CaptiveAire D76 Installation Manual
FOR YOUR SAFETY
Compact
Direct Fired
Heater
Installation, Operation, and Maintenance Manual
Save these instructions
RECEIVING AND INSPECTION
WARNING!!
FOR YOUR SAFETY
If you smell gas:
1. Open windows.
2. Don’t touch electrical switches.
3. Extinguish any open flames.
The use and storage of gasoline or other flammable vapors and liquids in open containers in the
vicinity of this appliance is hazardous.
Upon receiving unit, check for any interior and exterior damage, and if found, report it
immediately to the carrier. Also check that all accessory items are accounted for and are
damage free. Turn the blower wheel by hand to verify free rotation and check the damper (if
supplied) for free operation.
Improper installation, adjustment, alteration, service or maintenance can cause property
damage, injury or death. Read the installation, operating and maintenance instructions
thoroughly before installing or servicing this equipment. ALWAYS disconnect power and gas
prior to working on heater.
. This document is the property of the owner of this equipment and is
required for future maintenance. Leave this document with the owner when installation or service
is complete.
A0011029
April 2011 Rev. 8
TABLE OF CONTENTS
WARRANTY................................................................................................................................................................... 4
INSTALLATION.............................................................................................................................................................. 5
Mechanical ................................................................................................................................................................ 5
Site Preparation .................................................................................................................................................... 5
Assembly .............................................................................................................................................................. 5
Curb and Ductwork ............................................................................................................................................... 6
Roof Mount Installation ......................................................................................................................................... 6
Installation with Exhaust Fan ................................................................................................................................ 7
Indoor (INLINE) Installation .................................................................................................................................. 7
Gas ............................................................................................................................................................................ 8
Gas Connection Sizes .......................................................................................................................................... 8
Gas Pressure Table .............................................................................................................................................. 8
Gas Connection Diagram ..................................................................................................................................... 8
Electrical .................................................................................................................................................................... 9
Copper Wire Ampacity .......................................................................................................................................... 9
PSC (Permanent Split Capacitor) Motor Speed Control ..................................................................................... 10
ECM (Electronically Controlled Motor) Speed Control ........................................................................................ 10
Motorized Intake Damper ................................................................................................................................... 11
Remote Control Panel ........................................................................................................................................ 11
Fan to Building Wiring Connection ..................................................................................................................... 11
OPERATION ................................................................................................................................................................ 12
Start Up ................................................................................................................................................................... 12
Special Tools Required....................................................................................................................................... 12
Start Up Procedure ............................................................................................................................................. 12
Pilot Adjustment .................................................................................................................................................. 12
Pilot Assembly .................................................................................................................................................... 12
Main Burner Adjustment ..................................................................................................................................... 13
Heater Start Up Summary .................................................................................................................................. 14
Final Start Up Procedure .................................................................................................................................... 15
Pulley Adjustment ............................................................................................................................................... 15
Pulley Alignment ................................................................................................................................................. 15
Proper Belt Tension ............................................................................................................................................ 15
Pulley Setscrew Torque ...................................................................................................................................... 15
Pulley Combination Chart ................................................................................................................................... 16
Sequence of Operation ........................................................................................................................................... 16
Flame Safety Control .......................................................................................................................................... 16
Air Flow Switch ................................................................................................................................................... 17
Modulating Gas System...................................................................................................................................... 17
High Temperature Limit ...................................................................................................................................... 18
Operation Summary ........................................................................................................................................... 18
Optional Remote Panel Circuit ........................................................................................................................... 19
Components ............................................................................................................................................................ 20
Remote Panel Option ......................................................................................................................................... 21
Troubleshooting ....................................................................................................................................................... 22
Airflow Troubleshooting Chart ............................................................................................................................ 22
Burner Troubleshooting Chart ............................................................................................................................ 23
Remote Panel Troubleshooting Chart ................................................................................................................ 24
Troubleshooting Flowcharts ................................................................................................................................ 25
MAINTENANCE ........................................................................................................................................................... 26
General Maintenance .............................................................................................................................................. 26
2 weeks after startup ............................................................................................................................................... 27
Every 3 months ....................................................................................................................................................... 27
Filter Quantity Chart ........................................................................................................................................... 27
Yearly ...................................................................................................................................................................... 27
Burner Orifice Drill Size ..................................................................................................................................... 27
Start-Up and Maintenance Documentation ............................................................................................................. 28
Job Information ................................................................................................................................................... 28
Heater Information .............................................................................................................................................. 28
Maintenance Record .......................................................................................................................................... 28
Factory Service Department ............................................................................................................................... 28
3
WARRANTY
This equipment is warranted to be free from defects in materials and workmanship, under normal use and
service, for a period of 12 months from date of shipment. This warranty shall not apply if:
1. The equipment is not installed by a qualified installer per the MANUFACTURER’S installation
instructions shipped with the product,
2. The equipment is not installed in accordance with federal, state and local codes and regulations,
3. The equipment is misused or neglected,
4. The equipment is not operated within its published capacity,
5. The invoice is not paid within the terms of the sales agreement.
The MANUFACTURER shall not be liable for incidental and consequential losses and damages
potentially attributable to malfunctioning equipment. Should any part of the equipment prove to be
defective in material or workmanship within the 12-month warranty period, upon examination by the
MANUFACTURER, such part will be repaired or replaced by MANUFACTURER at no charge. The
BUYER shall pay all labor costs incurred in connection with such repair or replacement. Equipment shall
not be returned without MANUFACTURER’S prior authorization and all returned equipment shall be
shipped by the BUYER, freight prepaid to a destination determined by the MANUFACTURER.
4
INSTALLATION
CLEARANCES
It is imperative that this unit is installed and operated with the designed airflow, gas, and electrical supply
in accordance with this manual. If there are any questions about any items, please call the service
department at 1-866-784-6900 for warranty and technical support issues.
Mechanical
WARNING: DO NOT RAISE VENTILATOR BY THE INTAKE HOOD, BLOWER OR
MOTOR SHAFT, OR BEARINGS, THE USE OF A SLING IS ADVISED.
Site Preparation
1. Provide clearance around installation site to safely rig and
lift equipment into its final position. Supports must
adequately support equipment. Refer to manufacturer’s
estimated weights.
2. Consider general service and installation space when
locating unit.
3. Locate unit close to the space it will serve to reduce long,
twisted duct runs.
4. Do not allow air intake to face prevailing winds. Support
unit above ground or at roof level high enough to prevent
precipitation from being drawn into its inlet. The inlet must
also be located at least 10 feet away from any exhaust
vents. The heater inlet shall be located in accordance with the applicable building code
provisions for ventilation air. All air to the heater must be ducted from the outdoors. Recirculation
of room air is not permitted. If in doubt regarding the application, consult the manufacturer.
The top, back, and front
surfaces of this heater may not
be installed less than 6” from
combustible materials. The
heater base may be installed
on combustible surfaces.
Allow 24” minimum service
clearance on both sides of this
heater.
Assembly
Intakes and curbs are shipped unassembled. Upon unit arrival, follow the following procedure to
assemble the intake to the heater:
1. Apply silicone or weather-proof gasket on the back side of the flanges of the intake hood or
filtered intake.
2. Screw the flanges of the intake hood or filtered intake to the unit with the supplied sheet metal
screws. Cover screw heads with silicone to prevent water leaks.
5
Curb and Ductwork
This fan was specified for a specific CFM and static pressure. The ductwork attached to this unit will
significantly affect the airflow performance. Flexible ductwork and square elbows should not be used.
Also, transitions and turns in ductwork near the fan outlet will cause system effect and will drastically
increase the static pressure and reduce airflow. The minimum fan outlet duct size is 12 inches x 12
inches with a recommended minimum straight duct length of 36 inches. Follow SMACNA guides and
recommendations for the remaining duct run.
Fans designed for rooftop installation should be installed on a prefabricated or factory built roof curb.
Follow curb manufacturer’s instructions for proper curb installation. The unit should be installed on a curb
and/or rail elevated not less than 20” above any surface. Be sure duct connection and fan outlet are
properly aligned and sealed. Secure fan to curb through vertical portion of the ventilator base assembly
flange using a minimum of eight (8) lug screws, anchor bolts, or other suitable fasteners (not furnished).
Shims may be required depending upon curb installation and roofing material. Check all fasteners for
tightness. The diagrams below show different mechanical installation configurations.
Adequate building relief shall be provided so as to not over pressurize the building when the heating
system is operating at its rated capacity. This can be accomplished by taking into account, through
standard engineering methods, the structure’s designed infiltration rate; by providing properly sized relief
openings; or by interlocking a powered exhaust system; or by a combination of these methods.
Heaters installed with intake ductwork must be purged to replace at least four air changes of the volume
of the intake duct.
If the failure or malfunction of this heater creates a hazard to other fuel burning equipment in the building
(e.g. when the heater is providing make up air to a boiler room), the unit is to be interlocked to open inlet
air dampers or other such devices.
Units being installed in airplane hangars should be installed in accordance with the Standard for Aircraft
Hangars, ANSI/NFPA 409. Units being installed in public garages should be installed in accordance
with the Standard for Parking Structures, ANSI/NFPA 88A, or the Standard for Repair Garages,
ANSI/NFPA 88B, and with CAN/CGA B149 Installation Codes.
Roof Mount Installation
6
Installation with Exhaust Fan
Indoor (INLINE) Installation
7
Gas
NOTICE
Installation of gas 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.
WARNING: INLET GAS PRESSURE MUST NOT EXCEED PRESSURE INDICATED
ON NAMEPLATE. SEE UNIT NAMEPLATE FOR PROPER GAS SUPPLY
PRESSURE AND GAS TYPE.
1. Always disconnect power before working on or near a heater. Lock and tag the disconnect
switch or breaker to prevent accidental power up.
2. Piping to the unit should conform with local and national requirements for type and volume of gas
handled, and pressure drop allowed in the line. Refer to the Gas Engineer’s Handbook for gas
line capacities.
3. The incoming pipe near the heater should be sized to
match the connection on the outside of the unit. Unit inlet
sizes are shown in the table to the right. Avoid multiple
taps in the gas supply so the unit has a steady supply of
gas at all times.
4. Install a ground joint union with brass seat and a manual
shut-off valve external to the unit casing, as shown below,
adjacent to the unit for emergency shut-off and easy servicing of controls.
5. Provide a sediment trap, as shown below, before each unit and where low spots in the pipe line
cannot be avoided.
6. Blow out the gas line to remove debris
before making connections. Purge line to
remove air before attempting to start unit.
Purging of air from gas lines should be
performed as described in ANSI Z223.1latest edition “National Fuel Gas Code”, or
in Canada in CAN/CGA-B149.
7. All field gas piping must be pressure/leak tested prior to unit operation. Use a non-corrosive
bubble forming solution or equivalent for leak testing. The heater and its individual shut-off valve
must be disconnected from the gas supply piping system during any pressure testing of that
system at test pressures in excess of ½ psi. The heater must be isolated from the gas supply
piping system by closing its individual manual shutoff valve during any pressure testing of the gas
supply piping system at test pressures equal to or less than ½ psi.
8. This unit requires a constant 5 in. w.c. minimum
natural gas supply, when the unit is operating at
maximum gas flow. If the gas supply exceeds 14
in. w.c. it will damage the internal valve
components, and if it is below 5 in. w.c., the heater
may not perform to specifications.
Gas Pressure Type Gas Pressure
Natural 5 in. w.c. – 14 in. w.c.
LP 5 in. w.c. – 14 in. w.c.
Gas Connection Sizes
Unit Size Gas Pipe Size
(NPT)
76 1/2”
Gas Pressure Table
Gas Connection Diagram
Refer to the heater rating
plate for determining the
minimum gas supply pressure
for obtaining the maximum
gas capacity for which this
heater is specified.
8
Electrical
WARNING!!
Before connecting power to the heater, read and understand this entire section of this document. As-built
wiring diagrams are furnished with each fan by the factory, and
are attached to the door of the unit.
Electrical wiring and connections should be done in accordance
with local ordnances and the National Electric Code,
ANSI/NFPA70. Be sure the voltage and phase of the power
supply and the wire amperage capacity is in accordance with the
motor nameplate. For additional safety information refer to
AMCA publication 410-96, Recommended Safety Practices for
Users and Installers of Industrial and Commercial Fans.
Disconnect power before
installing or servicing fan. High
voltage electrical input is
needed for this equipment. This
work should be performed by a
qualified electrician.
1. Always disconnect power before working on or near a
heater. Lock and tag the disconnect switch or breaker to
prevent accidental power up.
2. An electrical drop containing the motor power wiring is
shipped with every fan. The electrical drop should be
brought through one of the conduit openings located in
the base of the unit, run through the curb, and connected
to a junction box inside the building.
3. A dedicated branch circuit should supply the motor circuit
with short circuit protection according to the National
Electric Code. This dedicated branch should be run to the junction box mentioned above and
connected as shown in a following illustration labeled “Fan to Building Wiring Connection”.
4. Make certain that the power source is compatible with the requirements of your equipment. The
heater nameplate identifies the proper phase and voltage of the motor.
5. Units shipped with an optional remote panel have two electrical circuit drops. It is important to
run the motor wires in a separate conduit from the remote control wiring. The DC wires from the
unit temperature controller, located in the control drop, should either be shielded cable or be run
in a separate conduit.
6. Before connecting heater to the building power source, verify power line wiring is de-energized.
7. Secure the power cables to prevent contact with sharp objects.
8. Do not kink power cable and never allow the cable to come in contact with oil, grease, hot
surfaces or chemicals.
9. Before powering up the heater, check fan wheel for free rotation and make sure that the interior of
the heater is free of loose debris or shipping materials.
10. If any of the original wire supplied with the heater must be replaced, it must be replaced with type
TW wire or equivalent.
Copper Wire Ampacity
Wire Size AWG Maximum Amps
14 20
12 25
10 30
8 40
6 55
4 70
9
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