Modine Manufacturing DBP, DCP Service Manual

5-565.1

5H080644A

November, 2009

INSTALLATION AND SERVICE MANUAL

gas-fired indoor power vented duct furnace/make-up air units

models DBP/DCP

9900100

All models approved for use in California by the CEC

FOR YOUR SAFETY

IF YOU SMELL GAS:

1. Open windows.

2. Don’t touch electrical switches.

3. Extinguish any open flame.

4. Immediately call your gas supplier.

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death, and could cause exposure to substances which have been determined by various state agencies to cause cancer, birth defects or other reproductive harm. Read the installation, operating and maintenance instructions thoroughly before installing or servicing this equipment.

CAUTION

To prevent premature heat exchanger failure do not locate ANY gas-fired units in areas where chlorinated, halogenated, or acid vapors are present in the atmosphere.

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.

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).

PLEASE BE SURE TO LEAVE IT WITH THE OWNER WHEN YOU LEAVE THE JOB.

THIS MANUAL IS THE PROPERTY OF THE OWNER.

SPECIAL PRECAUTIONS / TABLE OF CONTENTS

SPECIAL PRECAUTIONS

THE INSTALLATION AND MAINTENANCE INSTRUCTIONS IN THIS MANUAL MUST BE FOLLOWED TO PROVIDE SAFE, EFFICIENT AND TROUBLE-FREE OPERATION. IN ADDITION, PARTICULAR CARE MUST BE EXERCISED REGARDING THE SPECIAL PRECAUTIONS LISTED BELOW. FAILURE TO PROPERLY ADDRESS THESE CRITICAL AREAS COULD RESULT IN PROPERTY DAMAGE OR LOSS, PERSONAL INJURY, OR DEATH. THESE INSTRUCTIONS ARE SUBJECT TO ANY MORE RESTRICTIVE LOCAL OR

NATIONAL CODES.

HAZARD INTENSITY LEVELS

1. DANGER: Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.

2. WARNING: Indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.

3. CAUTION: Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury.

4. IMPORTANT: Indicates a situation which, if not avoided, MAY result in a potential safety concern.

dANGER

Appliances must not be installed where they may be exposed to a potentially explosive or flammable atmosphere.

WARNING

1. Gas fired heating equipment must be vented - do not operate

unvented.

2. A built-in power exhauster is provided - additional external

power exhausters are not required or permitted.

3. If you are replacing an existing heater, it may be necessary to

resize the venting systems. Improperly sized venting systems can result in vent gas leakage or the formation of condensate. Refer to the National Fuel Gas Code ANSI Z223.1 or CSA B149.1 latest edition. Failure to follow these instructions can result in injury or death.

4. Under no circumstances should two sections of double wall

vent pipe be joined together within one horizontal vent system due to the inability to verify complete seal of inner pipes.

5. 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.

6. Gas pressure to appliance controls must never exceed 14"

W.C. (1/2 psi).

7. Disconnect power supply before making wiring connections

to prevent electrical shock and equipment damage.

8. All appliances must be wired strictly in accordance with

wiring diagram furnished with the appliance. Any wiring different from the wiring diagram could result in a hazard to persons and property.

9. 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 duel rated units.

10. Ensure that the supply voltage to the appliance, as indicated

on the serial plate, is not 5% greater than the rated voltage.

11. Any original factory wiring that requires replacement must

be replaced with wiring material having a temperature rating of at least 105°C.

12. 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 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 owners risk.

CAUTION

1. 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.

2. Do not attempt to reuse any mechanical or electronic ignition controllers which has been wet. Replace defective controller.

3. Ensure that the supply voltage to the appliance, as indicated on the serial plate, is not 5% less than the rated voltage.

1. To prevent premature heat exchanger failure, do not locate ANY gas-fired appliances in areas where corrosive vapors (i.e. chlorinated, halogenated or acid) are present in the atmosphere.

2. To prevent premature heat exchanger failure, the input to the appliance, as indicated on the serial plate, must not exceed the rated input by more than 5%.

3. To prevent premature heat exchanger failure, observe heat exchanger tubes by looking at the heat exchanger through the field installed access openings in connecting ductwork in cooling package units or the unit access doors in blower package units. If the 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 15 for Blower Adjustments.

4. Start-up and adjustment procedures should be performed by a qualified service agency.

5. To check most of the Possible Remedies in the troubleshooting guide listed in Table 50.1, refer to the applicable sections of the manual.

Table of Contents

Inspection on Arrival..................................1

Special Precautions ..................................2

SI (Metric) Conversion Factors..........................3

Unit Location........................................3

Combustible Material and Service Clearances ..........3

Unit Lifting and Unit Mounting ..........................4

Duct Installation .....................................5

Unit Installation......................................6

Venting ........................................6

Gas Connections................................ 8

Electrical Connections............................ 9

Cooling Coil Specifications and Installation........... 10

Start-Up Procedure................................. 12

Pilot Burner and Main Burner Adjustment .............13

Blower Adjustment.............................. 15

Lubrication Recommendations .................... 15

Damper Linkage Adjustment...................... 15

Control Operating Sequence...................... 15

Options .......................................... 18

General Performance Data........................... 26

Unit Selection ..................................... 28

Blower Performance Data ........................... 30

Blower Sheave Assembly Data ....................... 34

Electrical Data .................................... 38

Motor Data ....................................... 38

Dimensions Unit ................................... 43

Weights.......................................... 47

Maintenance...................................... 48

Service & Troubleshooting ........................... 50

Model Designations ................................ 52

Start-Up Checklist.................................. 54

Model Nomenclature ............................... 55

Commercial Warranty......................... Back Page

IMPORTANT

5-565.12

SI (METRIC) CONVERSION FACTORS / UNIT LOCATION

Access

Slide

SI (METRIC) CONVERSION FACTORS

Table 3.1

To Convert Multiply By To Obtain

"W.C. 0.24 kPa psig 6.893 kPa °F (°F-32) x 0.555 °C inches 25.4 mm feet 0.305 meters CFM 0.028 m3/min

To Convert Multiply By To Obtain

CFH 1.699 m3/min Btu/ft3 0.0374 mJ/m pound 0.453 kg Btu/hr 0.000293 kW/hr gallons 3.785 liters psig 27.7 "W.C.

UNIT LOCATION

dANGER

Appliances must not be installed where they may be exposed to a potentially explosive or flammable atmosphere.

IMPORTANT

To prevent premature heat exchanger failure, do not locate ANY gas-fired appliances in areas where corrosive vapors (i.e. chlorinated, halogenated or acid) are present in the atmosphere.

Location Recommendations

1. When locating the furnace, consider general space and heating requirements, availability of gas and electrical supply, and proximity to vent locations.

2. Unit must be installed on the positive pressure side of the circulating blower.

3. Be sure the structural support at the unit location site is adequate to support the weight of the unit. For proper operation the unit must be installed in a level horizontal position.

4. Do not install units in locations where the flue products can be drawn into the adjacent building openings such as windows, fresh air intakes, etc.

5. Be sure that the minimum clearances to combustible materials and recommended service clearances are maintained. Units are designed for installation on noncombustible surfaces with the minimum clearances shown in Figure 3.1 and Tables 3.2 and 3.3.

6. Units installed downstream of refrigeration systems, or exposed to inlet air temperatures of 40°F or less, may experience condensation, therefore, provisions should be made for disposal of condensate. Means have been provided in the bottom pan of the unit to accommodate a condensate drain line connection flange.

7. When locating units, it is important to consider that the exhaust vent piping must be connected to the outside atmosphere.

8. In garages or other sections of aircraft hangars such as offices and shops that communicate with areas used for servicing or storage, keep the bottom of the unit at least 7' above the floor unless the unit is properly guarded to provide user protection from moving parts. In parking garages, the unit must be installed in accordance with the standard for parking structures ANSI/NFPA 88A, and in repair garages the standard for repair garages NFPA #88B. In Canada, installation of heaters in airplane hangars must be in accordance with the requirements of the enforcing authority, and in public garages in accordance with the current CAN/CGA-B149 codes.

9. Do not install units in locations where gas ignition system is exposed to water spray, rain, or dripping water.

Figure 3.1 - Combustible Material and Service

Clearances

➀ A 3'' minimum clearance to combustible material is required from the vent collar.

Table 3.2 - Combustible Material Clearances

Model Access Size Side (A) Side (B) (C) (D)

75-175 12" 1" 3" 2"

200-400 12" 2" 3" 2"

Non-Access

Top Bottom

Table 3.3 - Recommended Service Clearances

Model Access Non-Access Top Bottom Size Side (A) Side (B) (C) (D)

75 18" 6" 10" 0" 100/125 20" 6" 10" 0" 150/175 25" 6" 10" 0" 200/225 27" 6" 10" 0" 250/300 30" 6" 10" 0" 350/400 41" 6" 10" 0"

Combustion Air Requirements

Units installed in tightly sealed buildings or confined spaces must be provided with two permanent openings, one near the top of the confined space and one near the bottom. Each opening should have a free area of not less than one square inch per 1,000 BTU per hour of the total input rating off all units in the enclosure, freely communicating with interior areas having, in turn adequate infiltration from the outside. For further details on supplying combustion air to a confined (tightly sealed) space or unconfined space, see the National Fuel Gas Code ANSI Z223.1 of CAN/CGA B149.1 or .2 Installation Code, latest edition.

Sound and Vibration Levels

All standard blower mechanical equipment generates some sound and vibration that may require attenuation. Libraries, private offices and hospital facilities will require more attenuation, and in such cases, an acoustical consultant may be retained to assist in the application. Locating the equipment away from the critical area is desirable within ducting limitations. Generally, a unit should be located within 15 feet of a primary support beam. Smaller deflections mean lesser vibration and

noise transmission.

5-565.1 3

UNIT LOCATION/UNIT LIFTING/UNIT MOUNTING

5/8 Dia. (4)

BLOWER SECTION

DOOR

ELECTRICAL

SECTION

DOOR

DUCT

FURNACE

3/4" SUSPENSION

RODS (BY OTHERS)

(2) 3/4" NUTS & LOCKWASHER

(1) 3/4" NUT &

LOCKWASHER

UNIT LIFTING

All standard blower system units are shipped fully crated with skid supports below the unit. The unit may be lifted from the bottom by means of a fork lift or other lifting device only if the shipping support skids are left in place. DO NOT attempt to lift the unit from the bottom unless the shipping skid supports are still in place. When lifting units, make sure the load is balanced. All extended cabinet systems are shipped without a crate and cannot be lifted with a fork truck. Use a crane or other overhead lifting device in conjunction with the lifting holes (refer to page 45 for base rail lifting hole locations) for safe unit relocation. If the unit must be lifted from the bottom for final installation of the unit be sure to properly support the unit over its entire length to

prevent damage.

UNIT MOUNTING

Be sure the method of unit support (suspension or floor mounting) is adequate to support the weight of the unit (see Weights for base unit and factory installed option weights). For proper operation, the unit must be installed in a level horizontal position. Combustible material and service clearances as specified in Figure 3.1 and Tables 3.2 and 3.3 must be strictly maintained. To assure that flames are directed into the center of the heat exchanger tubes, the unit must be level in a horizontal position. Use a spirit level to ensure that the unit is suspended

or floor mounted correctly.

Unit Suspension

3/4" diameter suspension hanging locations are provided in the base rail assembly of the unit. Refer to Figure 45.1 for Suspension Hanging Locations and Figure 4.1 demonstrates how the unit should be suspended and the suspension rods fastened to the unit base rail. If required, vibration isolators may

be added.

Figure 4.1 - Unit Suspension Method

Floor Mounted Units

For floor installations, the floor structure must be adequately designed to support the live weight load of the unit and any other required support structure. Additional reinforcement should be provided, if necessary. The floor should include threaded 5/8inch anchor bolts spaced according to Figure 4.2, for securing the unit in place. Anchor bolts should extend at least 1-1/2" above the surface of the floor to allow clearance for mounting washers, nuts and bolts (mounting washers, nuts, and bolts by others).

Figure 4.2 - Floor Mounted Units

Model Blower Type DBP Units DCP Units All Units DBP Units

Size (Digit 16) (A) (A) (B) (C)

75 All 86.27 115.48 33.85 -

100/25 All 86.37 115.48 36.36 -

150/175 All 86.37 115.48 40.61 -

200/225 All 86.37 115.48 42.71 -

250/300 E,F,G, or H 86.37 115.48 45.75 -

250/300 I,J, or K 112.12 151.34 45.75 -

350/400 E,F,G or H 86.37 115.48 57.27 -

350/400 I,J, or K 122.2 151.34 57.27 -

500/600 G or H 119.52 - 45.75 33.5

500/600 I,J, or K 155.38 - 45.75 33.5

700/800 G or H 119.52 - 57.27 33.5

700/800 I,J,K, or L 155.37 - 57.27 33.5

840/960 I,J,K, or L 184.61 - 57.27 62.73

Standard blower cabinet shown

5-565.14

DUCT INSTALLATION

*DIMENSION "B" SHOULD NEVER BE LESS THAN 1/2 OF DIMENSION "A".

AIR

FLOW

SIDE VIEW

PROVIDE LEAK TIGHT ACCESS PANELS IN SIDE OF DISCHARGE DUCT FOR HEAT EXCHANGER INSPECTION

*DIMENSION "B" SHOULD NEVER BE LESS THAN 1/2 OF DIMENSION "A".

AIR

FLOW

PROVIDE LEAK TIGHT ACCESS PANELS IN SIDE OF DISCHARGE DUCT FOR HEAT EXCHANGER INSPECTION

TOP VIEW

12" MINIMUM

3" MINIMUM

TURNING VANES

3" MAXIMUM

3" MINIMUM

TURNING VANES

3" MAXIMUM

12" MINIMUM

DUCT INSTALLATION

Furnace discharge duct connection

1. The furnace discharge is designed to accept straight ductwork. (See Figure 5.1.) Provide an airtight seal between the ductwork and the furnace. Seams with cracks in the ductwork should be caulked and/or taped and be of permanent type. All duct connections MUST be airtight to prevent air leakage.

2. Provide removable access panels on the downstream side of the ductwork. (See Figure 5.1.) This opening should be large enough to view smoke or reflect light inside the casing to indicate leaks in the heat exchanger and to check for hot spots on heat exchangers due to poor air distribution or lack of sufficient air (CFM).

Figure 5.1 - Furnace Discharge Duct Connection

Blower section and cooling cabinet discharge duct connections

The blower section back and bottom and cooling cabinet section 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 MUST be airtight to prevent air leakage.

Figure 5.3 - Blower Section and Cooling Cabinet Discharge Duct Connections

1/2"

DUCTWORK WITH 90° 1/2" FLANGE

BLOWER OR COOLING COIL SECTION

3. Provide uniform air distribution over the heat exchanger. Use turning vanes where required to obtain uniform air distribution. (See Figure 5.2).

Figure 5.2 - Recommended Field Installed Discharge Duct Configurations for Blower Package Units

5-565.1 5

INSTALLATION

Venting

WARNING

1. Gas fired heating equipment must be vented - do not operate unvented.

2. A built-in power exhauster is provided - additional external power exhausters are not required or permitted.

3. If you are replacing an existing heater, it may be necessary to resize the venting systems. Improperly sized venting systems can result in vent gas leakage or the formation of condensate. Refer to the National Fuel Gas Code ANSI Z223.1 or CSA B149.1 latest edition. Failure to follow these instructions can result in injury or death.

4. Under no circumstances should two sections of double wall vent pipe be joined together within one horizontal vent system due to the inability to verify complete seal of inner pipes.

NOTE: A vent is the vertical passageway used to convey flue gases from the unit or the vent connector to the outside atmosphere. A vent connector is the pipe which connects the unit to a vent or chimney. Vent connectors serving Category I appliances shall not be connected into any portion of mechanical draft systems operating under positive pressure.

General Venting Instructions

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 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. All vertically vented units are Category I. All horizontally vented units are Category III. The installation must conform to the requirements from Table 6.2 in addition to those listed below.

3. For units vented as Category I, refer to Table 6.1 for vent sizing. Vent sizing for units vented as Category III are covered in a later section on page 7. Do not use a vent pipe smaller than the size of the outlet or vent transition of the appliance. The pipe should be suitable corrosion resistant material. Follow the National Fuel Gas Code for minimum thickness and composition of vent material. The minimum thickness for connectors varies depending on the pipe diameter.

Table 6.1 - Vertical Category I Vent Sizing Requirements

Vent Connector

Model Size

75-125

150-175 4" 5" ➀

200 6" 6"

225-400

➀ Requires a 4" to 5" adapter for the larger vent pipe diameter.

4. For Category I vent systems limit length of horizontal runs to 75% of vertical height. Install with a minimum upward slope from unit of 1/4 inch per foot and suspend securely from overhead structure at points no greater than 3 feet apart. For best venting, put vertical vent as close to the unit as possible. A minimum of 12" straight pipe is recommended from the power exhauster outlet before turns in the vent system. Fasten individual lengths of vent together with at least three corrosion-resistant sheet-metal screws.

5. It is recommended that vent pipes be fitted with a tee with a drip leg and a clean out cap to prevent any moisture in the vent pipe from entering the unit. The drip leg should be inspected and cleaned out periodically during the heating season.

6. The National Fuel Gas Code requires a minimum clearance of 6 inches from combustible materials for single wall vent pipe. The minimum distance from combustible materials is based on the combustible material surface not exceeding 160°F. Clearance from the vent pipe (or the top of the unit) may be required to be greater than 6 inches if heat damage other than fire (such as material distortion or discoloration) could result.

Diameter

4" 4"

6” 6”

Minimum Vent Pipe

Diameter

7. Avoid venting through unheated space. When venting does pass through an unheated space, insulate runs greater than 5 feet to minimize condensation. Inspect for leakage prior to insulating and use insulation that is noncombustible with a rating of not less than 350°F. Install a tee fitting at the low point of the vent system and provide a drip leg with a clean out cap as shown in Figure 7.1.

Table 6.2 - ANSI Venting Requirements

Appliance Venting Category Description Requirements

I Negative vent pressure Follow standard venting Non-condensing requirements.

II Negative vent pressure Condensate must be Condensing drained.

III Positive vent pressure Vent must be gastight. Non-condensing

IV Positive vent pressure Vent must be liquid and Condensing gastight. Condensate must be drained.

8. When the vent passes through a combustible wall or floor, a metal thimble 4 inches greater than the vent diameter is necessary. If there is 6 feet or more of vent pipe in the open space between the appliance and where the vent pipe passes through the wall or floor, the thimble need only be 2 inches greater than the diameter of the vent pipe. If a thimble is not used, all combustible material must be cut away to provide 6 inches of clearance. Any material used to close the opening must be noncombustible.

9. Do NOT use dampers or other devices in the vent pipes.

10. Precautions must be taken to prevent degradation of

building materials by flue products.

11. For category I vent systems the outlet of the vent should

extend as shown in Figure 7.1 and Table 7.1 if the following conditions are met:

• Vent diameter is less than 12 inches, vent is of double

wall construction and is a listed product, and the vent does not terminate within 2' of a vertical wall or similar obstruction.

• For vents that have a diameter of 12 inches or larger,

constructed of single wall, or terminate within 2' of a vertical wall or similar obstruction, the vent pipe shall extend at least 2' higher than any portion of a building within a horizontal distance of 10' (refer to Figure 7.1).

12. Use a listed vent terminal to reduce downdrafts and

moisture in vent.

13. For instructions on common venting refer to the National

Fuel Gas Code.

14. The vent must terminate no less than 5' above the vent

connector for Category I vent systems.

15. A unit located within an unoccupied attic or concealed space

shall not be vented with single wall vent pipe.

16. Single wall vent pipe must not pass through any attic, inside

wall, concealed space, or floor.

17. Do NOT vent this appliance into a masonry chimney.

18. When condensation may be a problem, the venting system

shall not terminate over public walkways or over an area where condensation or vapor could create a nuisance or hazard or could be detrimental to the operation of regulator relief openings or other equipment.

19. In cold ambient conditions, such as Canada, the following

items are recommended for proper operation and equipment life:

• The vent pipe must not pass through an unheated space

or interior part of an open chimney unless the vent pipe is insulated.

• Where the vent pipe may be exposed to extreme cold, or

come into contact with snow or ice, the entire vent must be insulated or double wall (includes outdoors). It is preferred that the double wall vent is one continuous piece but a joint is allowed outside the building.

• The heater system shall be checked at least once a year

by a qualified service technician.

5-565.16

12" MIN

RECOMMENDED

4" MIN

TEE WITH DRIP LEG AND CLEANOUT CAP

(SLOPE 1/4" PER FOOT DOWNWARD TOWARD DRIP LEG)

EXHAUST

"H" MIN*

12" MIN

RECOMMENDED

4" MIN

BACK VIEW

ROOF PITCH IS:

X / 12

TEE WITH DRIP LEG AND CLEANOUT CAP

(SLOPE 1/4" PER FOOT DOWNWARD TOWARD DRIP LEG)

ROOF FLASHING

USE LISTED THIMBLE THROUGH ROOF AND CEILING

EXHAUST

LISTED TERMINAL

* SIZE ACCORNING TO EXPECTED SNOW DEPTH.

TO WALL OR ADJOINING BUILDING

2' MIN

2' MIN* USE THIMBLE THROUGH

CELLING

ROOF FLASHING

TERMINAL

METAL

SLEEVE

FIBER GLASS

INSULATION

MIN. 2"

2" MIN.

VENT TERMINATION SUPPORT BRACKET

(where required)

(Make from 1" x 1" steel angle)

METAL

SLEEVE

2" MIN.

VENT PIPE DIAMETER

METAL FACE

PLATE

12" min

TEE WITH DRIP LEG

AND CLEANOUT CAP

AT LOW POINT OF

VENT SYSTEM

POWER EXHAUSTER OUTLET

PITCH VENT PIPE DOWNWARD

FROM UNIT 1/4" PER FOOT

12"

Min.

GARY STEEL

MODEL 1092 TERMINAL

INSTALLATION

Figure 7.1 - Vertical Category I Vent System

Table 7.1 - Minimum Height from Roof to Lowest Discharge Opening

Rise X (in) Roof Pitch Min Height H (ft) ➀

0-6 Flat to 6/12 1.00

6-7 6/12 to 7/12 1.25

7-8 7/12 to 8/12 1.50

8-9 8/12 to 9/12 2.00

9-10 9/12 to 10/12 2.50

10-11 10/12 to 11/12 3.25

11-12 11/12 to 12/12 4.00

12-14 12/12 to 14/12 5.00

14-16 14/12 to 16/12 6.00

16-18 16/12 to 18/12 7.00

18-20 18/12 to 20/12 7.50

20-21 20/12 to 21/12 8.00

➀ Size according to expected snow depth.

Additional Requirements for Horizontally Vented Category III Units

1. Seal the joints with a metallic tape or silastic suitable for temperatures up to 350°F. (3M tapes 433 or 363 are acceptable.) Wrap tape two full turns around the vent pipe.

2. Refer to Table 7.2 for total minimum and maximum vent lengths making the vent system as straight as possible. The equivalent length of a 90° elbow is 5 feet for 4" diameter and 7 feet for 6" diameter.

Table 7.2 - Horizontal Category III Vent Sizing Requirements

Vent Connector

Model Size

100-175

200

225 250-300 350-400

➀ Unit can be vented with 5" diameter pipe if a 6" to 5" reducer is used.

Otherwise, use 6" pipe.

Diameter

4" 4" 48' 4" 4" 55' 6" 6" 6" 6" 63' 6" 6" 70'

3. The vent terminal must be a Gary Steel 1092.

4. The vent must extend a minimum of 12" beyond the exterior wall surface as shown in Figure 7.2. The vent must be supported as shown in Figure 7.3. Precautions must be taken to prevent degradation of building materials by flue products.

5. The vent system shall terminate at least 3 feet above any

forced air inlet (except direct vent units) located within 10 feet,

and at least 4 feet below, 4 feet horizontally from, or 1 foot above any door, window, or gravity air inlet into any building. The bottom of the vent terminal shall be located above the snow line or at least 1 foot above grade; whichever is greater. When located adjacent to public walkways the vent system shall terminate not less than 7 feet above grade.

6. The venting system must be exclusive to a single unit, and no other unit is allowed to be vented into it.

7. Horizontally vented units must use single wall vent pipe although one continuous section of double wall vent pipe may be used with the vent system. Under no circumstances should two sections of double wall vent pipe be joined together within one vent system due to the inability to verify complete seal of inner pipes.

Minimum Vent Pipe Diameter

5" ➀ 70'

6" 70'

Maxium Vent

Length

Figure 7.2 - Horizontal Venting

Figure 7.3 - Venting Through Combustible Walls

5-565.1 7

UNIT INSTALLATION

GAS

SUPPLY LINE

GAS

SUPPLY LINE

GROUND

JOINT

UNION

W/ BRASS

SEAT

MANUAL GAS

SHUT-OFF V A LV E

MIN.

SEDIMENT

TRAP

PLUGGED

1/8" NPT TEST

GAGE CONNECTION

CONTROLS

Gas Connections

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 duel 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 heat exchanger failure, the input to the appliance, as indicated on the serial plate, must not exceed the rated input by more than 5%.

1. Installation of piping must conform with local building codes, or in the absence of local codes, with the National Fuel 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 14.1 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 unit or from below. Install a ground joint union with brass seat and a manual shut-off valve external of the unit casing, and adjacent to the unit for emergency shut-off and easy servicing of controls, including a 1/8" NPT plugged tapping accessible for test gauge 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

➀

➀ Manual shut-off valve is in the “OFF” position when handle is perpendicular

to pipe.

Table 8.1 - Gas Pipe Capacities

Gas Pipe Capacities (Up to 14” W.C. Gas Pressure through Schedule 40 Pipe)

Length Pipe Diameter Of Pipe 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" (feet) Natural Propane Natural Propane Natural Propane Natural Propane Natural Propane Natural Propane

10 132 83 278 175 520 328 1050 662 1600 1008 3050 1922

20 92 58 190 120 350 221 730 460 1100 693 2100 1323

30 73 46 152 96 285 180 590 372 890 561 1650 1040

40 63 40 130 82 245 154 500 315 760 479 1450 914

50 56 35 115 72 215 135 440 277 670 422 1270 800

60 50 32 105 66 195 123 400 252 610 384 1150 725

70 46 29 96 60 180 113 370 233 560 353 1050 662

80 43 27 90 57 170 107 350 221 530 334 990 624

90 40 25 84 53 160 101 320 202 490 309 930 586

100 38 24 79 50 150 95 305 192 460 290 870 548

125 34 21 72 45 130 82 275 173 410 258 780 491

150 31 20 64 40 120 76 250 158 380 239 710 447

Cubic Feet per Hour with Pressure Drop of 0.3” W.C.

Natural Gas - Specific Gravity - 0.60

Propane Gas - Specific Gravity - 1.50

5-565.18

BLOWER SECTION

DOOR

ELECTRICAL

SECTION

DOOR

DUCT

FURNACE

ELECTRIC SUPPLY

COMPONENTS MUST BE

CLEAR OF SERVICE DOORS

DISCONNECT

SWITCH WIRING,

AND CONNECTOR

UNIT INSTALLATIONUNIT INSTALLATION

Electrical Connections

WARNING

1. Disconnect power supply before making wiring connections to prevent electrical shock and equipment damage.

2. All appliances must be wired strictly in accordance with wiring diagram furnished with the appliance. Any wiring different from the wiring diagram could result in a hazard to persons and property.

3. Any original factory wiring that requires replacement must

be replaced with wiring material having a temperature rating of at least 105°C.

4. Ensure that the supply voltage to the appliance, as

indicated on the serial plate, is not 5% greater than rated voltage.

CAUTION

Ensure that the supply voltage to the appliance, as indicated on the serial plate, is not 5% greater than rated voltage.

1. Installation of wiring must conform with local building codes, or in the absence of local codes, with the National Electric Code ANSI/NFPA 70 - Latest Edition. Unit must be electrically grounded in conformance to this code. In Canada, wiring must comply with CSA C22.1, Part 1, Electrical Code.

2. Two copies of the job specific wiring diagram are provided with each unit, one located in the duct furnace electrical junction box and one in the electrical section of the unit. Refer to this diagram for all wiring connections.

3. The wire gauge must be sized according to the National Electric Code or CSA code based on the power supply voltage, amp draw, and length of run. Refer to Table 9.1 for maximum wire lengths. Once the wire gauge has been determined, refer to Table 9.2 for the number of wires for which the low voltage terminal blocks in the unit are rated.

Table 9.1 - Low Voltage (24V) Maximum Wire Length (Feet)

NEC-1996, Table 310-17, Copper wire with 90°C insulation, conductors in free space (not in conduit), 86°F ambient. For other wire types, refer to the NEC of CSA code.

Wire Gauge

Model No. Trans.

Digit 15 VA 18 GA 16Ga 14 Ga 12 Ga 10 Ga

1 40 162 216 315 360 495

2 75 86 115 168 192 264

3 150 43 58 84 96 132

4 250 26 35 50 58 79

Table 9.2 - Number of Wires Per Terminal

Wire Gauge Number of Wires per Terminal

#10 AWG 1

#12 AWG 1 to 2

#14 AWG 1 to 3

#16 AWG 1 to 4

#18 AWG 1 to 5

#22 AWG 2 to 5

4. Make sure all multi-voltage components (motors, transformers, etc.) are wired in accordance with the power supply voltage.

Figure 9.1 - Recommended Accessory Field Installed Disconnect Switch Mounting Locations

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 18.1) for the factory mounted disconnect switch location and then review the unit to determine if a factory installed dead front disconnect switch was provided. Accessory field installed disconnect switches should be mounted where shown in Figure 9.1. For fusible disconnect switches, refer to the Model Identification plate for the fuse size and type.

6. The power supply must be within 5% of the voltage rating and each phase must be balanced within 2 percent of each other. If not, advise the utility company.

7. External electrical service connections that must be installed include:

a. Supply power connection (120, 208, 240, 480, or 600

volts).

b. Connection of thermostats, remote monitoring panels,

building pressure sensors, CO detectors, time clocks, or any other accessory control devices that may be supplied (24 volts).

8. Refer to the unit dimensional drawings on Figures 43.1 through 44.1 for the electrical knock-out locations.

9. All supply power electrical connections are made in the electrical section of the unit. The low voltage (thermostat and accessory control devices) can be wired to either the electrical section or the duct furnace electrical junction box. Refer to the wiring diagram for the terminal location of all low voltage wiring.

Cooling Coil Units

Models with a cooling section can be provided with either a factory installed direct expansion (DX) evaporator, a chilled fluid (for use with water, ethylene glycol, or propylene glycol fluids) coil, or the coil can be field supplied and installed by others. For units equipped with a factory installed cooling coil (Digit 23 = 1), refer to the packing slip to determine the coil type provided. The cooling section is located downstream of the duct furnace heat exchanger in a blow-through configuration, preventing condensation on the heat exchanger in the cooling mode. Thus, a stainless steel heat exchanger is not required when a cooling section is used. (However, a stainless steel heat exchanger is still recommended when the combined entering/ return air to the unit is below 40°F.)

5-565.1 9

UNIT INSTALLATIONUNIT INSTALLATION

Suctio n Line

Expansion Valve

Remot e Sens ing Bulb

Straps

Suctio n Connection

Coil

Suctio n Header

Distributor

Equali zer Line

Nozzle

Liquid Line

(By Others)

The cooling section includes a full coverage, 3-way sloping 409 stainless steel drain pan to remove condensate from coil headers, thermal expansion valves, and refrigerant piping. Insulation is standard on outdoor units and optional on indoor units and double wall construction is optional on all units. The cabinet includes two doors, a removable upper door for service access to the coil once the plumbing has been installed and a lower door which includes a factory supplied 1" stubbed drain connection to the exterior of the cabinet. Field connections for coil inlet and outlet piping can be made through the cabinet corner post or back of the unit. The cooling section duct transition includes 1-1/2" flanges for fastening the sides of the coil. The bottom duct transition is angled to remove any condensation that may be entrained in the supply air stream.

For field supplied coils, do not exceed the maximum coil dimensions listed in Literature 82-135. The dimensions listed are for the maximum coil dimensions. If the coil supplied is smaller than the listed dimensions, field supplied blank off plates are required to prevent air bypass around the coil. The coil is supported by two 14 gauge support rails which contain mounting provisions for fastening 4", 5", 6", 7.5", 8.5", and 10" deep coils. When obtaining the specifications from a coil manufacturer, it is important to obtain the pressure drop through

the coil so that the proper motor horsepower can be selected.

Figure 10.1 - Cooling Section

Optional double wall construction

DX single circuit (shown) and dual circuit coils available

Direct Expansion (DX) Piping

The refrigerant lines should be insulated to prevent warming or cooling of the refrigerant. If the suction line is allowed to be cooled, liquid will condense in the line and can severely damage the compressor. If the liquid line is warmed, the refrigerant can "flash" into a gas. This will cause erratic operation of the expansion device and impair the heat transfer ability of the cooling coil. Long runs of piping need to be periodically supported to prevent excess vibration that can damage the piping and joints. It is recommended to provide dampening supports at intervals of length equivalent to 15 tube diameters.

Figure 10.2 - General DX Piping

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 steel drain pan

Right or left hand coil header access to

1” stubbed drain connection

match gas controls

For Both Chilled Water and Direct Expansion Coils: The condensate drain line needs to include a P-trap immediately downstream of the connection to the unit. This trap should extend at least two inches below the connection to prevent air pressure from forcing air into the unit. The trap should be primed with a water/glycol solution to prevent freezing. All points where refrigerant, water or condensate lines enter the structure should be sealed and vibration dampened. Include shut-off valves to isolate the cooling coil from the system in order to remove the coil for service or replacement without draining the entire system. For additional guidelines, refer to the ASHRAE Fundamentals Handbook section of piping recommendations.

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. Connect the suction line and suction connection.

4. Install the expansion valve (By Others). Follow the expansion valve manufacturer's recommendations for installation to avoid damaging the valve.

5. The expansion valve's remote sensing bulb should be securely strapped to the horizontal run of the suction line at the 3 or 9 o'clock position and insulated.

6. Connect the liquid line to the expansion valve. Pressurize the coil, expansion valve assembly and suction connection to 100 psig with dry nitrogen or other suitable gas. The coil should be left pressurized for a minimum of 10 minutes.

7. If the coil holds pressure, the hook-up 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. If the coil is found to be leaking, contact your local factory representative.

5-565.110

UNIT INSTALLATION

Air Vent

Gate Va lve

T e e

Vent Plug

Supply

Dirt Leg

Cap

Union

Drain Plug

Table 11.1 - Cooling Coil Performance Limits

DX - Single Circuit DX - Dual Circuit Chilled Water Max. Cooling Tons ② ③

Model

Max Coil Area Max Coil Area Max Coil Area DX Chilled

Size

CFM ➀ (Sq. Ft.) CFM ➀ (Sq. Ft) CFM ➀ (Sq. Ft.) Coils Water Coils

75 1891 3.44 1707 3.10 1676 3.05 609 ④ 9.38 10.56 100 2206 4.01 2048 3.72 2011 3.66 741 ⑤ 11.43 12.62

125 2206 4.01 2048 3.72 2011 3.66 926 11.43 12.62

150 2521 4.58 2416 4.39 2372 4.31 1111 13.42 14.77

175 2521 4.58 2416 4.39 2372 4.31 1296 13.42 14.77

200 3352 6.09 3165 5.76 3214 5.84 1481 18.12 19.28

225 3352 6.09 3165 5.76 3214 5.84 1667 18.12 19.28

250 3724 6.77 3538 6.43 3592 6.53 1852 20.24 21.33

300 3724 6.77 3538 6.43 3592 6.53 2222 20.24 21.33

350 5214 9.48 4996 9.08 5073 9.22 2593 27.26 29.25

400 5214 9.48 4996 9.08 5073 9.22 2963 27.26 29.25

Min

CFM

(All Units)

➀ Based on 550 feet per minute (FPM) coil face velocity. ➁ 1 Ton = 12,000 Btu/Hr ➂ Based on 95°F Entering Dry Bulb, 75°F Entering Wet Bulb. ➃ Model Size 75 CFM listed for Chilled Water - DX Single Circuit CFM minimum is 688 and DX Dual Circuit CFM min is 621. ➄ Model Size 100 CFM listed for Chilled Water - DX Single Circuit CFM minimum is 802 and DX Dual Circuit CFM min is 745.

8. Use a vacuum pump to evacuate the coil and any

Figure 11.1 - General Chilled Fluid Piping

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.

9. Failure to obtain a high vacuum is indicative of a great deal of moisture or a small leak. Break the vacuum with a charge of dry nitrogen or other suitable gas and recheck for leaks (soapy water works well). If no leaks are found, continue vacuuming the coil until the desired vacuum is reached.

10. All field piping must be self-supporting.

Chilled Fluid Piping

To prevent noise within a system, an air vent is necessary to bleed off the accumulated air in the system. The vent should be located on the top of the inlet manifold where the air collects. This vent should be opened twice a year. Air in the system will generate noise and may cause water hammer than can damage the joints of the piping and the cooling coil.

The outlet manifold should have a drain installed on the bottom of the manifold to allow for periodic flushing of the system to remove sediments and corrosion products from the cooling coil. This drain should be opened to allow some fluid to drain

twice a year. Check coloration and viscosity of the effluent for indications of corrosion in the system. The lines between the unit and the structure should be insulated to prevent freezing of the water.

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. If the coil itself is found to be leaking, contact your local factory representative.

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. All field piping must be self supporting. System piping should be flexible enough to allow for thermal expansion and contraction of the coil.

5-565.1 11

UNIT INSTALLATION / START-UP PROCEDURE

Operation

General - All coils

1. Proper air distribution is vital to coil performance. Air flow anywhere on the coil face should not vary by more than 20%.

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 fps for Water and 1 to 6 fps for Glycol solutions.

Chilled fluid coils - Initial Start-Up

1. Open all air vents so that air is eliminated from within the coil circuitry and headers. Verify that all vents and drains are not obstructed and do discharge a stream of water.

2. Fill the coil with water then close all vents.

3. Perform an initial hydrostatic leak test of all brazed, threaded or flanged joints, valves and interconnecting piping. Recheck the coil level and correct if necessary. When the setup is found to be leak free, discharge and discard initial water charge. It is important that all grease, oil, flux and sealing compounds present from the installation be removed.

Maintenance

General

1. Filters should be inspected on a regular basis and changed as needed. Maintaining clean filters is a costeffective way to help maintain maximum coil performance and service life.

2. Periodic inspection of the coil for signs of corrosion and for leaks is recommended. For DX coils, Small leaks can be detected using a Halide torch. Repair and replacement of the coil and the connecting piping, valves, etc., should be performed as needed by a qualified individual(s).

3. Should the coil surface need cleaning, caution should be exercised in selecting the cleaning solution as well as the cleaning equipment. Improper selection can result in damage to the coil and/or health hazards. Clean the coil from the 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.

4. For DX coils, the use of filter-dryers in the system piping is recommended along with a sight glass that has a moisture indicator. Replace the filter dryer(s) as needed.

5. For chilled fluid coils,

A) Maintain the circulated fluid free of sediment, corrosive products and biological contaminants. Periodic testing of the fluid followed by any necessary corrective measures along with maintaining adequate fluid velocities and proper filtering of the fluid will help to satisfy this goal.

B) Automatic air vents must be utilized to remove accumulated air.

C) Freeze Protection - During the winter, chilled water coils need to be protected against freezing. The two predominant protective measures are 1) Blowing-out the coils with air or 2) Flushing coils with inhibited glycol. It is recommended to use inhibited glycol designed for HVAC applications for corrosion protection. Select an inhibited glycol solution that will protect the coil from the lowest possible temperatures that can occur at the particular coil's locality.

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 15 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 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 the motor voltage. On three phase systems, check to make sure all legs are in balance.

18. Check the motor amp draw to make sure it does not exceed the motor nameplate rating. On three phase systems, check all legs to insure system is balanced.

5-565.112

UNIT INSTALLATION / START-UP PROCEDURE

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 the 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 54 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 13.1).

4. Replace the cap from the pilot adjustment screw.

Figure 13.1 - Correct Pilot Flame

3/4" to 1"

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 14.1).

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. If the unit has Electronic Modulation gas controls (determine from the Model Identification Digit 12), the low fire gas pressure needs to be adjusted. Using Figure 14.2 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

(5), 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 “ON” position and recheck pipe plugs

for gas leaks with soap solution.

5-565.1 13

START-UP PROCEDURE

Standard Controls

Premium Controls

Manifold Pressure Te st Point

Figure 14.1 - Checking Manifold Pressure with “U” Tube Manometer

Figure 14.2 - Maxitrol Modulating Valve Adjustments

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 gas valve in Figure 14.1. The larger models may require the removal of the manifold (see Manifold Assembly Removal).

Natural Gas Flame Control

Control of burner flames on duct furnaces utilizing natural gas is achieved by resetting the primary air shutters (See Figure

48.4) to either increase or decrease primary combustion air. Prior to flame adjustment, operate duct furnace for about fifteen minutes. The main burner flame can be viewed after loosening and pushing aside the gas designation disc on the side of the burner box.

To increase primary air, loosen the air shutter set screws and move the air shutters closer to the manifold until the yellowtipped flames disappear. (See Figure 48.4 for air shutter and

heat exchanger support locations.) To decrease primary air, move the air shutters away from the manifolds until flames no longer lift from burner ports, but being careful not to cause yellow tipping. Retighten set screws after adjustment.

Propane Gas Flame Control

An optimum flame will show a slight yellow tip. Prior to flame adjustment, operate furnace for at least fifteen minutes. Loosen air shutter set screws and move the air shutters away from the manifold to reduce the primary air until the yellow flame tips appear. Then increase the primary air until yellow tips diminish and a clean blue flame with a well defined inner cone appears.

Table 14.1 - Manifold Pressure and Gas Consumption

Model Size Type of Gas Natural Propane

Btu/Cu. Ft. 1040 2500

Specific Gravity 0.60 1.53

High Fire Manifold Pressure No. of Inches of Water Column 3.5 10 Orifices

Cfh 72.1 30.0

Orifice Drill Size 20 37 Cfh 96.1 40.0

100

Orifice Drill Size 30 45 Cfh 120.2 50.0

125

Orifice Drill Size 25 42 Cfh 144.2 60.0

150

Orifice Drill Size 30 45 Cfh 168.3 70.0

175

Orifice Drill Size 27 43 Cfh 192.3 80.0

200

Orifice Drill Size 23 40 Cfh 216.3 90.0

225

Orifice Drill Size 20 37 Cfh 240.4 100.0

250

Orifice Drill Size 25 42 Cfh 288.7 120.0

300

Orifice Drill Size 20 37 Cfh 336.5 140.0

350

Orifice Drill Size 27 43 Cfh 384.6 160.0

400

Orifice Drill Size 23 40 Cfh 240.4 ➀ 100.0 ➀

500 ➀

Orifice Drill Size 25 42 Cfh 288.7 ➀ 120.0 ➀

600 ➀

Orifice Drill Size 20 37 Cfh 336.5 ➀ 140.0 ➀

700 ➀

Orifice Drill Size 27 43 Cfh 384.6 ➀ 160.0 ➀

800 ➀

Orifice Drill Size 23 40 Cfh 336.5 ➁ 140.0 ➁

840 ➁

Orifice Drill Size 27 43 Cfh 384.6 ➁ 160.0 ➁

960 ➁

Orifice Drill Size 23 40

➀ Model contains 2 furnaces. Values shown are per furnace. ➁ Model contains 3 furnaces. Values shown are per furnace.

➀

➁

5-565.114

START- UP PROCEDURE

To ward Motor

Set Screw

Adjustable Half

of Sheave

ROD

CONNECTING

JOINT

Blower Adjustments

If blower fan speed changes are required, adjust motor sheave as follows:

1. Refer to page 34 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 15.1 - Motor Sheave Adjustment

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 15.3.

4. Tighten the 5/16" hex head screw on the ball joint.

Figure 15.3 - Damper Linkage Adjustment

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 lbs. of force.

Figure 15.2 - Belt Tension Adjustment

3/4" deflection with 5 lbs. 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 lubrication. 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.

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 power vented duct furnaces are supplied with intermittent pilot systems with continuous retry as standard. On mechanical modulation systems the main burner is turned off 100% when the thermostat is satisified, but the pilot remains lit. For intermittent pilot systems, except mechanical modulation both the main burner and pilot burner are turned off 100% when the thermostat is satisfied. Intermittent pilot systems, for both natural and propane gas, the ignition controller is 100% shut-off with continuous retry. On a call for heat, the system will attempt to light the pilot for 70 seconds. If the pilot is not sensed for any reason, the ignition control will wait for approximately six minutes with the combination gas control closed and no spark. After six minutes, the cycle will begin again. After three cycles, some ignition controllers lockout for approximately one hour before the cycle begins again. This will continue indefinitely until the pilot flame is sensed or power is interrupted to the system.

NOTE: Gas Control Options (see page 16) could change the

listed sequence of operation based on their function. The descriptions given are for the basic duct furnace.

5-565.1 15

START-UP PROCEDURE

Single-Stage Gas Controls (intermittent pilot)

Utilizes a single-stage combination gas control, an ignition control, and a single-stage low voltage thermostat.

1. The thermostat calls for heat.

2. The power exhauster relay is energized starting the power exhauster motor. Once the motor has reached full speed, the differential pressure switch closes. The power exhauster relay pre-purge timer closes after 20 to 40 seconds energizing the gas control circuit.

3. The pilot valve opens and the spark ignitor sparks in an attempt to light the pilot. (If the unit was not provided with a time delay relay, the blower starts at this time.)

4. Once the pilot is lit, the flame sensor proves the pilot and stops the spark ignitor from sparking.

5. The main gas valve is opened and the main burner is lit to 100% full fire.

6. If the unit was provided with a time delay relay, the blower starts after 30 to 45 seconds.

7. The unit continues to operate until the thermostat is satisfied, at which time both the main and pilot valves close 100%. (If the unit was not provided with a time delay relay, the blower stops at this time).

8. If the unit was provided with a time delay relay, the blower stops after 30 to 45 seconds.

Two-Stage Gas Controls (intermittent pilot)

Utilizes a two-stage combination gas control, an ignition control, and a two-stage low voltage thermostat. The unit fires at 50% fire on low stage and 100% fire on high stage.

1. The thermostat calls for low stage heat.

3. The pilot valve opens and the spark ignitor sparks in an attempt to light the pilot. (If the unit was not provided with a time delay relay, the blower starts at this time.)

4. Once the pilot is lit, the flame sensor proves the pilot and stops the spark ignitor from sparking.

5. The main gas valve is opened and the main burner is lit to 50% fire.

6. If the unit was provided with a time delay relay, the blower starts after 30 to 45 seconds.

7. If the temperature at the thermostat continues to fall, the thermostat will call for high stage heat.

8. The main gas valve is opened completely and the main burner is lit to 100% full fire.

9. The unit continues to operate until the high stage of the thermostat is satisfied, at which time the main valve closes to 50% fire.

10. The unit continues to operate until the low stage thermostat is satisfied, at which time both the main and pilot valves close 100%. (If the unit was not provided with a time delay relay, the blower stops at this time.)

11. If the unit was provided with a time delay relay, the blower stops after 30 to 45 seconds.

Mechanical Modulating Gas Controls

Dial Number

Lo 1 2 3 4 5 6 7 8 Hi

Discharge Air Temp. 58 62 65 69 72 76 79 83 86 90 (°F)

Utilizes a mechanical modulating gas control and an ignition control. The mechanical modulating gas control is designed for use in constant blower applications. The discharge air temperature is maintained by setting the control dial of the

modulating gas valve in one of ten positions. A hydrostatic sensing bulb located in the discharge air stream controls the gas flow between 40% through 100% full fire. When the discharge air hydrostatic sensing bulb is satisfied, the modulating valve closes completely, but the pilot remains lit. This control cannot be used with a room override thermostat.

1. Power is supplied to the unit through either an exhaust fan interlock contact or a start/stop switch.

3. The pilot valve opens and the spark ignitor sparks in an attempt to light the pilot. (If the unit was not provided with a time delay relay, the blower starts at this time.)

4. Once the pilot is lit, the flame sensor proves the pilot and stops the spark ignitor from sparking.

5. The hydrostatic sensing bulb, integral to the mechanical modulating gas valve, calls for heat. The main gas valve is opened and the main burner is lit. The burner modulates between 40% through 100% fire based on the call for heat.

6. If the unit was provided with a time delay relay, the blower starts after 30 to 45 seconds.

7. The unit continues to operate until the hydrostatic sensing bulb is satisfied, at which time the main valve closes 100%, but the pilot remains lit.

8. The unit blower (and pilot) continues to operate until either an exhaust fan interlock contact or a start/stop switch is opened. If the unit was provided with a time delay relay, the blower stops after 30 to 45 seconds.

Electronic Modulating Gas Controls Single Furnace - Model Sizes 75-400

Utilizes an electronic modulating/regulating gas control, combination gas valve, an ignition control, modulating amplifier, and either a modulating room thermostat or modulating duct thermostat with remote temperature set point adjuster. The thermostat controls can modulate the gas flow between 40% through 100% full fire. When the thermostat is satisfied, the amplifier cuts power to the combination gas valve which prevents gas flow to both the main and pilot burners.

When duct sensing is utilized, a room override thermostat can be added. When calling for heat, the room override thermostat provides full fire operation until the space temperature is satisfied. Control is then returned to the duct sensing control. In this situation, either the duct sensor or the room override thermostat can call for heat.

1. The thermostat calls for heat.

3. The pilot valve opens and the spark ignitor sparks in an attempt to light the pilot. (If the unit was not provided with a time delay relay, the blower starts at this time.)

4. Once the pilot is lit, the flame sensor proves the pilot and stops the spark ignitor from sparking.

5. The main gas valve is opened and the main burner is lit to 100% full fire.

6. If the unit was provided with a time delay relay, the blower starts after 30 to 45 seconds.

7. The modulating gas valve can be controlled by either an electronic modulating room or duct thermostat. The thermostat can modulate the firing rate between 40% through 100% full fire. The call for heat is created by a resistance signal (8000 to 12000 ohms) in the thermostat. The amplifier converts this resistance into a DC voltage (0 to 12 volts DC with 0 volts high fire and 12 volts low fire). The output voltage is applied to the modulating gas valve to control the gas flow to the

5-565.116

START-UP PROCEDURE

main burner. As the temperature drops, the voltage drops causing the modulating valve to open further. If the discharge air temperature increases, the voltage increases causing the modulating valve to close allowing less gas flow to the main burner. For further information regarding the operation of the electronic modulating system, consult the literature provided with the unit.

8. The unit continues to operate in this manner until the thermostat is satisfied, at which time both the main and pilot valves close 100%. (If the unit was not provided with a time delay relay, the blower stops at this time.)

9. If the unit was provided with a time delay relay, the blower stops after 30 to 45 seconds.

Electronic Modulating Gas Controls Two & Three Furnaces - Model Sizes 500-960

One Master furnace is provided with up to two Slave furnaces that utilize electronic modulating/regulating gas controls, combination gas valves, ignition controls, one multiple furnace modulating amplifier, and either a modulating room thermostat or modulating duct thermostat with remote temperature adjuster. The thermostat controls can modulate the gas flow of all the furnaces between 40% through 100% full fire. The amplifier sends a signal to all of the gas valves so that they modulate at the same percentage. When the thermostat is satisfied, the amplifier cuts power to the combination gas valves which prevents gas flow to both the main and pilot burners.

The sequence of operation for Electronic Modulating Gas Controls - Two & Three Furnaces is the same as Electronic Modulating Gas Controls - Single Furnace.

Electronic Modulating Gas Controls Building Management Control (0-10 Vdc or 4-20 mA Signal)

Utilizes an electronic modulating/regulating gas control, combination gas valve, an ignition control, modulating signal conditioner, and an inverted (0 Vdc or 4 mA being high fire and 10 Vdc or 20 mA being low fire) 0-10 Vdc or 4-20 mA input signal provided by a Building Management System (BMS).

The signal conditioner can modulate the gas flow between 40% through 100% full fire. When the BMS thermostat (field supplied) is satisfied, the BMS heat contact (field supplied) opens to cut power to the combination gas valve which prevents gas flow to both the main and pilot burners.

1. The BMS thermostat (field supplied) calls for heat and closes

the BMS heat contact (field supplied).

2. The power exhauster relay is energized starting the power

exhauster motor. Once the motor has reached full speed, the differential pressure switch closes. The power exhauster relay pre-purge timer closes after 20 to 40 seconds energizing the gas control circuit.

3. The pilot valve opens and the spark ignitor sparks in an

attempt to light the pilot. (If the unit was not provided with a time delay relay, the blower starts at this time.)

4. Once the pilot is lit, the flame sensor proves the pilot and

stops the spark ignitor from sparking.

5. The main gas valve is opened and the main burner is lit to

100% full fire.

6. If the unit was provided with a time delay relay, the blower

starts after 30 to 45 seconds.

7. The modulating gas valve is controlled by the BMS

thermostat. The thermostat can modulate the firing rate between 40% through 100% full fire by modulating the

input signal between either 0-10 Vdc or 4-20 mA (The signal conditioner can accept a 0-10 Vdc signal when all the dip switches are in the “OFF” position and 4-20 mA signal when all the dip switches are in the “ON” position). The signal conditioner converts the input signal into a DC voltage (0 to 12 volts DC with 0 volts high fire and 12 volts low fire). The output voltage is applied to the modulating gas valve to control the gas flow to the main burner. As the temperature drops, the voltage drops causing the modulating valve to open further. If the discharge air temperature increases, the voltage increases causing the modulating valve to close allowing less gas flow to the main burner. For further information regarding the operation of the electronic modulating system, consult the literature provided with the unit.

8. The unit continues to operate in this manner until the thermostat is satisfied, at which time the BMS heat contact opens resulting in both the main and pilot valves closing 100%. (If the unit was not provided with a time delay relay, the blower stops at this time.)

9. If the unit was provided with a time delay relay, the blower stops after 30 to 45 seconds.

Variable Air Movement Applications

Units may be supplied with variable frequency drives for applications where variable air volume is required. The minimum air flow may be varied between 30 and 100% of the full speed air flow depending on the controls selection of the unit. Due to the extra restrictions of the controller all selections must be performed with 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.

Additionally, when the air mover supplied by others can provide variable air movement (i.e. 2-speed or variable frequency drive units), the allowable minimum CFM of the duct furnace can be 66% of the minimum listed CFM in Table 26.1 if the unit is applied as follows:

1. The unit is provided with 2-stage, mechanical modulation,

or electronic modulating gas controls. (see Model Identification).

2. The unit is provided with a factory installed discharge air

controller.

3. The system does not include a room thermostat.

The factory installed discharge air thermostat will prevent the unit from firing above the allowable 100°F rise when the unit is at or above the minimum CFM by monitoring the discharge air and going to low fire. A room thermostat, because it is located remote from the unit, could cause the unit to over-fire.

5-565.1 17

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Modine Manufacturing DBP, DCP Service Manual

Specifications and Main Features

Frequently Asked Questions

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