DUO AIRE CAA-1D-10 Installation Manual

DUO-AIRE

GENERAL INSTALLATION INSTRUCTIONS

DIRECT-FIRED GAS HEATING AND MAKE-UP AIR UNITS

The following recommendations are not intended to replace or void any requirements of federal, state or
local codes having jurisdiction. All local authorities having jurisdiction should be consulted before
installation is made. The heater should be installed and piped in accordance with the requirements of the
National Fuel Gas Code, NFPA 54, and all wiring must be in accordance with the National Electrical
Code, NFPA 70 current edition.

Inspect the unit for visible damage. The unit was thoroughly inspected before leaving the factory, and the
carrier has accepted and signed for it. Any damage or irregularities should be noted at the time of
delivery and immediately reported to the delivery carrier. Request a written inspection report from the
Claims Inspector to substantiate any necessary claim. File the claim with the delivery carrier, not with
Duo-Aire.

Further inspect the unit as follows:

A) Unlatch and open Unit Access Doors. Inspect
for internal damage.

B) Remove and inspect all loose-shipped items, including remote mount control
panel. Make certain all items are undamaged.

If questions or complications should arise regarding the application or installation of the Duo-Aire Air
Handling Unit, that cannot be solved by using these instructions, our Maintenance Guidelines, or the
Troubleshooting Guide, please feel free to contact us at [phone].

It is the responsibility of the installing contractor to see that the unit is installed within the manufacturers
design parameters, as stated on the rating plate, and that the start-up procedure specified by the
manufacturer is followed. Failure to comply may void our warranty and/or the component manufacturer's
warranty.

INSTALLATION

Inspect the blower wheels, shaft and motor for any shipping blocks which must be removed before
operation.

ROOFTOP/CURB MOUNTED

For a unit that discharges downward through a curb, locate the required opening for connecting ductwork.
Cut through roof deck for connection of duct to blower discharge. Allow adequate, at least one inch,
clearance on all sides between ductwork and decking material. Position the curb on the roof in relation to
the roof penetration, as shown on the blueprint. Secure the curb to the structural members. The curb may
now be flashed into the roof. Roof top, down discharge units are provided with a skirt that is larger than
the curb on all sides. This allows for roofing up to the top of the curb, if so desired. On applicable "AA"
models, attach the furnished support legs to the intake end of unit, one on each side. The unit may now be
lifted up onto the curb.

MC-163-DA 03/07

NOTE: Units which discharge down through the curb with discharge dampers must have the roof
opening cut large enough to allow access to the damper motor and linkage from below the roof. The
damper should be mounted and motor wired with pigtail provided before the unit is set on the curb.

NOTE: We recommend the connection of a short length of ductwork to the unit before setting on the curb
to extend through the roof if minimum (1") clearance is being used around the duct.

PAD MOUNTED

For a unit designed to mount on a pad or other support and discharge horizontally, vibration isolators are
recommended. A channel iron support adequate to carry the weight of the unit must be secured to the
bottom of the unit, one at each end, extending at least 3" past the sides of the unit. On standard "AA"
models, four vibration isolators will be used, one for each corner of the unit. On some "AA" models, and
all R300 models, refer to your submittal or record drawing for size, quantity, and location of isolators.
Anchor the vibration isolators to the pad. The unit may now be set down onto the isolators and bolted to
them.

INDOOR/SUSPENDED

For a unit designed to be suspended within the building, hanger rods and channel iron adequate to
support the weight of the unit will be required. On standard "AA" models, the channel iron must be
secured to the bottom of the unit, one at each end, extending at least 3" past the sides of the unit. On
some "AA" models, and all R300 models, refer to your submittal or record drawing for size, quantity,
and location of channel iron and isolators. Attach the hanger rods to the building structure so they hang
down to the channel extensions under the unit. Make sure the rod location does not interfere with the
removal of unit access panels. Provide one suspension type vibration isolator in each hanger rod. The
minimum combined ratings of the vibration isolators and suspension materials should equal the total
weight of the fully assembled unit. Move the unit to its installation location. Fully assemble the unit with
all included components (motorized discharge dampers, etc.) Raise the unit so that one hanger rod drops
through holes in the channel extensions. Attach two nuts to hanger rods and level unit, jamb the two nuts
together to prevent loosening.

The unit is now ready for piping, wiring, and connection to any required ductwork.

PIPING

A female pipe connection has been provided on the upstream side of the first control within the unit for
connection of the inlet gas pipe. This is the only gas connection required. Be sure the gas supply pipe is
large enough to insure the proper gas volume and line pressure at the inlet of the unit. Gas pipe must be
sized and installed in accordance with applicable codes and standards.
After connection of the gas pipe, check for leaks and bleed the line.

NOTE: NFPA 54 National Fuel Gas Code requires that an approved manual gas valve be installed
within six feet of the unit. We recommend use of a gas valve with a pressure tap on the inlet to measure
gas supply pressure.

NOTE: An inlet gas pressure measurement must be taken to insure proper inlet gas pressure. Inlet
pressure should be neither too low or too high. Check your submittal or unit nameplate for the minimum
and maximum pressure requirements for your unit. If the supply gas pressure exceeds the maximum inlet
supply pressure as stated on the unit rating plate, an auxiliary high pressure regulator must be installed in
the incoming gas line by the contractor. The gas supply pressure must meet or exceed the minimum inlet

MC-163-DA 03/07

gas supply pressure, as stated on the unit rating plate, while the burner is under full fire. (See Start-Up
Procedure to operate unit on high fire).

This heater and it's individual shut-off valve must be disconnected from the gas supply piping system
during any pressure testing of that system at pressures in excess of 1/2 PSI

(3.5 KPA). In addition,
pressure testing of the gas supply piping system at pressures at or below 1/2 PSI (3.5 KPA) requires
isolation from the heater by closing it's individual manual shut-off valve.

WIRING

All electrical wiring must be in accordance with applicable codes and standards. See the electrical
diagram on the unit door or in the service manual before attempting any wiring. Refer to the unit rating
plate for required incoming voltage and phase. Check for concurrence with voltage and phase shown on
the wiring diagram.

Refer to wiring diagram for numbers of wires needed for main power connection and remote control
wiring. Field wiring is shown with dashed lines.

WARNING! ! ! - Spark testing or shorting of control wires by any means will render the control
transformer inoperative. DO NOT allow this to happen as it IS NOT covered under the warranty.

We recommend that the wires for the control circuit be routed through the conduit provided with the main
electrical service to the equipment. This procedure is provided for in Chapter 3, Article 300-3(a) of the
NFPA 70 1984 National Electrical Code. It reads as follows: "Conductors of 600 volts or less shall be
permitted to occupy the same equipment wiring enclosure, cable or raceway, without regard to whether
the individual circuits are alternating current or direct current, where all conductors are insulated for the
maximum voltage of any conductor within the enclosure, cable or raceway."

An electric disconnect switch having adequate ampacity shall be installed in accordance with Article 430
of the National Electric Code (N.E.C.), ANSI/NFPA 70. If not factory installed, please refer to the unit
rating plate for voltage and ampacity requirements.

Open cover on disconnect box, connect line voltage wiring to terminal block provided. Then feed the
control wiring through the conduit to the master panel. Connect color coded and/or numbered control
wires to terminal strip per the wiring diagram.

NOTE: Wires for Maxitrol Series 14 and Series 44 temperature controls must be run in shielded cable.
For best results, run control wiring in separate conduit if the run is over 100 feet. For longer runs see
Maxitrol Installation Instructions.

DUCTWORK

Ductwork must be sized and installed in accordance with applicable codes and standards. On units
mounted outdoors, it is recommended that all discharge and return air ducts be insulated to prevent
condensation during the "Off" cycle in cold weather. A fresh air intake hood with bird screen and/or
filters can be supplied by Duo-Aire with the heater. Our intake hood or one of a similar design is
recommended.

On units mounted indoors with through the roof intake ductwork, a suitable weather resistant intake hood
must be installed. Sheet metal standards should be adhered to to ensure uniform air delivery to the heater
inlet. This aids in preventing moisture entrainment. When using a through the wall intake duct, an intake
louver properly sized should be used, having adequate moisture baffling characteristics for the design air
volume.

MC-163-DA 03/07

In lieu of an intake louver, a wall mounted intake hood with mesh screen may be used. This can be
supplied by Duo-Aire. It is recommended that all intake ductwork which is exposed to the heated space
be insulated.

The requirements for discharge ductwork are usually considerably less than with a conventional system,
as the pressurization principle lends itself to effective air distribution. Generally, a "Splash Plate" or
other method of distributing the air is all that is necessary.

SOUND CONTROL

Flexible connectors should be employed on all ductwork connections. Unit vibration isolators are
recommended for suspended units and can be supplied by Duo-Aire as optional equipment.

DO NOT OPERATE UNIT FOR MORE THAN SIXTY (60) SECONDS WITHOUT ALL

ACCESS DOORS CLOSED. WITH THE EXCEPTION OF THE MASTER ELECTRICAL

PANEL OR GAS MANIFOLD ENCLOSURE DOORS.

Energize the system and check for unusual noises or vibrations, etc. Check the fan for proper rotation.
THIS MUST BE A VISUAL CHECK as fans will move air even if they are running backward, but the
system will not perform properly. Check the amp draw to all motors to insure it does not exceed the rated
maximum current rating of the motor.

If not factory installed, a low temperature limit switch should be interlocked with this heater to
prevent prolonged discharge of cold air in the event of burner lockout or shutdown.

Recirculation of room air may be hazardous in the presence of:
*Flammable liquids, solids and gases
*Explosive dusts or powders
*Substances which become toxic when exposed to heat

In order to reduce the chance of interior condensation, recirculation is not recommended in non­insulated buildings where outdoor temperatures fall below 32°F (0°C).

PROCEED WITH THE FIELD START-UP AND CHECK LIST

DUO-AIRE

316 West Central Ave., Suite 606
Winter Haven, FL. 33880

Telephone: [phone]
Facsimile: [phone]

MC-163-DA 03/07

Field Start-Up Sheet

Direct Fired Gas Equipment

***Please Print***

Customer:__________________________________________

Sales Representative: _________________________________

Model Number: ____________________

Serial Number: _____________________

INITIAL INSPECTION

I. Installer Responsibilities

1. Remote Panel: All interconnecting wires run from remote to unit  Yes
Temperature control interconnect wires to remote ran in:  Shielded Cable  Separate Conduit
Remote Panel Location:  Inside Wall  Outside Wall ____ Feet From Unit (approx.)

NOTE: If the Remote to Main Panel Interconnect Wiring is over 200' Long, Please Consult Factory

2. Indoor Return Air Unit: Building Pressure Switch Tubing for "Low-Tap" is run outdoors

3. Outdoor Return Air Unit: Building Pressure Switch Tubing for "High-Tap" is run indoors

4. R366-R389 Models: The panel with the high & low temp limit switches & Maxitrol mixing tube is mounted at fan wall  Yes

5. Gas supply run connected with proper gas pressure regulator and drip leg  Yes

6. Electrical Supply properly installed to main panel, at the voltage and amperage as stated on the unit nameplate  Yes

7. Multi-section units: joints caulked at mating frames, all bolts and nuts installed and tightened, seam tape applied  Yes

8. Upright Units: Legs attached and bolted, shimmed properly so unit does not "rock"  Yes

9. Duct connections made and sealed properly  Yes Return air screen installed at building wall  Yes

10. Discharge head installed secure, with diffuser blades tightened and in the open position  Yes

11. All "shipped loose" items installed properly - filters, vibration isolators, smoke detectors, dampers, louvers, service lights supply fan
belts, service platform, roof curb, humidistat, CO detector, etc.  Yes

12. All paint scratches have been properly touched-up  Yes
Comments:___________________________________________________________________________________________

II. Miscellaneous Items

1. Visible Physical Damage? ______ NO IF YES, Specify________________________________________________

2. Type of Installation:  Outdoor  Indoor  Roof Curb  Platform  Post  Suspended  Upright

3. Hardware Tight & Secure ____ 4. Damper Linkages Secure _____
Comments: ___________________________________________________________________________________________

III. Fan & Motor Sheaves

1. ___ Fan & Motor Sheaves Secured Tightly to Shafts 5. ___ Fan Hub Set Screws Tight

2. ___ V-Belts Aligned Properly 6. ___ V-Belts Tensioned Properly

3. ___ Fan Bearing Set screws Tight 7. ___ Fan Bearing Mounting Bolts Tight

4. ___ Fan Motor: Manufacturer______________________________ HP________ FLA________ Frame Size _________
Comments: ___________________________________________________________________________________________

IV. Burner Inspection

1. ___ Spark Igniter Secured Properly 4. ___ UV Scanner Secured Properly

2. ___ Flame Rod Secured Properly 5. ___ Pilot Line Fittings Tight

3. ___ Ignition Wire Attached at Igniter & Transformer 6. ___ Unions Tight and Secure

Comments: ___________________________________________________________________________________________

 Yes

 Yes

— Duo-Aire —

V. Gas Manifold & Vent Piping

1. ___ Manifold Assembly and Individual Components Tight and Securely Mounted 2. ___ Vent Screens Installed If Required

3. ___ Vent Piping Run to Outdoors (Some Indoor Models) 4. ___ Tighten Fittings and Components as Necessary

Comments: ___________________________________________________________________________________________

VI. Filters

1. ___ Filters Installed Properly 2. Type:  Aluminum  Pleated 30%  Pad & Frame  Other ____________________

Comments: ___________________________________________________________________________________________

VI. Electric Service

1. Electrical Service Provided to Unit: ____ Volts ____ Phase ____ Hertz _____ Amps

2. Unit Nameplate Electrical Requirement: ____ Volts ____ Phase ____ Hertz _____ Amps

3. Terminal Strip Wires Tight: Main Panel  Yes Remote Panel  Yes

4. Componentry and Relays Mounted Securely in Place  Yes

5. Light Bulbs Installed in Sockets for Control Enclosure Lighting  Yes

6. Main Fusing Size: ____ Volts ____ Amps 6. Overload Heater Size ____________

7. The Unit has been grounded by the installer at the main unit panel  Yes
Comments: ___________________________________________________________________________________________

VII. Gas Service (See maximum and minimum gas pressure requirements on unit rating plate)

1.  Natural Gas  LP Gas Service Pressure: ____ " W.C. -or- ____ Oz. -or- ____ Lbs

2. Manual Gas Shut-off Cock in line-of-sight  Yes  No 3. Handle Present on Manual Shut-off Cock  Yes  No

VERIFICATION OF OPERATION

NOTE: Refer to the Sequence of Operation & Wiring Diagram in the Owners Manual for specific data on this unit.
See Factory Start-up & Test Sheet in the Unit Owners Manual to note the unit settings prior to shipment.

I. Fan Operation

1. The Inlet Damper is fully open when fan comes on  Yes  NA Discharge Damper operates properly  Yes  NA

2. The low-temperature limit switch is field set at ______ºF. (Factory set at 40ºF.)

3. The low-limit by-pass timer completes its cycle in ______ minutes ______ seconds (normal: 5 minutes)

4. Fan Rotation is in the same direction as the rotation arrow  Yes

5. Discharge External Static Pressure ______ " W.C.

6. Check the following:
Unit Off

A-B ______ Volts A-B _____ Volts _____ Amps Verify the motor running
B-C ______ Volts B-C _____ Volts _____ Amps
A-C ______ Volts A-C _____ Volts _____ Amps

7. Approximate Outdoor Air Temperature _______° F

II. Burner Operation

1. The Profile Pressure Drop is ____" W.C. (Measured using taps provided near airflow switch).

1. The Burner Suction Static Pressure is _____ " W.C. (Measured at the manifold pressure tap with unit fan on and gas off)

2. The Burner High Fire Pressure is _____ "W.C. (Measured as above, but with fan and gas on, and unit in forced high fire)

Note: Burner High Fire Pressure plus Suction Pressure = Manifold Pressure (Example: -1.2 +3.4 = 4.6...ignore signs)

Refer to the unit rating plate for correct high fire manifold pressure and Maxitrol Bulletin in the O&M manual

3. The High Temperature Limit Switch is field set to _____ ºF (Maximum recommended setting is 150ºF)

4. The Low Gas Pressure Limit Switch is field set to _____ " WC (Factory set at 3" WC)

5. The High Gas Pressure Limit Switch is field set to _____ " WC (Factory set at 1.5" WC above the high fire pressure)

6. The Fan Airflow Switch is field set at ______" W.C. (Adjust as needed - Factory set at 0.35" WC)

Fan Running (Burner Off)

amps does not exceed the
motor nameplate FLA

— Duo-Aire —

7. The Pilot Flame should be the approximate size of a baseball  Yes (Adjust as needed)

8. Set the burner low-fire gas pressure so there is a continuous "ribbon" of flame approximately 1" wide across face of burner

9. Flame Relay. If a Honeywell model, it should read 1.25 to 5.0 VDC at terminals marked (+ -) on the flame relay face,
if Fireye, it should read 4.0 to 10.0 VDC at terminals marked (+ -) on the flame relay face

10. Mild Weather Stat (optional) trips the burner when outside air temp is higher than the stat set point  Yes, _____ºF Set
(Factory setting is 65ºF)

III. Space Temperature Control Systems (Maxitrol 44 and DFM Series)

1. Modulating Regulator Valve ("MR Valve"): Voltage at Low Fire ____ VDC Voltage at High Fire ____ VDC

2. The Minimum Discharge Temperature is field set at ____ ºF (Factory set at 55ºF)

3. The Maximum Discharge Temperature is field set at ____ ºF (Factory set at 95ºF, Maximum

setting is 120ºF)

4. Burner responds to demand for heat from Room Temperature Selector in remote panel  Yes

5. Check calibration of the minimum/maximum discharge temperature control. Adjust if necessary.

6. Operation of Occupied/Unoccupied Switch (if applicable) or time clock verified  Yes

7. Is there evidence of temperature hunting?  Yes **  No

IV. Discharge Temperature Control Systems (Maxitrol 14 Series)

1. Modulating Regulator Valve ("MR Valve"): Voltage at Low Fire ____ VDC Voltage at High Fire ____ VDC

2. Check calibration of the Discharge Air Temperature Selector. Adjust if necessary.

3. Is there evidence of temperature hunting?  Yes **  No

** Refer to the Maxitrol Troubleshooting Guide in the Owners Manual for further instructions

V. Damper Control Options

Manual Pot Control:

1. With the manual pot set to zero (0%), the outdoor air damper is closed and the return air damper is open.  Yes

2. With the manual pot set to 100%, the outdoor air damper is open and the return air damper is closed.  Yes

3. The manual pot was left set at _______% and the owner was instructed on its operation by me.  Yes

Building Pressure Control:

1. The differential setting on the building pressure switch is field set at _______ " WC (Typical is .01 - .03" WC)

2. By opening a building door or turning on an exhaust fan in the building, the unit pressure switch calls for more outside air (OA),
causing the OA damper to open, and the return air (RA) damper to close. When the building door is closed, or the exhaust fan turned
off, the OA and RA dampers react opposite.  Yes
Comments: ___________________________________________________________________________________________

VI. Miscellaneous Operational Checks:

1. With the unit fan and burner operating, all of the circuit check lights are illuminated (except the burner lock-out pilot light and the
low temperature switch pilot light)  Yes

2. If furnished, the time clock has been programmed per owner instructions, and training provided to him by me  Yes

3. If provided, the following temperature control stats have been set by me, and instructions provided to the owner:

_____ Cycle Stat _____ Cool-down Stat ____ Mild Weather Stat ____ Freeze Stat

4. The electrical drawing and sequence of operation is taped to the enclosure door.  Yes

5. The owners manual was reviewed by me with the owner, and placed back inside the unit enclosure  Yes

6. The owner was instructed by me on the operation of the following controls and options (check those that apply):

 Keyed Switches on remote panel  Maxitrol 44 Space Temperature Selector
 Remote Reset for Flame Relay  Maxitrol 14 Discharge Temperature Selector
 Burner Alarm Horn  3-phase Power Monitor
 Natural Gas/Propane Changeover Switch  Smoke Detector
 CO Detector  Magnahelic Gauge
 Photohelic Gauge  120V GFI Outlet
 Dirty Filter Light/Alarm  Evaporative Cooler

Continued on Next Page

— Duo-Aire —