sensor or the room override thermostat can call for heat d BMS Signal The main gas valve is opened 10096 and the burner firing rate is modulated between 40 and 100 full fire ABMS 0 10VDC or 4 20mA signal inverted such that 0 VDC or 4 mA is high fire and 10 VDC or 20 mA is low fire is converted by the signal conditioner modulating amplifier into an inverted DC voltage OVDC for high fire to 12 VDC for low fire The output voltage is applied to the modulating gas valve to control the gas flow to the main burner The signal co
37. 200000 200000 741 200000 225000 926 225000 926 225000 1111 250000 1111 250000 1296 250000 Btu Hr Output 160000 160000 160000 180000 180000 180000 200000 200000 200000 Blower Style Digit 16 Letter Max Temp Rise F CorD EorF G or H Cor D Eor F G or H EorF G or H l J or K Min Temp Rise F Max CFM Min 2 Model Size Digits 4 6 Btu Hr Input 300000 300000 300000 350000 350000 350000 400000 400000 400000 Btu Hr Output 240000 240000 240000 280000 280000 280000 320000 320000 320000 Blower Style Digit 16 Letter EorF G or H l J or K EorF GorH l J or K EorF GorH I J or K Max Temp Rise F Min Temp Rise F 100 100 100 100 100 100 100 100 100 Max CFM Min 2 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 GorH I J L GorH I J orK L GorH I J L Max Temp Rise F 120 120 120 120 120 120 120
38. 5 Hp Y 15 Hp with Motor Starter 20 Hp Z 20 Hp with Motor Starter Motor Type MT ODP 5 TE ODP High Eff 6 TE High Eff Sheave Arrangement SA See Sheave Tables 20 21 Air Control AC AA BA CA DA EA EQ FA RA Opening FAOpening FA amp RA Openings FA Dampers w 2 pos motor No RA amp RA Dampers w 2 pos motor ASHRAE Cycle EA with Warm up Stat FA Damper amp RA Opening w 2 pos motor GA FA amp RA Mod motor w 0 10 Vdc External Input GB amp RA Mod 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 Panel GE FA amp RA Mod motor w 3 pos damper 10096 RA Variable 10096 OA GG FA amp RA Mod motor w Minimum Position amp Prop Temp Controller GH GJ GK FA amp RA Mod motor w Remote Position amp Prop Temp Controller FA amp RA Mod motor w FA Enthalpy Controller ASHRAE Cycle II GG with Warm up Stat GM ASHRAE Cycle II GH with Warm up Stat HP JA KA 22 B D 0 23 0 5 572 8 FA amp RA Floating motor w Space Pressure Controller Manual FA amp RA Dampers Manual FA Damper with Return Air Opening Evaporative Cooling EC 12 CELdek Media Stainless Steel Casing 12 GLASdek Media Stainless Steel Casing None Cooling Coil CC None 1 Factory Installed Coil 57 58 THIS PA
39. 5125B8 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 5 572 8 37 BLOWER SHEAVE ASSEMBLY DATA Table 38 1 Blower Sheave Assembly Components Sheave Assembly Motor Sheave Blower Sheave Sheave Assembly Motor Sheave Blower Sheave Browning Browning z 2 S p Belt Pitch Dia Pitch Dia Bore Belt Pitch Dia Pitch Dia Bore 3H35125 3H35126 ang in 3H35129 alo oj o Oo mi i 3H35130 3H35127 BX75 Qty 2 BX82 Qty 2 BX82 Qty 2 B86 Qty 2 B86 B
40. 7 25 Leveling Legs NOTES 1 Holes visable on right side are also on left side in the same location 2 Holes on top are also on the back in the same location horizontally 1 down vertically Table 48 3 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 75 Blower Type Digit 16 All Maximum Cooling CFM in inches Media Face Area ft2 Face Velocity at Max CFM ft min 6 Media Digit 23 3 5 A or C 12 Media Digit 23 4 6 B or D Operating Weight Dry Weight Operating Weight 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 or K 500 600 GorH 500 600 I J KorL 700 800 GorH 700 800 J KorL 840 960 l J KorL All weights in pounds 48 5 572 8 WEIGHTS Table 49 1 HBG HBP Blower Package Unit Operating Weights Blower HBG Dampers Dampers Double Wall Digit 16 Vent Cap Motor Filters Fash Air 8 Sections All All All All E F G or H I J or K E F G or H I J or K GorH I J orb GorH I J I J orb Ra
41. 71 BX74 3H36622 Seas Qty 2 BX79 Qty 2 B83 Qty 2 83 B77 3H35128 Qty 2 B82 Qty 2 B82 Qty 2 81 Qty 2 81 Qty 2 B80 7 Qty 2 B80 Qty 2 80 Qty 2 B80 38 5 572 8 OS ELECTRICAL DATA Total Unit Amp Draw The total unit amp draw is a combination of the motor the control step down transformer the power exhauster motor and the evaporative cooler pump motor or step down transformer for 208V 1Ph 208V 3Ph 460V 3Ph or 575V 3Ph units where applicable The control step down transformer includes damper actuators ignition controllers gas valves control relays amplifiers and motor starters Motor Amp Draw Tables 39 2 to 40 2 Control Step Down Transformer Amp Draw Table 39 1 Power Exhauster Motor Amp Draw Table 39 1 Evaporative Cooler Amp Draw Table 39 1 e oH og Total Amp Draw Table 39 1 Unit Amp Draws Control Transformer Amp Draw Power Exhauster Amp Draw Evap Cooler Supply Digit 15 Transformer Digits 4 6 Model Size Amp Draw Voltage 1 2 3 200 400 500 800 840 960 Digit 22 or D 208 60 1 230 60 1 208 60 3 230 60 3 460 60 3 G 575 60 3 0 00 Amp draw is for a 250 VA transformer Amp draw is for a 500 VA transformer G Amp draw is for 750 VA transformer Only include evaporative cooler amp draw for gravity ve
42. 9 43 F 50 37 F 43 33 F 38 29 F 34 26 F 31 24 F 28 21 F 25 00 F 113 89 F 100 F 85 F 95 74 F 83 66 F 74 59 F 67 54 F 61 49 F 56 200 225 F 95 F F 83 F 67 56 F 48 F 42 F 37 F 33 F 30 F 28 F Total static pressure should include external static pressure and accessory option static pressure from Table 31 1 Unit internal resistance has been included in the unit performance tables Brake Horsepower and RPM values are approximate values only Please consult the AccuSpec selection software for values at other than listed CFM static pressures 32 5 572 8 BLOWER PERFORMANCE DATA Table 33 1 Unit Performance Tables 2 Total Static Pressure W C 1 00 1 25 1 50 7 83 F 100 F 74 F 89 F 62 F 74 F 53 F 63 F 46 F 56 F 41 F 49 F 37 F 44 F 34 F 40 F 250 300 G H 100 120 F 83 F 100 F 74 F 89 F 62 F 74 F 53 F 63 F 46 F 56 F 41 F 49 F 37 F 44 F 34 F 40 F 31 F 37 F 28 F 34 F 250 300 i J k 46 56 37 F 44 31 F 37 26 32 23 F 28 F End 250 s 20 F 04 F 122 F 20 350 400 EF 100 F 96 F Start 4
43. ED CONDITION OR WITHIN Other 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 Steam Hot Water Units Oil Fired Units Electric Units Cassettes Vertical Unit Ventilators 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 Compressors Vertical Unit Ventilators Burners High Intensity Infrared Units Sheet Metal Parts All Products As Modine Manufacturing Company has a continuous product improvement program it reserves the right to change design and specifications without notice TP 6 MODINE Modine Manufacturing Company 2015 Modine Manufacturing Company 1500 DeKoven Avenue Racine WI 53403 Phone 1 800 828 4328 HEAT www modinehvac com
44. GE INTENTIONALLY LEFT BLANK 5 572 8 THIS PAGE INTENTIONALLY LEFT BLANK 5 572 8 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 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 WARRANT
45. IL NEOPRENE VIBRATION ISOLATOR 36 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 37 Convenience Outlet OPT WARNING Do not perform service the convenience outlet without disconnecting its power supply The convenience outlet power supply is separate from main power supply to the unit When the 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 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 38 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 singl
46. ODUCED Figure 55 3 HBG HBP HCG HCP HDG HDP HPG HPP Serial Number Designations Serial Number Designations 01 10 201 01 02 1000 MOTOR SEQUENCE VENDOR CODE NUMBER 01 Century m 15 Marathon etc YEAR OF FAN OR BLOWER MANUFACTURE VENDOR CODE 01 2001 10 Lau 02 2002 20 Morrison etc etc m 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 serial number ready from the unit s 5 572 8 55 START UP CHECKLIST 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
47. OFF PANEL ON POSITION 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 18 Step Down Transformer OPT The step down transformer is factory installed in the eletrical section The transformer is required for power exhausted units Digit 2 P with a supply voltage of 460V 3Ph and 575V 3Ph and all units that have an evaporative cooler Digit 22 3 4 5 or 6 For all units with an evaporative cooler when the supply power voltage is 208V 1Ph or 208V 3Ph the transformer is provided to step down the voltage from 208V to 115V In this case the evaporative cooler pump motor operates at 115V For power exhausted units and all units with an evaporative cooler when the supply power voltage is 460V 3Ph or 575V 3Ph the transformer is provided to step down from supply power voltage to 115V In this case the evaporative cooler pump motor operates at 115V 5 572 8 21 5 19 Factory Installed Minimum Positioner 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
48. OL This 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 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 Gas Heat option on MPR models 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 RESALE 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 Compressors MPR Models 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 UNCHANG
49. R 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 ASA 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 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 CONTR
50. RE A GAZ A CONDUIT POUR EXTERIEUR Dhone 90048291323 POUR USAGE TNDUSTRIEL COMMERCTAI e MODEL NUMBER MIN INPUT BTU HR mon HEP 75SMRHPAOAL or 30000 i SERIAL NUMBER MIN INLET PRESS FOR PURPOSE OF c US sm 0917093615 0034mw som mum 11 msi casted D iLIMEETLTIQN NIN 1 9900100 TYPE OF GAS MANIFOLD PRESSURE IN W C a OF GAZ Propane PRESSION A LA TUBULURE 10 a HERTZ 60 DESIGN COMPLIES WITH DUCT FURNACE STANDARD TEMPERATURE RISE RANGE BLEVATION DE TEMPERATURE 0 70 2000 FT AIR THROUGHPUT 01T 610 M 2 DEBIT D IR INPUT 75000 BTU HR 67500 BTU HR MIN 556 DERIT CALDEIFTOUE 21960 1 9764 V 16 OUTEUT 60000 54000 BTU ER CEH 2778 RENDEMENT 17568 w 15811 1 19 Es n RECOMMENDED SERVICE CLEARANCE DIGAGENENT DE SERVICE RECOMENDE COMBUSTIBLE MATERIALS AND SERVICE CLEARANCES MATERIAUX COMBUSTIBLES 17 D GAGEMINTS D ENTRE TIEN AIR FLOW ATR COURANT ACCESS SIDE 18 7 45 7 COMMON REPLACEMENT PARTS NON ACCESS SDB 6 T COTE MON ACCES 15 204 COTE D ACCES For parts ordering contact the parts wholesaler or 3 A the manufacturer s representative serving your area T6 When inquiring about parts always provide model TOP VIEW number serial number description and part number WUE DE DESSUS When ordering parts provide part number listed For service contact your local qualified i
51. STABLE FILTER GREASE MOTOR RACK LINES SHEAVE MOTOR EXTENDED f GREASE LINE ZERK FITTINGS 1 4 PERIMETER GASKETED BLOWER CONNECTION CONVENIENCE OUTLET BLOWER DOOR BOTTOM DIRECT SAFETY SWITCH SUPPORTED DRIVE BLOWER AND DAMPER MOTOR ACTUATOR Blower Sheave Assembly Numbers Table 35 1 Digit 16 A or B 9 7 Blower Units RPM Range Motor Frame 656 1001 978 1265 1150 1561 1526 1858 1763 2147 Size Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly 48 3H35125B1 3H35125B3 56 3H35125B2 3H35125B4 3H35125B6 3H35125B8 3H35125B10 143 or 145 3H35125B5 3H35125B7 3H35125B9 3H35125B11 RPM Range Motor Frame 656 1001 978 1265 1150 1561 1526 1858 1763 2147 Size Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly 48 3H35126B1 3H35126B3 56 3H35126B2 3H35126B4 3H35126B6 3H35126B9 3H35126B12 143 or 145 3H35126B5 3H35126B7 3H35126B10 3H35126B13 182 or 184 3H35126B8 3H35126B11 3H35126B14 5 572 8 35 BLOWER SHEAVE ASSEMBLY DATA Blower Sheave Assembly Numbers Con t Table 36 1 Digit 16 E or F 12 12 Blower Units Motor Frame Size RPM Range 468 715 644 874 863 1078 1029 1332 1150 1438 1327 1659 Digit 19 Sheave Assembly 3H35127B1 Digit 19
52. 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 45 Service Switches OPT 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 components will remain energized Figure 25 4 Service Switches cepa ots ee eee a SYSTEM OVERRIDE SWITCH POSITIONS DAMPERS ONLY ON OFF OFF qq DAMPERS amp BLOWER ONLY ON OFF ON DAMPERS BLOWER amp FURNACE ONLY ON ON ON RESET SWITCHES TO OFF POSITION AFTER TESTING ON OFF SH75637A ON ON e OFF OFF 5 572 8 25 5 46 Electronic Modulation Amplifier An electronic modulation amplifier is provided factory installed in the duct furnace electrical junction
53. SYSTEM DATA Seve Voltage 4Phase ger Sistem Amps 1 MODINE Serial Number 02 710196 Size Time Delay 7 Modine Manufacturing Company 1500 DeKoven Ave Racine WI 53403 Phone 800 828 4328 COMMON REPLACEMENT PARTS For parts ordering contact the parts wholesaler or the manufacturer s representative serving your area complete listing of both can be found in your Installation and Service Manual 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 appropriate utility company 2 BTE Motor cuum ssim Design conforms to UL Std 1995 Certified to CAN CSA C22 2 No 236 Il 157697 9900100 9900100 5H76471B Rev B Figure 55 2 HFG HFP Serial Number Designations SERIAL NUMBER PREFIX lt blank gt if standard S if Special Product Order SERIES IDENTITY NUMBER CONTROL SUPPLIER 01 Robertshaw 09 White Rodgers 05 Honeywell 17 Technologies 08 Fenwal GAS VALVE SUPPLIER 01 Robertshaw 09 White Rodgers 05 Honeywell 17 0123 10000 SPO NUMBER lt blank gt if standard THHHHE if Special Product Order 09 09 36 10 SEQUENTIAL NUMBER Varies 0000 TO 9999 Each unit in a week has a unique number YEAR PRODUCED WEEK PR
54. T DOWN INSTRUCTIONS 1 TURN OFF POWER 6 CLOSE ALL GAS VALVES REFER TO INSTALLATION 6 SERVCE MANUAL FOR MORE INSTRUCTIONS FOR UNITS WITH 2 STAGE MECHANICAL MODULATION OR ELECTRONIC MODULATING GAS CONTROLS A FACTORY DISCHARGE AIR CONTROLLER AND NO ROOM THERMOSTAT INCLUDED n ge O LA GENERAL SEULEMENT POUR L INSTALLATION EXTERIEURE LA TEMPERATURE MINIMUM DE L AIR DEHORS EST 40 C POUR L INSTALIATION QUE SULVE LES SYSTEMS REFRIGERANTS INSTALLER DU C T DE L PRESSION POSITIVE DU VENTILATEUR POUR APPAREILS AVEC INTERRUPTHUR MANUEL HAUT LINITE REMISE EST SITU E DANS LA BO TE JUNCTION LECTRIQUE POUR REMETTRE PRESSER LE BOUTON INSTRUCTIONS D ALLUMAGE 1 DUVRIR TOUTES LIS ROBINETS GAZ DONNER LE COURANT 2 REGLER LB THERMOSTAT SUR LA POSITION DESIREE INSTRUCTIUNS DE FER METURE 1 COUPER LE COURANT ET FERMER TOUTES LES ROBINETS GAZ REFERREZ AU MANUAL D INSTALLATION ET DE SERVICE POUR PLUS D INSTRUC POUR APPAREILS AVEC DEUX PHASES MODULATION M CHANIQUE OU APPAREILS DE CONTROLE DE GAZ LECTRIQUES MODULES UN AIR CONTR LEUR DICHARGE INSTALL A LA MANUFACTURE 17 THERMOSTAT DE CHAMERI N EST PAS INCLUS 54 5 572 8 MODEL DESIGNATIONS Figure 55 1 Model Identification Plate MODEL IDENTIFICATION PLATE Model Number HBG 75AFRHN10A1AA1AAA1A al MOTOR DATA Mekos dP n L L 6 6 3 0 3 3
55. THE SPECIAL PRECAUTIONS LISTED BELOW FAILURE atmosphere ee 2 To prevent premature heat exchanger failure the input to RESULT IN PROPERTY DAMAGE OR LOSS PERSONAL the appliance as indicated on the serial plate must INJURY OR DEATH THESE INSTRUCTIONS ARE SUBJECT exceed ihe tated input by more than 5 TO ANY MORE RESTRICTIVE LOCAL OR NATIONAL CODES put 9y 3 To prevent premature heat exchanger failure observe heat HAZARD INTENSITY LEVELS exchanger tubes by looking at the heat exchanger through 1 DANGER Indicates an imminently hazardous situation the field installed access openings in connecting ductwork which if not avoided WILL result in death or serious injury in models HBG HBP or the unit access doors in models 2 WARNING Indicates a potentially hazardous situation HDG HDP HCG HCP or HPG HPP If the bottom of the tubes become red while blower and duct furnace are in th aue inui which if not avoided COULD result in death or serious injury operation Check to be sure the blower has baen setto th 3 CAUTION Indicates a potentially hazardous situation ication Refer t 16 for BI which if not avoided MAY result in minor or moderate injury application Meter t9 page 16 Tor Blower 4 IMPORTANT Indicates a situation which if not avoided 4 Start up and adjustment procedures should be performed by a qualified service agency 5 check most of the Possible Remedies in the troub
56. UNIT LOCATION Sl METRIC CONVERSION FACTORS clearances are maintained to the combustion air vent cap Tabl 1 For HBP HCP HDP HPP units be sure clearances are able 3 maintained to the combustion air inlet louvers and power Convert Multiply By Obtain Convert Multiply By To Obtain exhauster discharge cover Units are designed for 0 24 CFH 1 699 m3 min installation on non combustible surfaces or combustible psig 6 893 0 0374 mJ m3 surfaces with the minimum clearances shown in Figure 3 1 F JCF 32 x 0 555 pound 0 453 kg Table 3 2 and Table 3 3 inches 25 4 Btu hr 0 000293 kW hr 6 On units that have fresh air openings a method should be feet 0 305 meters gallons 3 785 liters provided to prevent water and debris from entering the unit CFM 0 028 m3 min psig 27 7 W C such as a rainhood and bird screen evaporative cooler etc 7 On HBG HBP and HCG HCP models adequate space must UNIT LOCATION be provided to install the discharge duct as shown in Figure 6 1 to insure even air flow across the heat exchanger A DANGE R Table 3 2 Combustible Material Clearances Appliances must not be installed where they may be exposed to potentially explosive or flammable atmosphere CAUTION Access Access Front amp Non Access Side Side Rear Side A B Appliances are designed for outdoor installation only DO NOT LOCATE APPLIANCES INDOORS IMPORTANT 250
57. Y 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 AGREES THAT IN NO EVENT WILL SELLER BE LIABLE FOR COSTS OF PROCESSING LOST PROFITS INJURY TO GOODWILL OR ANY OTHER CONSEQUENTIAL OR INCIDENTAL DAMAGES OF ANY KIND RESULTING FROM THE ORDER OR USE OF ITS PRODUCT WHETHER ARISING FROM BREACH OF WARRANTY NONCONFORMITY TO ORDERED SPECIFICATIONS DELAY IN DELIVERY OR ANY LOSS SUSTAINED BY THE BUYER Component Applicable Models Heat Exchangers Gas Fired Units except MPR Models OCCURS FIRST BUYER S REMEDY FOR BREACH OF WARRANTY EXCLUSIVE OF ALL OTHER REMEDIES PROVIDED BY LAW IS LIMITED TO REPAIR OR REPLACEMENT AT THE FACTORY OF SELLER ANY COMPONENT WHICH SHALL WITHIN THE APPLICABLE WARRANTY PERIOD DEFINED HEREIN AND UPON PRIOR WRITTEN APPROVAL BE RETURNED TO SELLE
58. apilary to be field installed in duct work The thermostat body contains the discharge air set point adjuster that must be field set 5 572 8 Figure 19 2 Two Stage Capillary Type Thermostat Downstream Ductwork by others Setpoint Adjuster Capillary Thermostat body Shown with cover removed 19 5 b Two stage Electronic Thermostat Includes a field installed discharge air sensor The thermostat body is field installed remotely and includes the discharge air set point adjuster that must be field set Refer to Literature 5 577 latest revision Figure 20 1 Two Stage Electronic Type Thermostat Sensor Note Second stage 5350 module not shown c Electronic Modulating Discharge Air Thermostat Includes a field installed mixing tube and discharge air sensor field installed in duct work The set point adjuster is field installed remotely and must be field set Refer to Literature 5 578 latest revision Figure 20 2 Electronic Modulating Discharge Air Thermostat Figure 20 3 Low or High Gas Pressure Switch 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 4 Power Exhauster STD HBP HCP HDP HPP units The power exhauster is fa
59. as and recheck for leaks soapy water works well If no leaks 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 and coil damage from water hammer 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 The outlet manifold should have a drain installed on the bottom 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 1 Once installed 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 2 All fiel
60. ay is factory installed 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 satisfied to remove the residual heat from the heat exchanger For single phase units below 1 1 2 Hp the time delay relay controls the motor directly For single phase units 1 1 2 Hp and greater and all three phase units the time delay relay controls the motor starter 10 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 11 Power Exhaust Relay STD on HBP HCP HDP HPP units 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 po
61. commended 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 50 1 Filter Replacement Arrangement for Blower Size Digit 16 A B C D E F Gand H FILTER SPACER 500 600 350 400 A 20 X 25 FILTER 700 800 B 16 X 25 FILTER 15 X 25 FILTER Filter Spacer to be inserted on non access side of unit Figure 50 2 Filter Replacement Arrangement for Blower Size Digit 16 J K and L NON ACCESS SIDE NON ACCESS IDE FILTER SPACER FILTER 20 25 16 25 2508068 C 20 x 16 230 800 500 600 D 15 X 25 840 960 Cooling Coil Drain Pan and Drain System The drain pan trap and drain pipe must be cleaned regularly to avoid blockage that can reduce or stop water flow as follows 1 At the beginning of the cooling season inspect and clean the entire cooling coil cabinet and condensate drain pan to remove contaminants 2 Inspect and clean the condensate drain trap and piping The use of a cleanout opening at the top of the trap can help facilitate this maintenance 3 Fill the trap with water to ensure proper operation and replace the cap on the cleanout opening to c
62. correct to direction of air flow Belt tension checked Electric supply to unit Volts Hz Phase Gas supply to uni Natural _ Propane Gas supply pressure to unit _ PSIG Inlet and or discharge dampers operating correctly Blower rotation correct Blower speed Hi Speed Lo Speed RPM Motor speed Hi Speed RPM Lo Speed RPM Is unit noisy Excessive vibration Motor voltage L1 _V L2 V L3 V Motor amps L1 _ Amp L2 Amp 3 _ Amp High temperature limit control continuity checked Burner light off Low Fire Does entire burner light off Hi Fire Burner 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 F psi Inches W C etc Device Setting F psi Inches W C etc Device Setting F psi Inches W C etc Customer Owner instructed operation and maintenance of unit Yes No Name of Person s Instructed Comments Start Up Company Name Phone Signature Date
63. ctory 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 the power exhauster motor centrifugal switch that closes when the motor reaches full speed The unit door includes a factory installed power exhauster discharge cover and inlet combustion louvers For information about venting refer to the Installation Venting section 5 Timed Freeze Protection OPT 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 a manual 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 20 4 Timed Freeze Protection Module 2 Low Gas Pressure Switch OPT 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 a
64. d 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 3 All field piping must be self supporting System piping should be flexible enough to allow for thermal expansion and contraction of the coil 4 Fill the coil with water with all air vents open 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 5 Close all vents and perform a 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 Figure 13 1 General Chilled Fluid Piping Air Vent ees Vent Plug Gate Valve Te e gt a Drain Plug Dirt Leg_ Union Cap Table 13 1 Cooling Coil Performance Limits Dual Circuit Max Area Cooling ft2 Tons Single Circuit Max Area Max ft Chilled Water Based on 550 feet per minute FPM coil face velocity Based 95 F 75 F Entering Dry Bulb W
65. d 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 If the factory installed motor starter option was not ordered with a unit that has a three phase motor or single phase motor 1 1 2 Hp or greater a motor starter must be field supplied and installed Figure 25 2 Motor Starter 6 Ww 5 CONTACTOR MODULE TRIP INDICATOR CURRENT WINDOW SET POINT DIA JAL NE amp 8 RESET Rh 69 OVERLOAD T MODULE i 8 9 Q Q amp 9 9 L I li 41 Mild Temperature Thermostat The mild temperature thermo
66. deck to top of curb 7 Caulk butt joints after curb is assembled and installed on roof structural members and roof flashing is added Figure 4 3 Typical Curb Details Curb Gasketing 2x4 Wooden Nailing Strip Counterflashing By Others Roofing Material By Others Lj Curb Insulation By Others 2 Acoustic one N Fiberglass y By Others EE Roofinsulation 02222 bs i By Others Xy 2 x 2 7 72 Roof 6 Inverted Roof Truss Channel Deck Both Sides By Others Available as a factory supplied field installed accessory 4 5 572 8 SLAB MOUNT DUCT INSTALLATION Slab Mounted Sites Models HBG HBP amp HCG HCP For ground level installation of a front discharge unit prepare a level concrete slab at least four inches thick on adequate footings and a generous bed of gravel for drainage See Figure 5 1 The slab should include threaded 5 8 inch anchor bolts spaced according to Figure 5 2 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 The slab should extend out at least six inches around the perimeter of the unit Figure 5 1 Slab Mounted Furnace CONCRETE SLAB ANCHOR BOLTS 4 MIN QTY 2 EACH SIDE ON GRAVEL BED Figure 5 2 Slab Anchor Bol
67. ducts Figure 5 3 Duct Connections FLANGED DUCTWORK 3 When a roof curb is used in conjunction with a factory supplied return air connector the ductwork can be fastened to the connectors prior to the unit installation The connectors will accept 90 flanged ductwork See Figure 6 2 4 Provide uniform air distribution over the heat exchanger Use turning vanes where required to obtain uniform air distribution See Figure 6 1 5 On model HBG HBP provide removable access panels on the downstream side of the unit See Figure 5 3 These openings 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 the heat exchanger due to a lack of sufficient air CFM Not required on model HCG HCP because the cooling cabinet access door can be removed for this purpose 5 572 8 5 DUCT INSTALLATION RIGGING INSTRUCTIONS UNIT INSTALLATION Figure 6 1 Recommended Field Installed Discharge Duct Configurations for models HBG HBP and HCG HCP Dimension B should never be less than 1 2 of dimension A Turning Provide leak tight access panels in discharge duct for heat exchanger inspection Provide leak tight access panels in discharge duct for heat exchanger inspection Turning Provide leak tight access panels in discharge duct for heat exchanger inspection and overheat control service Turning Vanes
68. e Control Options 24 Once proper operation of the unit has been verified remove any jumper wires that were required for testing 25 Close the electrical compartment door 26 Replace all exterior panels Refer to page 56 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 and 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 14 1 4 Replace the cap from the pilot adjustment screw Figure 14 1 Correct Pilot Flame aso to 1 d
69. e 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 off valve The minumum 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 W C 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 for intermitent pilot ignition 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 th
70. e phase units 1 1 2 Hp and greater the door switch de energizes the motor starter that controls blower motor operation For servicing the switch is equipped with an override position that can be manually pulled out to override the switch See Figure 24 2 Figure 24 2 Blower Door Switch with Manual Override DOOROPEN OVERRIDE DOOR CLOSED POSITION POSITION POSITION COM 39 Dirty Filter Switch OPT The dirty filter pressure switch is factory installed in the electrical section 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 25 1 3 Set the 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 i
71. eat 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 Gas 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 B149 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 9 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 8 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 8 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 u
72. econd fps for Water and 1 to 6 fps for Glycol solutions 16 5 572 8 START UP PROCEDURE Control Operating Sequence IMPORTANT To prevent premature heat exchanger failure with all control systems a blower starting mechanism must be provided so that the blower is running or energized within 45 seconds of the gas control operation Indoor duct furnaces are supplied with intermittent pilot systems with continuous retry which both the main burner and pilot burner are turned off 100 when the thermostat is satisfied 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 Gas Control Options see page 19 could change the listed sequence of operation based on their function The descriptions given are for the basic duct furnace Single Furnace Controls Staged Control Digit 12 1 or 2 These units utilize a single or two stage combination gas valve an ignition control and a low voltage thermostat Electronic Modulating Control Digit 12 4 7 or 8 These units utilize a single s
73. ected the heat exchanger should be replaced before the unit is put back into service If the tubes are dark gray airflow across the heat exchanger should be checked to insure that a blockage has not occurred or the blower is operating properly Gas Piping amp Controls The gas valves and piping should be checked annually for general cleanliness and tightness The gas controls should be checked to insure that the unit is operating properly Manifold Assembly Removal To remove the manifold Refer to Figure 51 1 Shut off gas and electric supply Remove the side access panel Disconnect gas manifold at ground union joint 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 Follow steps 3 6 in reverse to install the manifold assembly Turn on the electric and gas supp o NOC RONS Tighten if necessary 10 Install the side access panel Figure 51 1 Manifold Assembly Removal SERIAL PLATE ELECTRICAL JUNCTION BOX GROUND UNION JOINT MANIFOLD BURNER SIDE ACCESS PANEL HEAT EXCHANGER SUPPORT Burner and Pilot Assembly Removal To remove the burner Refer to Figure 51 2 1 Shut off gas and electric supply 2 Disconnect the pilot supply line from the gas valve 3 Disconnect the ignition cable from the ignition controller located in the electrical junct
74. eel or concrete must provide required support with the unit bolted to sub base The following are some general guidelines for roof curb installed units 1 The roof structure must be adequately designed to support the live weight load of the unit and any other required support structure For the bearing loads normally encountered the roof curb should be supported at points no greater than five feet apart Additional truss reinforcement should be provided if necessary 2 Roof curbs supplied by Modine are fabricated from 16 gauge galvanized steel and supplied knocked down for assembly on the job site The curb consists of two side pieces two end pieces gasketing four joiner angles four 2x4 inch wood nailing strips nuts bolts and washers Roof curbs over 120 inches long include two additional side pieces and two splice plates Refer to the latest revision of Modine literature 5 590 for instructions 3 Outside dimensions must be held when installing curb Top surface must be level and straight to insure weather tightness All corners must be square 4 All dimensions are 1 8 inch 5 Final electric and gas connections must be made after unit is installed to allow for tolerance in setting of unit on curb For electrical power supply allow approximately eight feet of wire plus provisions for weathertight flexible conduit for connection to unit as required by local codes 6 Maintain an 12 inch minimum height from top of roof
75. ement 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 the factory will be at the owner s risk A CAUTION Do not attempt to reuse any mechanical or electrical controllers which have been wet Replace defective controller IMPORTANT To check most of the Possible Remedies in the troubleshooting guide listed in Table 52 1 refer to the applicable sections of the manual All 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 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 re
76. en 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 IMPORTANT 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 report 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 IM PO RTANT THIS MANUAL MUST BE FOLLOWED TO PROVIDE SAFE 1 To prevent premature heat exchanger failure do not locate EFFICIENT AND TROUBLE FREE OPERATION IN ADDITION ANY gas fired appliances in areas where corrosive vapors PARTICULAR CARE MUST BE EXERCISED REGARDING i e chlorinated halogenated or acid are present in the
77. er that are obtained from item 5 Using the Model Nomenclature on page 59 the Model Configuration and Venting HDP Determine the Furnace Input Rating MBH Using the Heating output capacity the Furnace Input Rating is determined from Table 27 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 Determine the Heat Exchanger Burner Drip Pan Material From item 2 listed above 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 Determine the Development Sequence From item 8 listed above the modulating gas controls result in the Development Sequence M Determine the Access Side From item 5 listed above the Right Hand Gas controls result in the Access Side R Determine the Air Temperature Rise From item 2 listed above the Air Temperature Rise is 60 F 70 F 10 F However using the output capacity of the HDP400 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 Determine the Gas Type From item 7 listed above the Natural Gas results in the Gas Type N Determine the Gas Valve From item 8 listed above the Electronic Modulating with Duct Sensing results in the Gas Valve 4
78. er High Altitude Kit Equation 10 1 Manifold Pressure for Gas Heating Values Different Than Shown in Table 10 1 TBL ey x MP ACT Where gy Manifold Pressure W C at installed elevation BTUTBL BTU ft content of gas from Table 10 1 BTUACT BTU ft content of gas obtained from the utility company MPs Manifold Pressure W C at Sea Level use 3 5 W C for natural gas and 10 0 W C for propane NOTE For units equipped with two stage or modulating gas controls only the high fire manifold pressure needs to be adjusted No adjustments to the low fire manifold pressure are necessary on these units Selection of the Proper High Altitude Kit All units installed at elevations greater than 2000 feet above sea level require a kit in addition to potential manifold pressure adjustment outlined in the previous step To determine the proper kit to use refer to Table 10 2 Table 10 3 shows the contents of the kit For more information refer to the latest revision of Modine Bulletin 75 530 Table 10 2 High Altitude Kit Selection Table Model Elevation Above Sea Level ft Size 2 001 5 500 5 501 6 500 6 501 7 500 Item Code 67248 67248 67248 Applies to both installations in the U S and Canada Applies to both natural and propane gas Sizes 75 400 require a kit qty of 1 sizes 500 800 require a kit qty of 2 sizes 840 960 require a kit
79. erent 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 and EQ Digits 20 amp 21 The two position damper 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 outside air percentages lower than 100 refer to the following section Setting the Damper Limiter 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 Setting the Damper Limiter The two position damper limiter is factory set to prevent the outside air damper from opening 100 Field adjustment of the two position damper limiter is accomplished by the following 1 Determine the amount of damper rotation required Percentage of outside air 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 23 1 which is shown at 50 rotation limit 3 Position the limiter back to the desired position making sure the locating teeth on the limiter are engaged into
80. et Bulb G Model Size 75 minimum CFM for DX Dual Circuit is 621 Model Size 100 minimum CFM for DX Dual Circuit is 745 5 572 8 13 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 access 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 16 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 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
81. et the thermostat so that there is a call for heat This should start the blower and then the burner ignition sequence 2 Turn 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 49 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 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 Switch 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 50 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 man
82. f unit and one on bottom For Right Hand Access Units Location of drill locator dimples for field drilled electrical connection entry holes identical as side electrical connections For Left Hand Access Units Location of drill locator dimples for field drilled electrical connection entry holes identical as side electrical connections For Gravity Vented Models the combustion air vent cap is required so only dimensions B C and D apply For Power Vented Models the power exhauster discharge cover and inlet louvers are included so only dimensions Q and R apply 5 572 8 41 DIMENSIONS UNIT Figure 42 1 HBG HBP Outdoor Blower Package Unit Dimensions with Blower Type I J K or L 47 27 36 58 f b Conduit Entry Holes 2974 2 00 Qty 4 Drill MN Dimples for Field illed Electrical Optional Rainhood 232 amp Birdscreen P Over Roof 2 41 62
83. g 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 12 2 General DX Piping Equalizer Line Liquid Line Expansion Valve By Others Suction Line Remote Sensing Bulb Suction Connection 1 Inspect the refrigerant distributor and verify that the nozzle is in place 2 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 3 For DX coils the use of filter dryers in the system piping is recommended along with a sight glass that has a moisture indicator 4 Connect the suction line and suction connection 5 Install the expansion valve By Others Follow the expansion valve manufacturer s recommendations for installation to avoid damaging the valve 6 Connect the liquid line to the expansion valve Pressurize the coil expansion valve assembly and suction connection to 100 psig w
84. g vent runs excessive vent diameter restricitve vent terminal negative pressure within space etc See Troubleshooting section for more information 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 operating 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 26 1 Circuit Analyzer Circuit analyzer tagging will vary based on the unit ordered Circuit analyzer shown is for reference only Vy v 26 5 572 8 GENERAL PERFORMANCE DATA Table 27 1 General Performance Data Models With Blower Model Size Digits 4 6 Btu Hr Input 100000 100000 125000 125000 150000 150000 175000 175000 Btu Hr Output 80000 80000 100000 100000 120000 120000 140000 140000 Blower Style Digit 16 Letter CorD EorF CorD EorF CorD EorF Cor D EorF Max Temp Rise F 100 85 100 100 100 100 100 100 Min Temp Rise F 21 20 27 20 33 20 39 23 3450 3450 4630 3350 5556 3350 5556 2 Model Size Digits 4 6 Btu Hr Input
85. h Unit F Input Output e 75 85 90 105 110 CFM 500 000 400 000 8230 7407 6734 600 000 480 000 9877 8889 8081 700 000 560 000 11523 10370 9428 800 000 640 000 13000 11852 10774 1 050 000 840 000 960 000 E Ratings 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 For Variable Air Movement Applications see page 18 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 maximum allowable total static pressure of 3 0 W C 28 5 572 8 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 9 Required air handling capacity CFM 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 Outdoor and indoor design temperature The outdoor design temperature is determ
86. he unit to over fire 18 5 572 8 OPTIONS FACTORY INSTALLED Figure 19 1 Factory Mounted Option Locations OOOO Roo I cs a aa amp Discharge Thermostat Low Gas Pressure Switch High Gas Pressure Switch Power Exhauster Timed Freeze Protection Ignition Controller Combustion Air Exhaust Cap Control Relay Time Delay Relay Furnace Low Voltage Terminal Strip Power Exhauster Relay 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 Enthalpy Sensor Rainhood and Birdscreen Direct Drive Damper Actuator Enthalpy Controller 7 ideolo oae eje l NS MAY I L L
87. ial General Performance Data 27 number and company address Any substitution of parts or Unit 2 2 4 068000 29 controls not approved by the factory will be at the owners risk Pressure Drop and Blower Performance Data 31 Blower Sheave Assembly 35 A CAUTION Electrical Data 39 Motor BIOL 39 1 Appliances designed for outdoor installation only DIMENSIONS aniran nanninannan da aesa 41 DO NOT LOCATE APPLIANCES INDOORS eh dae re aaie stan IC Ese 49 2 Purging of air from gas lines should be performed as Maintenance sess 50 described in ANSI Z223 1 latest edition National Fuel Service amp Troubleshooting 52 Gas Code or in Canada in CAN CGA B149 codes PASS LS SINR a NE IT 54 3 Ensure that the supply voltage to the appliance as indicated Start Up Checklist 56 on the serial plate is not 5 less than the rated voltage Start Up 4 Do not reuse any mechanical or electrical component Model Nomenclature E EN 57 which has been wet Such component must be replaced Commercial Warranty m M Back Page N 5 572 8 SI METRIC CONVERSION FACTORS
88. icates NEMA Premium Efficiency Motor manufacturers typically do not list efficiency for three phase motors smaller than 1hp 40 5 572 8 DIMENSIONS UNIT Figure 41 1 HBG HBP Outdoor Blower Package Unit Dimensions Y 33 50 33 50 48 00 B B Over Roof Pr n Qty 4 Drill Locator 1 D T Dimples for Field 1 1 Drilled Electrical i Conduit Entry Holes 2 32 2 Rainhood 2 00 spaced 2 0 apart 1 34 25 HJ i __ 2 56 5 4 16 E Height i F3 MY 2400 F Width Inside Inside 1 Aly S Fresh Air 9 21 oe i Duct Connecti
89. il 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 fastening 4 5 6 7 5 8 5 and 10 deep coils Figure 12 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 us steel drain pan Right or left hand coil 1 stubbed drain header access to match connection gas controls Condensate Drain Pan Trap 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 Direct Expansion DX Piping The refrigerant lines should be insulated to prevent warmin
90. ility connections should be done with care to prevent air and water leaks Unit Installation Follow site preparation instructions for applicable curb sub base or slab sites before installation Check Model Identification Plate of unit with plans to be sure unit is properly located See pages 54 and 55 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 often vary Check dimensions If unit is to be installed on a factory supplied curb 1 Install roof curb using previous roof curb instructions page 4 2 Thoroughly clean and dry the top of the curb surface 3 Lay a bead of weather resistant caulking on top perimeter of roof curb as illustrated in Figure 4 3 4 Orient hoisted unit to its ductwork and set it down evenly on curb 5 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 If unit is to be installed on a separate sub base or slab use steps 4 and 5 Venting 1 Installation of venting must conform with local building codes or in the absence of local codes with the National Fuel Gas Code ANSI Z223 1 NFPA
91. ined 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 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 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 Unit configuration with options and accessories Rainhood filters dampers or evaporative cooler The unit configuration is determined by the location where the unit is to be installed The critical options and accessories are those that add internal static pressure I S P 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 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
92. ing Package Unit Dimensions 105 49 24 00 33 50 48 00 B Qty 4 Drill Locator D Max Conduit Entry Holes spaced 2 0 apart Dimples for Field 2 00 Drilled Electrical HA amp Birdscreen 2 20 Optional Rainhood P Over Roof P 2 LITT uM fae te Outlet Air 34 25 5 a _ 256 2 connection 4 La 1 45 Wa 4 16 J Height Dd Y i 24 00 Nw 4 me 2 on Inside ii n sida A 2 03 y OK Fresh Air i 9 21 7 65 921 Duct Connection IY NL 16 75 02590 4 35 st 50 300 4 29 24 94 Dott 5 29 5 29 108 39 6 28 6 28 Figure 43 2 HPG HPP Outdoor Packaged Unit Dimensions 134 82 29 32 24 00 33 50 48 00 P Over Roof Ee P 2 Qty 4 Drill Locator Dimples for Field Optional Rainhood D Max Drilled Electrical a
93. inhood See Motor Data See Evaporative Cooler Data Blower Type HCG Motor Dampers Dampers Double Wall Digit 16 Vent Cap Fresh Air F amp RA All Sections All All All All E F G or H I J or K E F G or H I J or K Rainhood See Motor Data Table 49 3 HDG HDP Outdoor w Downturn Package Operating Weights Blower HDG Dampers Dampers Double Wall Digit 16 Vent Cap Fresh Air amp RA All Sections All All All All E F G or H I J or K E F G or H l J or K G or H I J or L GorH I J I J or L Rainhood See Motor Data See Evaporative Cooler Data Table 49 4 HPG HPP Outdoor Packaged Operating Weights Model Blower Type HPG Filter Dampers Dampers Double Wall Size Digit 16 Unit Cap Fresh Air amp RA All Sections All All All Rainhood All E F G or H I J or K E F G or H I J or K See Motor Data See Evaporative Cooler All weights in pounds 5 572 8 MAINTENANCE A WARNING When servicing or repairing this equipment use only factory approved service replacement parts A complete replac
94. ion box Feed the cable through the bushing in the bottom of the electrical junction box 4 Remove the screws holding the burner side access panel Attached to the panel are the burner retaining pins that align the burner 5 Slide the burner assembly out The pilot is attached to the burner assembly 6 Examine the burner and pilot assembly for cleanliness and or obstructions as necessary see Duct Furnace for cleaning instructions 7 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 8 Reconnect the ignition cable and pilot gas supply line 9 Turn on the electric and gas supply Figure 51 2 Burner and Pilot Assembly Removal ly Check the ground union joint for leaks with a soap solution PILOT IGNITION PILOT ASSEMBLY AIR SHUTTERS CABLE SUPPLY LINE NOT SHOWN HEAT ARE LOCATED EXCHANGER ON THE SUPPORT MANIFOLD 5 572 8 51 SERVICE amp TROUBLESHOOTING A WARNING When servicing or repairing this equipment use only factory approved service replacement parts A complete replacement parts list may be obtained by contacting Modine Manufacturing Company Refer to the rating plate on the unit for complete unit model number serial number and company address Any substitution of parts or controls
95. iring that requires replacement must Gas 8 be replaced with wiring material having a temperature Considerations for 10 rating of at least 105 C Electrical Connections eee 11 6 To reduce the opportunity for condensation the minimum Evaporative 11 sea level input to the appliance as indicated on the serial Cooling Coil Specifications and Installation 12 plate must not be less than 5 below the rated input or Start Up Procedure 14 5 below the minimum rated input of dual rated units Pilot Burner and Main Burner Adjustment 14 7 Ensure that the supply voltage to the appliance as indicated Blower AdjUStMeNt ccccccccsecesscesecesseesscesseceeeees 16 on the serial plate is not 5 greater than the rated voltage Lubrication Recommendations 16 8 When servicing or repairing this equipment use only Damper Linkage Adjustment 16 factory approved service replacement parts A complete Control Operating Sequence 17 replacement parts list may be obtained by contacting Modine MB co C Manufacturing Company Refer to the rating plate on the iis 19 appliance for complete appliance model number ser
96. itch 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 11 2 For fusible disconnect switches refer to the Model Identification plate for the fuse size and type 5 572 8 11 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 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 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 co
97. ith dry nitrogen or other suitable gas The coil should be left pressurized for a minimum of 10 minutes 7 If the coil holds pressure the installation can 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 8 Use a 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 the system is ready to be charged or refrigerant pumped down in another portion of the system can be opened to the coil 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 12 5 572 8 UNIT INSTALLATION 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 g
98. leshooting guide listed in Table 52 1 refer to the applicable sections of the manual MAY result in a potential safety concern DANGER Appliances must not be installed where they may be exposed to a potentially explosive or flammable atmosphere Table of Content A WARN N G proe 1 2 Special 1 All field gas piping must be pressure leak tested prior to operation Never an open flame Use soap solution or 7 0 equivalent for testing ob b ee sassssssssssssssssasssasssassuessue 2 Gas pressure to appliance controls must never exceed 14 EAE 4 Service Clearances W C 1 2 psi 3 Disconnect power supply before making wiring connections Rigging Instructions 4 to prevent electrical shock and equipment damage Curb or Sub Base 0 4 4 8 4 4 All appliances must be wired strictly in accordance with Slab Mounting 4 wiring diagram furnished with the appliance Any wiring Duct Installation Ems 5 different from the wiring diagram could result hazard Unit Installato Miss n 6 to persons and property zem 6 5 original factory w
99. lose the system 4 During the end of cooling season shutdown of the system disconnect and remove all water from the trap and drain to prevent freeze damage If local building codes permit the trap may be filled with an antifreeze solution 5 If the unit is used year round regularly inspect and clean the cooling coil cabinet condensate drain pan and trap drain System to ensure proper function 6 Depending on climate freeze protection of the trap may be required during non cooling days Cooling Coil Maintenance 1 Periodically inspect the coil for signs of corrosion and leaks Repair and replacement of the coil and the connecting piping valves etc must be performed as needed by a qualified technician 2 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 Cleaning solutions must not be corrosive or cause damage to copper tube aluminum fin coils Clean the coil from the leaving 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 3 For DX coils replace the filter dryer s as needed 4 For chilled fluid coils a Maintain the circulated fluid free of sediment corrosive products and biological contaminants
100. lt 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 33 1 with spider bearings the Blower Size and Bearing Type 13 Determine the Motor Horsepower The motor horsepower determined in step 12 was a 3 Hp Since the supply voltage is 460 60 2 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 14 Determine the Motor Type The motor type was not specified so for purposes of this selection Open Drip Proof ODP will be used Reviewing Table 40 2 the available ODP motor type is high efficiency ODP resulting in the Motor Type 2 15 Determine the Sheave Arrangement To establish the Sheave Arrangement the motor frame size must be determined The Motor Data tables on pages 39 to 40 contain the motor frame size A Using the Supply Voltage 460V 60Hz 3Ph enter the correct Motor Data table Table 40 2 Using Model Nomenclature Digits 17 and 18 G1 determined in steps 13 and 14 find the motor frame size 182 g Using the Motor Frame Size enter the Sheave Selection table for the selected blower determined by step 13 Table 36 2 Using the rpm calculated in step 12 920 rpm select the sheave range that contains the required rpm Find the intersection with the Motor
101. mp Birdscreen Conduit Entry Holes r 2 00 spaced 2 0 m f pe cx L256 446 F K Insid 24 00 22 00 Inside N aA Downturn Z Connection AS Fresh Air 9 21 No eu Duct Connection b 2 4 27 inside 2490 4 35 1 50 1 50 3 00 Return Ai 5 29 i 4 29 24 94 Duct Connection 529 6 28 6 28 137 63 Blower Type Dimensions H J 75 100 125 150 175 200 225 250 300 E F orH 350 400 E F G or H 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 as side electrical connections For Left Hand Access Units Location of drill locator dimples for field drilled electrical connection entry holes identical as side electrical connections For Gravity Vented Models the combustion air vent cap is required so only dimensions B C and D apply For Power Vented Models the power exhauster discharge cover and inlet louvers are included so only dimensions Q and R apply 43 5 572 8 DIMENSIONS UNIT Figure 44 1
102. n Pillow block bearings 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 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 16 3 4 Tighten the 5 16 hex head screw on the ball joint Figure 16 3 Damper Linkage Adjustment BALL CONNECTING ROD BLADE ARM DAMPER Cooling Coil Operation 1 Proper air distribution is vital to coil performance Air flow anywhere on the coil face should not vary by more than 20 2 Air velocities should be maintained between 200 and 550 feet per minute 3 For chilled fluid coils fluid velocities should be maintained within the recommended values of 1 to 8 feet per s
103. n 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 C for propane gas 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 38 30 28 5 oS x B n mc Oy 404 P70 45 19 MIN o B n Ows E Low Lt 6 Ignition Controller STD The ignition controller is factory installed in the duct furnace electrical junction box with the spark ignitor and sensor located o
104. n mode the economizer is automatically locked out and holds the outdoor air damper at the minimum position setting 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 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 a temperature of 53 F default adjustable at the mixed temperature air 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 A call for cooling from the space thermostat brings on mechanical cooling For complete details on the Enthalpy Economizer controller setup and operation please refer to the latest revision of Modine publication 5 598 Setup Instructions Enthalpy Economizer Controller Figure 23 3 Enthalpy Controller 5 572 8 23 5 32 Damper to Damper Linkage 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 r
105. n the burner For both natural and propane gas units the ignition controller is 10096 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 20 5 572 8 5 7 Combustion Air Exhaust Cap STD HBG HCG HDG HPG units The combustion air exhaust cap is shipped loose in a separate carton for field installation For information about venting refer to the Installation Venting section For information about installation of the cap refer to Literature 5 573 Vent Cap Installation amp Submittal Data which is provided with the cap 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 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 rel
106. nditioner can accept a 0 10 VDC signal when all the dip switches are in the DFF position and 4 20 mA signal when all the dip switches are in the ON position The modulating valve is modulated open or closed based on the voltage from the amplifier less gas flow required higher voltage more gas flow required lower voltage which correlates to the control signal from the BMS Note For further information regarding the operation of any of the electronic modulating system options above consult the literature provided with the unit If the unit was provided with a time delay relay the blower starts after 30 to 45 seconds The unit continues to operate until the thermostat is satisfied Once satisfied a Single Stage Units Both the main and pilot valves close 100 b Two Stage Units Once the high stage of the thermostat is satisfied the main valve closes to 5096 fire The unit continues to operate until the low stage thermostat is satisfied at which time both the main and pilot valves close 10096 c Electronic Modulation Units The unit continues to operate in this manner until the thermostat is satisfied or the BMS heat enable contact opens Power is then cut to both the main and pilot valves closing them 100 and stopping gas flow to the main and pilot burners If the unit was not provided with a time delay relay the blower stops immediately If the unit was provided with a time delay relay the blower stops af
107. nit 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 9 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 Too Much Heat 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 Power Exhauster Motor will not start Power supply is off HFP Models Only No 24V power to thermostat Thermostat malfunction Defective power exhauster relay Defective power exhauster motor Automatic Reset High Limit Figure 53 1 Possible Remedy Adjust to a maximum of 14 W C Check orifice size with those listed on the serial plate Clean louvers in vent cap Clean correct duct system Adjust to a maximum of 14 W C Check correct to insure blower motor operates within 45 seconds of when gas controls are energized d Adjust belt tension e Check correct blower drive settings for proper rpm f Check correct venting system 9 Replace air distribution baffle h Replace high limit switch Adjust main gas pressure Minimum for Natural Gas 6 W C Minimum for Propane Gas
108. nit 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 connection See Figure 8 1 Verify the manual shut off valve is gas tight on an annual basis 4 Provide a sediment trap before each unit in the line where low spots cannot be avoided See Figure 8 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 8 1 Recommended Sediment Trap Manual Shut off Valve Installation Side or Bottom Gas Connection GAS SUPPLY LINE GROUND JOINT UNION W BRASS MANUALGAS d SEAT SHUT OFF VALVE GAS SUPPLY LINE Ho CM rue CONTROLS PLUGGED 3 1 8 NPT TEST MIN GAGE CONNECTION SEDIMENT TRAP Manual shut off valve is in the OFF position when handle is perpendicular to pipe Table 8 1 Gas Pipe Capacities Natural Gas Pipe Natural Gas Length ft 1 2 1
109. nstallatipn and service contactor or appropriate utility compan 5H080682 Comb Gas Valve lt q 5H080706 Ignition Control 5H604852 Power Exh Relay 02088 cmi ru 5H76722 1 Power Exhauster 91 4 5H76783 10 Wiring Diagram 0 IN 5H74977 1 Ctrl Transformer 3 0 t 5H73903 Modulation Valve aj 3H37454 1 Pilot Replace Kit 5H73604 Control Amplifier 3H35746 23 Heat Exch Kit 1 MINIMUM CLEARANCE TO COMBUSTIBLES IS 0 0 PROM 3H35629 1 Burner Kit allemaal 5H71790 Optional TDR 1 LE D GAGEMENT MINIMUM DU COMBUSTIBLE EST 0 OCH D 5 78167 Rev B DE L ENVELOPPE DE 7018 D M 9 MAXIMUM EXTERNAL STATIC PRESSURE IN W C 2 0 100 F PRESSION ee UE puis MAXIMUM 3 Ames 1 75 7 38 q 0 75 BAS DE LA BARRE QUI SUPPORT L L MENT OU 7 6CM DU ANSI 283 8 2013 CSA 246 2013 APPROVED FOR USE IN MASSACHUSETTS APPROVED FOR USE IN CA BY THE GENERAL FOR OUTDOOR INSTALLATIONS ONLY MINIMUM AMBIENT TEMPERATURE 40 F FOR INSTALLATION DOWNSTREAM OF REFRIGERATION SYSTEMS INSTALL ON THE POSITIVE PRESSURE SIDE OF AIR CIRCULATING BLOWER POR UNITS WITH MANUAL RESET HIGH LIMIT SWITCH RESET BUTTON IS LOCATED IN ELECTRICAL JUNCTION BOX 6 IN USA FOR INSTALLATIONS ABOVE 2000 FEET DERATE 4 PERCENT FOR EACH 1000 FEET OF ELEVATION ABOVE SEA LEVEL LIGHTING INSTRUCTIONS 1 OPEN ALL GAS VALVES TURN ON POWER 2 SET THERMOSTAT TO DESIRED SETTING SHU
110. ntain furnaces Values shown are per furnace 5 572 8 INSTALLATION Considerations for Elevation The standard ratings for Models HFG HFP duct furnace portion are certified for elevations up to 2000 feet above sea level Operation at elevations above 2 000 feet requires ratings be reduced 4 for each 1000 feet above sea level per ANSI Z223 1 The exception is for units in Canada CSA requires that ratings be reduced 10 for elevations between 2 001 and 4500 feet The following instructions are for units that will be installed over 2 000 feet elevation If this does not apply you may skip ahead to the Electrical Connections section on page 11 Manifold Pressure Adjustment The unit manifold pressure is factory set for operation at elevations up to 2000 feet as follows For Natural Gas units 3 5 W C based on a gas heating value of 1 050 BTU ft3 For Propane Gas units 10 0 W C based on a gas heating value of 2 500 BTU ft3 For higher elevations some utility companies may derate the BTU content heating value of the gas provided at altitude to a lower value to allow certain heating appliances to be used with no manifold pressure adjustments For this reason it is necessary that the supplying utility be contacted for detailed information about the gas type and BTU content heating value before operating any heater Table 10 1 shows the standard derated heating values of natural and propane gases at various elevations
111. nted models For power vented models the step down transformer used for the power exhauster motor also powers the evap cooler pump Table 39 2 Motor Data 2 Table 39 3 Motor Data Supply Voltage Digit 14 Supply wotor Size Motor Type Full Load NEMA Efficiency Digit 17 Digit 18 Amp Draw Frame Size Motor Size Motor Type Full Load Efficiency Digit 17 Digit 18 6 Amp Draw Size 208V 60Hz 1ph B 115V 60Hz 1ph A Single phase motors not rated for use with a variable frequency drive Motors rated below 1hp have integral thermal overload protection Motors rated 1hp and larger require the use of a motor starter for overload protection Motor Sizes Digit 17 A through H do not include a motor starter D through H require a motor starter by others All others include a motor starter ODP Open Drip Proof TE Totally Enclosed Motor manufacturers typically do not list efficiency for single phase motors 230V 60Hz 1ph C 5 572 8 39 MOTOR DATA Table 40 1 Motor Data Table 40 2 Motor Data ord Motor Size Motor Type Full Load NEMA Efficiency Supply Motor Size Motor Type FullLoad NEMA Frame Efficiency Digi
112. nual gas valve Turn on main power Purge gas line Check for plugged pilot orifice and clean with compressed air if necessary Adjust to a maximum 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 power exhauster centrifugal switch HFP Models Only 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 Increase primary air Adjust to a maximum of 14 W C Check orifice size with those listed on the serial plate Clean louvers in vent cap SERVICE amp TROUBLESHOOTING Trouble Possible Cause Flame Rollout See Figure 53 3 Main pressure set too high Orifice too large Blocked vent cap Not Enough Heat U
113. od For adjustment refer to Damper Linkage Adjustment 33 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 III leakage resistance less than 40 CFM ft at 1 W C dampers with self compensating stainless steel side seals and santoprene blade seals are used 34 Proportional Temperature Controller Sensor OPT A proportional temperature controller sensor is provided with Air Control options GG GH GK or GM 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 35 Motor and Blower Vibration Isolation STD 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 Figure 24 1 Blower Motor Vibration Isolation BLOWER SUPPORT BLOWER SUPPORT RA
114. om 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 Pillow Block Bearings 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 wi
115. on no ea R eee nnn T HE A zi 24 00 4 35 be 199 5G 5 29 5 29 Return Air Duct Connection 6 28 6 28 1 S 500 800 Model Shown Figure 41 2 HDG HDP Outdoor Downturn Package Unit Dimensions 2 29 32 33 50 33 50 48 00 m P Over Roof ras C 2 i Qty 4 Drill Locator Dimples for Field T Drilled Electrical Max 1 Conduit Entry Holes 232 Optional Rainhood i E 2 00 spaced 2 0 apart V amp Birdscreen 256 4 16 24 00 L F i 24 00 Inside Inside Inside Downturn Fresh Air N ion i Duct Connection A 9 21 5 31 2522 oe ated 22 4 27 H _ X 9 1 g 1 50 Inside Inside 4 3 1 50 3 00 1 Return Air Duct Connection 529 5 29 6 2 6 28 500 800 Model Shown Table 41 1 HBG HBP HDG HDP Outdoor Unit Dimensions All dimensions in inches Blower Type Qty of Dimensions Digit 16 84 41 84 41 84 41 84 41 84 41 84 41 117 58 117 53 For Right Hand Access Units Location of drill locator dimples for field drilled gas connection entry holes side of unit and on bottom For Left Hand Access Units Location of drill locator dimples for field drilled gas connection entry holes one side o
116. on IRows 2 13 141 6 w 7 5 6 75 10 VIEW n L EET wee di je A Distributor Inlet Liquid 7 Line Connection s Suction Line Connections in direction o of airflow Second Inlet on Dual Circuit Coils iil for Right Hand Units Second Inlet on Dual Digit 9 R Circuit Coils deaders on opposite de for Left Hand Units H FRONT VIEW ium SIDE VIEW Airflow Direction Table 47 1 DX Coil Dimensions DX Dual Circuit 24 81 27 27 34 30 S All 1 5 Below 185 MBH 200 225 25 5 35 75 28 5 185 MBH amp Up 27 34 5 30 Below 185 MBH 250 300 185 MBH amp Up Below 185 MBH 185 MBH amp Up 350 400 Single Circuit DX coils have 1 each Suction Line and Liquid Lines Refer to AccuSpec for line size diameters Dual Circuit DX coils have 2 each Suction Line and Liquid Lines Refer to AccuSpec for line size diameters Figure 47 2 Chilled Water Coil Drawing All dimensions in inches A J Airflow Direction z Rows 4 amp TOP VIEW Fal gt j E gt 6 1 5 15 i 1 8 gt I Return Water Line 5 24 i Connection turned 90 in 4 direction of airflow S Coil for Right Hand Units Digit FL 225
117. onic 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 A 115 60 1 E 230 60 3 B 208 60 1 F 460 60 3 C 230 60 1 G 575 60 3 D 208 60 3 15 Transformer TR 1 40 VA 4 250 VA 2 75 0 None 3 150 11 12 13 14 15 GT GV SS SV TR BB HP 16 A B D F 17 A B Gs D gt H J V 18 4s 2 19 A MT SA Blower Size amp Bearing Type BB 9 7 Spider Bearings G 15 15 Spider Bearings 9 7 Pillow Block Bearings H 15 15 Pillow Block Bearings 9 9 Spider Bearings 18 18 Spider Bearings under 15 Hp 9 9 Pillow Block Bearings J 18 18 Pillow Block Bearings under 15 Hp 12 12 Spider Bearings 18 18 Pillow Block Bearings for 15 Hp amp up 12 12 Pillow Block Bearings L 20 18 Pillow Block Bearings 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 N 3 4 Hp with Motor Starter 1 Hp P 1 Hp with Motor Starter 1 1 2 Hp Q 1 1 2 Hp with Motor Starter 2 Hp R 2 Hp Hp with Motor Starter 3 Hp S 8 Hp with Motor Starter 5 Hp T 5 Hp with Motor Starter 7 1 2 Hp W 7 1 2 Hp with Motor Starter 10 Hp X 10 Hp with Motor Starter 1
118. or requires 150 seconds All modulating damper actuators operate using a 0 10 Vdc 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 operation 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 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
119. proof duct furnace make up air units contain an AGA CGA and ETL ETL Canada certified weatherproof duct furnace This duct furnace is combined with either a blower section or a blower and or cooling and or downturn sections to make a complete make up air or heating ventilating cooling unit that is ETL ETL Canada certified For this reason 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 cooling and or downturn 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 54 1 The part number for some common replacement parts are listed on the serial plate See Figure 54 2 and the model identification plate See Figure 55 1 For a complete description of the model number see Model Identification Figure 54 2 Serial Plate Figure 54 1 Serial Plate and Model ID Plate Locations SERIAL PLATE MODEL IDENTIFICATION PLATE Modine Manufacturing Company OUTDOOR GAS FIRED DUCT FURNACE Made in U S A APPROVALS 1500 DeKoven Avenue FOR INDUSTRIAL COMMERCIAL USE Racine WI 53403 2552 CHAUDIE
120. qty of 3 Table 10 3 High Altitude Kit Contents Kit Contents Pressure Switch High Altitude Installation Instructions Conversion Label If a unit is to be installed at higher elevations AND converted from natural gas to propane gas operation a propane conversion kit must be used in conjunction with the manifold pressure adjustment and high altitude kit listed above For the Selection and Installation Instructions for propane conversion kits please see the latest revision of Modine Bulletin 75 511 10 5 572 8 UNIT INSTALLATION Electrical Connections 6 The power supply must be within 5 percent of the voltage rating and each phase must be balanced within 2 percent of A WARN NG each other If not advise the utility company 7 External electrical service connections that must be installed 1 Disconnect power supply before making wiring connections include to prevent electrical shock and equipment damage a Supply power 120 208 240 480 or 600 volts 2 All appliances must be wired strictly in accordance with wiring b Thermostats remote monitoring panels building pressure diagram furnished with the appliance Any wiring different sensors time clocks or any other accessory control from the wiring diagram could result in a hazard to persons and devices that may be supplied 24 volts property 8 All outdoor electrical connections must be weatherized to 3 Any original factory wiring that requires
121. replacement must be prevent moisture from entering the electrical compartment replaced with wiring material having a temperature rating of 9 Refer to the unit dimensional drawings on pages 41 through at least 105 C 44 for the location of the drill locator dimples in the side and 4 Ensure that the supply voltage to the appliance as indicated bottom of the unit for field drilling the hole for the electrical on the serial plate is not 5 greater than rated voltage conduit entry 10 All supply power electrical connections are made in the T CAUTION electrical section of the unit The low voltage thermostat and accessory control devices can be wired to either the m electrical section or the duct furnace electrical junction box T Ensure that the supply voltage to the appliance as indicated Refer to the wiring diagram for the terminal location of all on the serial plate is not 5 less than the rated voltage low voltage wiring 1 Installation of wiring must conform with local building Figure 11 2 Recommended Accessory Field codes or in the absence of local codes with the National Electric Code ANSI NFPA 70 Latest Edition Unit must installed Disconnect Switch Mounting Locations be electrically grounded in conformance to this code In Canada wiring must comply with CSA C22 1 Part 1 Electrical Code 2 Two copies of the job specific wiring diagram are provided ELECTRIC SUPPLY COMPONENTS MUST BE CLEAR OF
122. return air to the unit is below 40 F Type of fuel Either natural or propane gas determined by the design engineer Gas control staging method Either single stage two stage or electronic modulation determined by the design engineer 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 Selection Example Conditions Select an indirect fired 100 make up air unit to meet the following conditions 1 2 3 os 1 at sea level 5 000 cfm Outdoor design temp 10 F Indoor design temp 70 F Heating output capacity 5000 cfm x 70 F 10 F x 1 08 324 000 Btu Hr External Static Pressure 0 65 The Power Vented unit with the controls on the Right Hand Side is to be provided with the following 2 Permanent Filters a Rainhood with Fresh Air Damper and a Downturn Heat exchanger and burner 409 Stainless Steel Gas Type Natural Gas Controls Electronic Modulating with Duct Sensing Supply Voltage 460V 60Hz 3Ph Altitude 1000 feet With the information listed above the basic model using the Model Nomenclature shown on page 57 can be selected as shown in the following example 1 5 572 8 Determine the Model Configuration and Venting The Model Configuration is determined by the required sections of the unit Blower and Downturn and the venting style Pow
123. s controls determine from the Model Identification Digit 12 the low fire gas pressure needs to be adjusted Using Figure 15 2 for item number locations this is accomplished as follows a Disconnect power b Remove all wires from Maxitrol Amplifier terminal 3 or duct furnace terminal 43 if available c Turn on power at the disconnect switch d Remove the maximum adjustment screw 4 spring 5b 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 Maxitrol amplifier terminal 3 or 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 position and recheck pipe plugs for gas leaks with soap solution Figure 15 1 Checking Manifold Pressure with U Tube Manometer
124. 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 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 th
125. ssure from Table 31 1 Unit internal resistance has been included in the unit performance tables Brake Horsepower and RPM values are approximate values only Please consult the AccuSpec selection software for values at other than listed CFM static pressures 34 5 572 8 BLOWER SHEAVE ASSEMBLY DATA Adjusting the Blower Drive Setting 2 Locate the unit Model Identification Plate and note Digit 16 and Digit 19 of the model number Digit 16 is the Blower Based on the Sheave Arrangement Tables 35 1 through 36 5 Size and Type and Digit 19 is the Sheave Arrangement give the Sheave Assembly numbers used on units that include 3 Once the Blower Size and Type Digit 16 is known enter a blower The Sheave Arrangement is Digit 19 and is found the proper Sheave Arrangement table on the unit Model Identification Plate The Sheave Assembly 4 Use the Sheave Arrangement Digit 19 to determine the describes the motor and blower sheave size and bore as well h A ided the belt provided Sheave Assembly provided 5 Use Table 37 1 and the Sheave Assembly number to determine the required turns open to achieve the desired blower rpm 6 Set the motor sheave as described in Blower Adjustments To determine how many turns open the motor sheave should be set for 1 Follow the Selection Procedure found on pages 29 and 30 to determine what blower rpm is required to meet the job specifications Figure 35 1 Blower Section EXTENDED ADJU
126. stat is factory installed in the electrical section The mild temperature thermostat is designed to lockout the burner during mild weather conditions which prevents the burner from cycling The thermostat must be field set to the desired mild temperature condition refer to the latest revision of Modine Literature 75 540 42 Proportional Temperature Controller OPT A proportional temperature controller is provided with Air Control options GG GH GK or GM 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 Figure 25 3 Proportional Temperature Controller 43 Warm Up Stat OPT A warm up stat is provided with Air Control options GK or GM 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 44 Blower Supply Power Terminal Strip
127. t 14 Voltage Digit 14 ODP 1 ODP 1 aa SEU E SEU TIE DES PEG TEHE i a TE HE ODP ODP H TE HE ODP as ODP Ser TE HE 6 ODP H E Soie di SEO SEXO BED BED TEHE TEHE ODP H Eo ODP PEG TE HE 6 TE HE 6 ODP 1 ODP 1 TE 5 E 5 m ooo TE 5 ODP m 6 a i Da g ae ODP ODP ae TE HE 6 ODP a ODP Sree TE HE 6 ODP ae TE ODP ae TE HE 6 TE HE 6 Digit 17 Digit 18 6 Amp Draw Frame Size Digit 17 Digit 18 9 Amp Draw Size 9 208V 60Hz 3ph D 460V 60Hz 3ph F 230V 60Hz 3ph E 575V 60Hz 3ph G Motors rated 1hp and larger are inverter duty rated as standard Three phase motors do not have thermal overload protection Overload protection is required through the use of a motor starter or variable frequency drive G Motor Sizes Digit 17 A through K and V do not include a motor starter used with either a motor starter by others or variable frequency drive others include a motor starter ODP Open Drip Proof TE Totally Enclosed the added suffix HE ind
128. t Dimensions 5 8 Dia 4 Blower Type Model Size Digit 16 HBG HBP 75 All 82 91 33 85 HBG HBP 100 125 All 82 91 36 36 HBG HBP 150 175 All 82 91 40 61 HBG HBP 200 225 All 82 91 42 71 HBG HBP 250 300 E E G or H 82 91 45 75 HBG HBP 250 300 I J orK 118 50 45 75 HBG HBP 350 400 E F G or H 82 91 57 27 HBG HBP 350 400 I J or K 118 50 57 27 HBG HBP 500 600 GorH 116 03 45 75 I J 151 62 45 75 GorH 116 03 57 27 I J 151 62 57 27 185 02 57 27 106 89 33 85 106 89 36 36 106 89 40 61 106 89 42 71 106 89 45 75 142 48 45 75 106 89 57 27 142 48 57 27 HBG HBP 500 600 HBG HBP 700 800 HBG HBP 700 800 HBG HBP 840 960 All HCG HCP 75 HCG HCP 100 125 All HCG HCP 150 175 All HCG HCP 200 225 All HCG HCP 250 300 E E G or H HCG HCP 250 300 I J orK HCG HCP 350 400 E E or H HCG HCP 350 400 I J or K Duct Installation For HBG HBP HCG HCP Horizontal Discharge 1 The blower section back and bottom and the furnace discharge are designed to accept 90 flanged ductwork See Figure 5 3 Provide an airtight seal between the ductwork and the unit Seams with cracks in the ductwork should be caulked and or taped and be of permanent type All duct connections outside the building MUST be weathertight to prevent rain and snow from entering the ductwork 2 Acoustic duct liners are recommended on all internal return air
129. t 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 approx imately 0 25 W C This will allow for the increase in static pressure due to dirty filters 24 5 572 8 5 Figure 25 1 Dirty Filter Pressure Switch and Air Flow Proving Switch Negative pressure Positive pressure connector connector pr Pressure adjustment set screw 40 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 1 1 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 40 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 The overloa
130. tage combination gas valve an electronic modulating gas valve a modulating amplifier an ignition control and one of the following 6 Modulating room thermostat Modulating duct thermostat with remote temperature set point adjuster Building Management System BMS signal by others an inverted signal where 0 VDC or 4 mA is high fire and 10 VDC or 20 mA is low fire The control operating sequence for all units is as follows 1 The thermostat calls for heat For BMS controlled units the BMS closes a heat enable contact at the unit 2 Model HBP HCP HDP HPP only 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 pre purge time delay relay then closes after 20 to 40 seconds and energizes the 8 gas control circuit 3 The pilot valve opens and the spark igniter sparks in an attempt to light the pilot If the unit was not provided with a time delay relay the blower starts 4 Once the pilot is lit the flame sensor proves the pilot and stops the spark igniter from sparking 5 The main gas valve is opened and the main burner is controlled as follows a Single Stage Units The main burner is lit to 100 full fire b Two Stage Units The main burner is lit to 5096 fire If the temperature at the thermostat continues to fall the thermostat will call for high stage heat and the main burner is lit to
131. tem is determined by Internal Static External Static Total Static Pressure For this example 0 24 0 65 0 89 W C T S P From page 31 for the Model Size 400 with Digit 16 1 J or K 2 Permanent Filters 0 04 W C Rainhood 0 11 W C Downturn 0 07 W C Internal Static Pressure Drops 0 22 W C The Total Static Pressure for the system is determined by Internal Static External Static Total Static Pressure For this example 0 22 0 65 0 87 W C T S P g Using the total static pressure T S P calculated step 12a use blower performance tables for the Model Size 400 Tables 33 1 Using Table 33 1 enter the table at the required 5000 cfm for E F blowers and follow the cfm 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 this process for 1 00 T S P and iterate 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 89 W C T S P the horsepower is 5 hp and 920 rpm Following this procedure for 1 blowers Using 5000 cfm and 0 87 W C T S P the horsepower is 3 hp and 700 rpm Although I J H blowers results in a 3 hp motor this blower requires the use of the extended cabinet length As a resu
132. ter 30 to 45 seconds 17 START UP PROCEDURE Multiple Furnace Controls Staged Control Digit 12 1 For control of multiple staged units each furnace would be individually controlled Refer to the section for Single Furnace Controls Staged Control Digit 12 1 or 2 Electronic Modulating Control Digit 12 4 These units are the same as Electronic Modulating Gas Controls Single Furnace Digit 12 4 except the Master unit features a modulating amplifier capable of driving multiple modulating gas valves for systems with a Master and up to two Slave units Slave units do not have a modulating amplifier The units would be controlled by one of the following Modulating room thermostat Modulating duct thermostat with remote temperature set point adjuster The sequence of operation for Electronic Modulating Gas Controls Master Slave is the same as Electronic Modulating Gas Controls Single Furnace The modulating amplifier sends an equal voltage signal to all of the modulating gas valves so that they modulate at the same percentage between 40 and 100 full fire Electronic Modulating Control Digit 12 7 or 8 For control of multiple electronic modulation units for BMS control each furnace would be individually controlled Refer to the section for Single Furnace Controls Electronic Modulation Control Digit 12 7 or 8 Variable Air Movement Applications Units may be supplied with variable frequency drives for
133. th 1 or 2 permanent filters 2 FARR Aeropleat MERV 7 or 2 FARR 30 30 MERV 8 filters For filter replacement refer to Maintenance 27 Fresh Air Damper 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 11 leakage resistance less than 10 CFM ft at 1 W C dampers with self compensating stainless steel side seals and santoprene and galvanized steel blade seals are used 29 Rainhood and Birdscreen The rainhood and birdscreen is shipped loose for field installation at the back of the blower section For installation instructions refer to Literature 5 589 supplied with the rainhood and birdscreen 30 Direct Drive Damper Actuator 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 2 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 2 L during operation the actuator should rotate in the clockwise direction when viewed from the service side of the unit Three diff
134. the locating holes on the actuator 4 Fasten the limiter to the actuator using the screw provided 5 Test the damper rotation either manually with the manual crank or apply power Re adjust if necessary 6 If the damper end switch is being used in the control circuit and needs to be adjusted for the new minimum position refer to the next section Adjusting the Damper End Switch 22 5 572 8 5 Figure 23 1 Two position Damper Actuator and Limiter Philips screwdriver Adjusting the Damper End Switch If the damper limiter was adjusted in the previous section it may be required to adjust the Damper End Switch as follows 1 The actuator must be in its fail safe position 2 Insert the crank handle into the torx shaped hole located in the center of the adjustable switch pointer as shown in Figure 23 2 3 Gently rotate the crank until the switch pointer is at the desired switch point in degrees as shown Figure 23 2 Adjusting the Damper End Switch Rotate with Factory setting 90 crank handle 60 set Modulating Damper Actuator A modulating damper actuator is provided with Air Control options GA GB GC GD GE GG GH GJ GK and GM 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 actuat
135. 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 31 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 whenever 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 The components used for the Enthalpy Economizer are Enthalpy Economizer Controller The Enthalpy Controller is used in conjunction with the Enthalpy Sensor and a Mixed Air Temperature sensor The controller is factory mounted in the blower control cabinet Outside Air Enthalpy Sensor The sensor provides a signal in relation to enthalpy temperature and humidity of the outside air The sensor is installed in the outside air stream e Mixed Air Temperature Sensor The sensor is factory installed in the blower section to sense the mixed air temperature of the fresh and return air streams Typical Sequence of Operation Heating or Ventilation Mode When the space thermostat calls for heat or the fan is on without a call for cooling ventilatio
136. tic Fiberglass 3 Lb Density Within Curb On Top of Roof Deck Roof Curb Structural Truss Flexible Connection Acoustic Duct Liner Inside Acoustic Duct Liner Inside Flexible Connection Suspended Ceiling Rigging Instructions Four 3 4 inch holes at the extended ends of the mounting channels are supplied to facilitate lifting the unit with eyebolts to be furnished by the installer For either crane or helicopter lift of the equipment to the rooftop connect sturdy steel cables with eye loops as illustrated in Figure 4 2 To prevent cable from marring the cabinet end tops use spreader bars or an angle iron frame at least 6 longer and wider than the unit to spread the lifting cables above the unit For stability in lifting and lowering include a spreader piece between the two cable spreaders as illustrated in Figure 4 2 Figure 4 2 Typical Rooftop Furnace Rigging INSTALLER S CABLE AND pan SPREADERS Ww 3 TS ROOF CURB MOUNTED ON ROOF INSTALLER S EYE BOLTS Curb or Sub Base Mounted Sites An optional roof curb is available to simplify site preparation and raise the unit above roof water and snow level for drainage It can be installed with the roof and in advance of the unit A sub base must be furnished by the installer if no curb is supplied for the roof The sub base either st
137. ual 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 51 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 52 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 54 Discharge Damper When discharge air damper is supplied with the unit the damper is factory installed in the downturn plenum section The discharge air damper is used an outside air shut off damper so ultra low leak Class II leakage resistance less than 10 CFM ft at 1 W C dampers with self compensating stainless steel side seals and santoprene and galvanized steel blade seals are used 55 Differential Pressure Switch A differential pressure switch is supplied on all power vented duct furnaces and is designed to prevent operation of the main burner in the event there is improper venting through the vent System This may occur due to a restricted vent inadequate vent draw uninsulated vent pipe in cold ambient or lon
138. wer exhauster motor 12 Furnace Supply 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 See description of Option 8 for additional details 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 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

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