Modine Manufacturing MPR Installation And Service Manual

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MCP15-500.7

5H0816400000

March, 2018

INSTALLATION AND SERVICE MANUAL

commercial packaged ventilation system units

model MPR

Model MPR Commercial Packaged Ventilation System Unit (C-Cabinet size shown)

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.

This unit contains R-410A high pressure refrigerant. Hazards exist that could result in personal injury or death. Installation, maintenance, and service must only be performed by an HVAC technician qualified in R-410A refrigerant and using proper tools and equipment. Due to much higher pressure of R-410A refrigerant, DO NOT USE service equipment or tools designed for refrigerants other than R410A.

WARNING

(for units with 24 digit model numbers)

FIRE OR EXPLOSION HAZARD

Failure to follow safety warnings exactly could result in serious injury, death or property damage.

Be sure to read and understand the installation, operation and service instructions in this manual.

Improper installation, adjustment, alteration, service or maintenance can cause serious injury, death or property damage.

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch, do not use any phone in your building.

• Leave the building immediately.

• Immediately call your gas supplier from a phone remote from the building. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency or the gas supplier.

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).

WARNING

THIS MANUAL IS THE PROPERTY OF THE OWNER.

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

1MCP15-500.7

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

de-energized.

11. This unit contains R-410A high pressure refrigerant. Hazards exist that could result in personal injury or death. Installation, maintenance, and service must only be performed by an HVAC technician qualified in R-410A refrigerant and using proper tools and equipment. Due to much higher pressure of R-410A refrigerant, DO NOT USE service equipment or tools designed for refrigerants other than R410A.

12. The power supply wiring for the Energy Recovery Section comes from a single point power connection on the unit. Disconnect power supply at model MPR before making wiring connections to prevent electrical shock and equipment damage.

13. 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 owner's risk.

WARNING

1. Failure to follow proper lifting instructions could result in property damage, serious injury, or death. Lifting should only be done by a qualified rigging company. Use ALL lifting points. Test lift to ensure proper balance and rigging. Never lift in high winds.

2. Disconnect power supply before making wiring connections or working on this equipment. Follow all applicable safety procedures to prevent accidental power up. Failure to do so can result in injury or death from electrical shock or moving parts and may cause equipment damage.

3. For units equipped for dual power supply sources, both sources of power must be disconnected to prevent electrical shock and equipment damage.

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

5. Any original factory wiring that requires replacement must be replaced with wiring material having a temperature rating of at least 105°C.

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

7. 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.

8. Gas pressure to appliance controls must never exceed 14" W.C. (1/2 psi).

9. To reduce the opportunity for condensation, the minimum sea level gas input to the appliance, as indicated on the serial plate, must not be less than 5% below the rated input, or 5% below the minimum rated input of dual rated units.

10. When the dead front disconnect switch(es) (for main unit and/or powered convenience outlet option) is in the “OFF” position, supply power remains energized at the line (supply) side of the dead front disconnect switch(es). The switch body is located inside of another junction box to protect against contact with the live wiring. The junction box must not be disassembled unless the main power supply from the building to the unit is

CAUtIoN

1. Appliances are designed for outdoor installation only. DO NOT LOCATE APPLIANCES INDOORS.

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

3. Purging of air from gas lines should be performed as described in ANSI Z223.1 - latest edition “National Fuel Gas Code”, or in Canada in CAN/CGA-B149 codes.

4. Units not approved for use in potable water systems.

5. Do not operate the unit with steam. The coil is not designed for steam condensate removal which can damage the unit.

6. Hot water supplied to the hot water heating option must not exceed 180°F temperature or 75 PSIG pressure.

7. When servicing the unit, some components may be hot enough to cause pain or injury. Allow time for cooling of hot components before servicing.

8. Do not overcharge the refrigeration system. This can lead to elevated compressor discharge pressure and possibly flooding the compressor with liquid. This may result in compressor failure not covered under warranty.

9. Do not reuse any mechanical or electrical component which has been wet. Such components must be replaced.

IMPoRtANt

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

2. A properly designed drain with trap must be installed immediately after the unit evaporator coil condensate drain pan connection. Failure to do so will result in condensate that cannot properly drain from the unit,

2 MCP15-500.7

TABLE OF CONTENTS / SI (METRIC) CONVERSION FACTORS / UNIT LOCATION

TABLE OF CONTENTS

IMPoRtANt

eventually causing the drain pan to fill. To prevent damage to the building or unit, a drain pan float switch is included as standard and will disable the unit if the maximum condensate level is reached.

3. 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%.

4. To prevent premature heat exchanger failure, check to be sure the blower has been set to deliver the proper airflow for the application. Refer to page 17 for Blower Adjustments.

5. Start-up and adjustment procedures must be performed by a qualified service agency.

6. All scroll compressors requires the correct supply power phase rotation. Phase reversal may result in compressor failure not covered under warranty. Refer to the Start-Up Procedure section.

7. All refrigeration checks must be made by a qualified R-410A refrigeration technician.

8. Do not release refrigerant to the atmosphere. When adding or removing refrigerant, all national, state/ province, and local laws must be followed.

9. On units with the electric preheat option, to prevent premature heat exchanger failure, check to be sure the blower has been set to deliver the proper airflow for the application. Refer to page 17 for Blower Adjustments.

10. The exhaust fan is not designed for high temperature or smoke control exhaust applications. Exhaust air temperature must not exceed 104°F. Operating the exhaust fan above 104°F will result in failure of the exhaust fan.

SI (METRIC) CONVERSION FACTORS

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 m

Special Design Requests

Modine Manufacturing Company will sometimes build units with special features as requested by the customer. This manual only covers standard features and does not include any changes made for special feature requests by the customer. Units built with special features are noted with an SPO (Special Product Order) Number on the Serial Plate

To Convert Multiply By To Obtain

CFH 1.699 m

0.0374 mJ/m

Btu/ft pound 0.453 kg Btu/hr 0.000293 kW gallons 3.785 liters psig 27.7 "W.C.

/min

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

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

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

Special Design Requests .................................................... 3

Storage Prior to Installation ................................................. 3

Unit Location ....................................................................... 4

Installation ......................................................................4-15

Combustible Material and Service Clearances .........4-5

Roof Curb Installation ................................................... 4

General Rigging Instructions/Unit Installation ...........6-7

Duct & Condensate Drain Installation .......................... 8

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

Gas Connections ........................................................ 10

Vent Terminals and Combustion Air Hoods ................ 11

Gas Heating Option Condensate Drains & Traps ......14

Hot Water Piping Connections ...................................15

Start-Up Procedure ......................................................16-29

General. ...................................................................... 16

Blower Adjustments .................................................... 17

Airflow Proving Switch and Dirty Filter Switch............ 19

Variable Air Movement Applications ........................... 19

Checking Refrigerant Charge ..................................... 20

Gas Heating Option .................................................... 21

Energy Recovery Option (B-Cabinet units only) ........ 28

Unit Features/Options Location Drawings .................... 30-35

Dimensions/Weights .................................................... 36-44

B-Cabinet Size Unit without Energy Recovery. .......... 36

B-Cabinet Size Unit with Energy Recovery. ............... 38

C-Cabinet Size Unit .................................................... 40

D-Cabinet Size Unit .................................................... 42

Base Model Weights ...................................................44

Option and Accessory Pressure Drop Tables ..............45-47

Maintenance .................................................................48-50

Service & Troubleshooting ...........................................51-55

Serial Plates ...................................................................... 56

Model Nomenclature ....................................................57-59

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

Storage Prior to Installation

If the unit is stored outside prior to installation, the unit should be covered.

3MCP15-500.7

*Available as a factory supplied, field installed accessory.

Curb Gasketing*

2 x 4 Wooden Nailing Strip*

Curb*

2” Acoustic

Fiberglass

(By Others)

Roof Deck

6” Inverted Channel

(Both Sides)

(By Others)

Roof

Trusses

Cant Strip

(By Others)

Roof Insulation

(By Others)

Counterflashing

(By Others)

Roofing Material

(By Others)

Insulation

(By Others)

UNIT LOCATION

dANGeR

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

CAUtIoN

Appliances are designed for outdoor installation only. DO NOT LOCATE APPLIANCES INDOORS.

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 packaged rooftop unit, Model MPR, consider general space and cooling/heating requirements and availability of gas and electrical supply.

2. Be sure the structural support at the unit location site is adequate to support the weight of the unit and any other required support structure. For proper operation the unit must be installed in a level horizontal position.

3. All mechanical equipment generates some sound and vibration that may require attenuation. Locating the equipment away from the critical area is desirable within ducting limitations. Frequently, units can be located above utility areas, corridors, restrooms, and other non-critical areas. Generally, a unit should be located within 15 feet of a primary support beam. Smaller deflections mean lesser vibration and noise transmission. For critical applications, please consult with an acoustical attenuation expert.

4. Do not install units in locations where the flue products (if equipped with a gas fired heating option) 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. For units with the gas heating option, be sure clearances are maintained to the combustion air inlet louvers and power exhauster discharge cover. Units are designed for installation on non-combustible surfaces with the minimum clearances shown in Figure 5.1.

6. On units that have fresh air openings, a method must be provided to prevent water and debris from entering the unit such as a rainhood, which is available as an accessory from Modine. Where possible, install the unit so that the inlet is not facing into the prevailing wind to prevent water entrainment.

7. The exhaust fan is not designed for high temperature or smoke control exhaust applications. Exhaust air temperature must not exceed 104°F. Operating the exhaust fan above 104°F will result in failure of the exhaust fan.

Roof Curb Installation

An optional roof curb is available to simplify site preparation and raise the unit above roof water and snow level for drainage. It can be installed in advance of the unit. The curb is shipped knocked down with separate instructions (Literature #MCP15-590) for its assembly, flashing, and sealing with the roof. The following are some general guidelines for roof curb installed units:

1. The roof structure must be adequately designed to support the live weight load of the unit and any other required support structure. The roof curb should be supported at points no greater than five feet apart. Additional truss reinforcement should be provided, if necessary.

2. Roof curbs supplied by Modine are fabricated from 10 gauge galvanized steel and supplied knocked down for assembly on the job site. The curb consists of two side pieces, two end pieces, gasketing, four joiner angles, four 2x4 inch wood nailing strips, nuts, bolts, and washers.

3. Outside dimensions must be held when installing curb. Top surface must be level and straight to ensure weathertightness. If roof is pitched it will be necessary to construct a sub-base on which to install the curb. All corners must be square.

4. All dimensions are +1/8 inch.

5. When a roof curb is used in conjunction with factory supplied discharge and/or return air connectors, the ductwork can be fastened to the connectors prior to the unit installation. The connectors will accept 90° flanged ductwork (see Figure 7.1).

6. Final electric and gas connections must be made after unit is installed to allow for tolerance in setting of unit on curb. For electrical power supply allow approximately eight feet of wire, plus provisions for weathertight flexible conduit for connection to unit, as required by local codes.

7. Maintain a 12-inch minimum height from top of roof deck to top of curb.

8. Caulk butt joints after curb is assembled and installed on roof structural members and roof flashing is added.

9. For improved sound attentuation, line the roof deck within the curb area with 2" acoustic fiberglass.

Figure 4.1 - Typical Curb Details

4 MCP15-500.7

CLEARANCES / ROOF CURB INSTALLATION

Figure 5.1 - Combustible Material & Service Clearances

B- AND C-CABINET UNITSWITHOUT ENERGY RECOVERY D-CABINET UNITSWITHOUT ENERGY RECOVERY

FIELD INSTALLED

SEE NOTE 2

36.0

SEE NOTE 2

36.0

ACCESSORY

RAINHOOD

48.0

SEE NOTE 3

36.0

SEE NOTE 4

FOR UNITS WITH GAS HEAT,

MAINTAIN 48" MINIMUM

FROM VENT TERMINATIONS

48.0

SEE NOTE 1

B- AND C-CABINET UNITSWITH ENERGY RECOVERY

FIELD INSTALLED

36.00

36.0

SEE NOTE 4

FOR UNITS WITH GAS HEAT,

MAINTAIN 48" MINIMUM

FROM VENT TERMINATIONS

48.0

SEE NOTE 1

ACCESSORY

RAINHOOD

48.0

SEE NOTE 3

SEE NOTE 4

48.00

SEE NOTE 3

48.00

SEE NOTE 1

FOR UNITS WITH GAS HEAT,

MAINTAIN 48" MINIMUM

FROM VENT TERMINATIONS

j The minimum recommended clearance for service is 48". For service

clearances less than shown, applicable local code requirements must be followed. If the ability for future condenser coil replacement is desired, the minimum clearance must be:

• 102" for B-Cabinet sized units

• 112" for C-Cabinet sized units

• 100” for D-Cabinet sized units

See Note k for alternate coil replacement direction.

k The minimum recommended clearance for service is 36". For service

clearances less than shown, applicable local code requirements must be followed. If the ability for future condenser coil replacement is desired, the minimum clearance must be (from the end panel of the condenser, not the end of the inlet hood):

• 102” for B-Cabinet sized units

• 112” for C-Cabinet sized units

• 100” for D-Cabinet sized units

See Note j for alternate coil replacement direction.

l The minimum recommended clearance for service is 48". For service

clearances less than shown, applicable local code requirements must be followed. If the ability for future evaporator coil, hot gas reheat coil, and/or energy wheel replacement is desired, the minimum clearance must be:

• 55" for B-Cabinet sized units

• 64" for C-Cabinet sized units

• 100” for D-Cabint sized units

m Additional Required Clearances:

-Clearance above unit must be unobstructed.

-Clearance to combustibles below the unit is 6" minimum.

48.00

SEE NOTE 3

5MCP15-500.7

GENERAL RIGGING INSTRUCTIONS / UNIT INSTALLATION

SPREADER BAR

AND LIFTING

CHAINS/STRAPS

BY INSTALLER

ADJUST CHAIN/STRAP

LENGTH SO UNIT IS

LEVEL WHEN LIFTED

RAINHOOD

ACCESSORY

(FIELD INSTALL)

(4) 1.50" LIFTING EYE BOLTS

(EACH CORNER OF UNIT)

SPREADER BAR

AND LIFTING

CHAINS/STRAPS

BY INSTALLER

ENSURE THE LIFTING

CHAINS/STRAPS CLEAR

THE CASING ON EACH SIDE

(6) 1.0" LIFTING LUGS

MIN. 65

SPREADER BAR AND LIFTING CHAINS/STRAPS BY INSTALLER

ADJUST CHAIN/STRAP

LENGTH SO UNIT IS

LEVEL WHEN LIFTED

RAINHOOD ACCESSORY (FIELD INSTALL)

ENSURE THE LIFTING CHAINS/STRAPS CLEAR THE CASING ON EACH SIDE

(4) 1.0" LIFTING LUGS

LIFTING LUG KIT IS SHIPPED LOOSE IN SUPPLY FAN SECTION. INSTALL (4) LIFTING LUGS PER MCP15-505 USING (4) GRADE 5 BOLTS PER LUG, TORQUED TO 75 ft-lb.

B-CABINET UNIT - NO ENERGY RECOVERY C-CABINET UNIT - ALL

D-CABINET UNIT - ALL

B-CABINET UNIT - WITH ENERGY RECOVERY

General Rigging Instructions

WARNING

Failure to follow proper lifting instructions could result in property damage, serious injury, or death. Lifting should only be done by a qualified rigging company. Use ALL lifting points. Test lift to ensure proper balance and rigging. Never lift in high winds.

Lifting Lug Installation

Before attaching lifting equipment, verify location of lifting lugs or eyes. B- and C-Cabinet sized units have the lifting lugs or eyes factory installed as follows:

• B-Cabinet sized units without Energy Recovery include (4) eye bolts at each corner on the top of the unit.

• B-Cabinet sized units with Energy Recovery include (6) lifting lugs on the base, one at each corner and one on each length-wise side of the unit between the corners.

• C-Cabinet sized units include (4) eye bolts at each corner on the top of the unit. For units that include the shipped separate Energy Recovery Module (model ERM) option, refer to the latest revision of the Installation and Service Manual, #MCP15-520, that shipped with the ERM for separate rigging instructions.

• D-Cabinet sized units must have the lifting lugs installed in the unit base assembly prior to rigging as follows:

1. Locate the lifting lug kit box, kit # 66802, located in

the supply fan compartment.

2. Install the kit per the “Installation Instructions, Lifting

Lugs D-Cabinet”, #MCP15-505, included with the kit.

3. After installing the kit, verify that all (4) lugs are

installed following the instructions in Step 2. Verify that each lug is secured using (4) Grade 5 bolts provided with the kit. Each bolt must be torqued to 75 ft-lb.

Unit Rigging and Lifting

Rigging and lifting of the units should only be done by a qualified rigging company. With the lifting lugs or eyes identified and installed, the units can be lifted by crane or helicopter.

1. Follow site preparation instructions for the roof curb or equipment stand before installation.

2. Check the Serial Plate(s) of unit with plans to be sure unit is properly located. Although units may look outwardly similar, their function, capacities, options, and accessories will often vary.

3. Check unit dimensions of both the unit base and the curb or stand on which the unit will be installed.

4. If the unit will be installed on a roof curb:

a. Thoroughly clean and dry the top of the curb surface.

b. Lay a bead of weather resistant caulking on top

perimeter of roof curb as illustrated in Figure 7.1. Note: If roof curb is supplied by Modine, full perimeter gasket material is supplied and caulking is not necessary.

5. When lifting the equipment, connect sturdy steel cables, chains, or straps with eye loops as illustrated in Figure 6.1. For stability in lifting and lowering and to prevent damage to the unit, include a spreader bar as illustrated in Figure

6.1. Avoid twisting or uneven lifting of the unit. The cable length from the lifting point on the unit to the spreader bar should always be longer than the distance between the outer lifting points.

6. Test lift the unit to check for proper rigging balance before hoisting to the desired installation location.

7. Once lifted to the installation location, orient the hoisted unit to match the ductwork locations and set evenly on the curb or stand.

8. Following the instructions in this manual, make final unit connections to the electric power supply and remote control circuits. Connect the gas lines to the unit heating compartment. Seal all utility line clearance holes on the unit after connections are completed so they are watertight.

Figure 6.1 - Typical Rigging for Model MPR

6 MCP15-500.7

DUCT INSTALLATION AND UTILITY CONNECTIONS

RETURN AIR CONNECTOR

DISCHARGE AIR CONNECTOR

90° FLANGED DUCTWORK

(By Installer)

UNIT BASE (Shown without unit for clarity)

ROOF CURB

BEFORE UNIT INSTALLATION CAULK ALL MATING SURFACES ➀ (Caulk by installer)

➀ If roof curb is supplied by Modine, full perimeter gasket material is supplied and caulking is not necessary.

Duct Installation

1. The unit is designed to accept 90° flanged ductwork on both the supply and return air openings. Refer to the roof curb or the unit base dimensional drawings to determine the location of the openings.

2. Acoustic duct liners are recommended on all internal supply and return air ducts.

3. When ductwork is installed prior to unit arrival, flexible connections should be included to make connections easier and to simplify possible future service.

4. When a roof curb is used in conjunction with factory supplied discharge and/or return air connectors, the ductwork can be fastened to the connectors prior to the unit installation. The connectors will accept 90° flanged ductwork (see Figure 7.1).

Figure 7.1 - Discharge and/or Return Air Connectors

5. To assure proper air flow from the unit, follow these duct design recommendations:

a. Be sure ducts are properly sized and installed. b. As a general rule, all discharge ducts should have a

A = Cross Sectional Area of Rectangular Duct P = Perimeter of Rectangular Duct D = Diameter of Round Cut

c. Wherever turns in the duct work are made, include

d. Supply air ducts in a “T” configuration should be

avoided to prevent air temperature stratification. If this configuration must be used, provide appropriate mixing devices and/or the necessary straight duct length before the “T” to provide uniformly mixed air temperature delivery to both supply air duct trunks.

Utility Connections

Utility and control connections can be made to the unit from the bottom or through the fixed side panels. Holes can be field drilled in fixed side panels to accommodate utility connections as shown on the unit dimensional drawings and the utility entrance location area label located on the unit. All gas and electrical connections to the unit must be weatherized so they are watertight.

straight run of at least three (3) hydraulic duct diameters before making turns in the ductwork.

Hydraulic Duct Diameter for Rectangular Ducts = 4A/P Hydraulic Duct Diameter for Circular Ducts = D where:

turning vanes.

7MCP15-500.7

CONDENSATE DRAIN INSTALLATION

Evap Condensate Drain Trap Installation

IMPoRtANt

A properly designed drain with trap must be installed immediately after the unit evaporator coil condensate drain pan connection. Failure to do so will result in condensate that cannot properly drain from the unit, eventually causing the drain pan to fill. To prevent damage to the building or unit, a drain pan float switch is included as standard and will disable the unit if the maximum condensate level is reached.

All units require a drain system with a condensate trap to be

connected to the condensate drain pan connection which is accessible from the exterior of the unit casing. Failure to install a condensate drain trap may result in condensate overflowing from the drain pan, causing damage to the unit and building. See Figure 30.1 or 31.1 for location. The drain system is to be installed as follows:

1. The condensate drain pan includes a 1-1/4" female NPT stainless steel connection accessible from the exterior of the unit casing. Do not reduce the drain diameter. A drain pan connection kit is shipped loose for field installation to allow connection exterior to the casing. Refer to Figure 8.1 for assembly details.

Figure 8.1 - Condensate Drain Pan Connection Kit

Threaded Connection on Evap Coil Drain Pan

Threaded Nipple

Note: All kit components shown are factory supplied for field installation.

Rubber Washer

Corrosion Resistant Steel Washer

Corrosion Resistant Steel Locknut

Figure 8.2 - Condensate Drain Trap Installation

Note: All piping components shown are supplied by others.

 •Thetrapdepthmustbe½xthetrapheight.Forexample,if

the trap height is the minimum 6”, the trap depth must be 3” (see Figure 8.2).

 •Formaintenance,itisrecommendedtohaveacapped

cleanout at the top of the trap as shown in Figure 8.2.

5. After the exit from the trap, the drain must be pitched down from the unit connection at least 1” for every 10 feet of horizontal run to promote proper drainage. If the local installation code allows, the drain can be run to a waste water system.

6. If the trap may experience below freezing temperatures during non-cooling periods, heating wraps must be used to avoid water from freezing in and damaging the trap and drain system.

7. The trap must be primed before the unit is put into operation and properly maintained on a regular schedule. Refer to the Start-Up Procedure section and the Maintenance section for additional guidance.

TRAP HEIGHT

(6" MINIMUM)

CAPPED CLEANOUT

1/2 x TRAP

HEIGHT

2. The drain line should include provisions for disconnecting the line at or near the unit for maintenance/servicing of the unit. The drain line must not interfere with access panels, which are removable for maintenance/service.

3. The drain line must include a trap immediately after the unit, as shown in Figure 8.2. Failure to do so will result in condensate that cannot properly drain from the unit, eventually causing the drain pan to fill and overflow. If the drain pan overflows, significant damage can occur to the unit and/or building on which the unit is installed. A drain pan float switch is included as standard and will disable the unit if the maximum condensate level is reached.

4. The design of the trap is critical to ensure proper drainage. If the trap is not constructed properly with the dimensions as outlined in the following instructions, air could be drawn through the drain pipe and into the system or could back up into the drain pan.

 •Thedrainislocatedonthesuctionsideofthemain

supply air fan, resulting in a negative pressure relative to outside the unit cabinet. The trap height must be at least 6” to account for maximum negative pressure, including allowance for dirty filters. Note that the trap height is the difference in height from the drain connection of the unit to the leaving side of the trap. Refer to Figure 8.2.

8 MCP15-500.7

ELECTRICAL CONNECTIONS

Electrical Connections

WARNING

1. Disconnect power supply before making wiring connections or working on this equipment. Follow all applicable safety procedures to prevent accidental power up. Failure to do so can result in injury or death from electrical shock or moving parts and may cause equipment damage.

2. For units equipped for dual power supply sources, both sources of power must be disconnected to prevent electrical shock and equipment damage.

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

4. Any original factory wiring that requires replacement must be replaced with wiring material having a temperature rating of at least 105°C.

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

roltage.

CAUtIoN

Ensure that the supply voltage to the appliance, as indicated on the serial plate, is not 5% less than the 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 permanently affixed to the inside of the door of the controls compartment and the other as a loose copy with the literature packet that ships with the unit. Refer to this diagram for all wiring connections.

3. Control wiring consists of both 24V analog control wiring and low current digital control signal wiring. To avoid signal interference, the two types should be run in separate conduits. If run in the same conduit, the digital signal wiring should be shielded at one end of the wiring run. Wiring should be twisted, stranded, and shielded communication wire.

4. The wire gauge must be sized according to the National Electric Code or CSA code based on amp draw and length of run. Refer to Table 9.1 for maximum wire lengths and the number of wires that can be wired to each low voltage terminal block based on the wire gauge being used.

Table 9.1 - 24V and Digital Control Wire Lengths

Minimum

Recommended

Wire Gauge

22 n/a 120

20 n/a 200

18 75 300

16 125 500

14 175 n/a

24V Control Wiring Digital Control Wiring

Maximum Distance from

Control Device to Unit

5. For field wiring to the factory terminal strip, the terminal strip connections are designed to clamp down on the wires. To properly connect the wires to the terminal strip:

• Push a small flat-head screwdriver into the square hole on the terminal. Press firmly until the screwdriver hits the back stop and opens the terminal (see Figure 9.1).

• Remove approximately 3/8” of insulation from the end of the wire and push the stripped wire into the oval hole in the terminal.

• Remove the screwdriver. Pull on the wire to make sure that it is securely clamped in the terminal.

• Make sure that the terminal clamp is in contact with bare wire (insulation removed).

Figure 9.1 - Terminal Strip Wiring

Oval Holes

for Wiring

(two rows each)

Square Holes

for Wire Release

(two rows each)

Terminal

Numbers

Test Probe

Points

6. Depending on the configuration of the unit controls, there may be sensors that are field installed. Review the unit ordered to verify that the sensors supplied match the configuration of the unit. The following are sensors that may be included for field installation:

• Supply Air Temperature Sensor

This sensor is required on all units and should be mounted in the supply air ductwork downstream of the unit. The sensor should be located at least 5 feet, but not more than 20 feet downstream from the unit discharge.

• Space Temperature/Humidity Sensor

This sensor is required on all units that have space temperature/humidity reset control. The sensor is to be wall-mounted in the space at a height of approximately 5 feet from the floor.

• Building Pressure Sensor This sensor is required on all units that have space pressure control, either through modulating dampers or variable frequency drive control on the supply air blower. The sensor is to be mounted inside a control panel in the space and includes two pressure taps. One pressure tap is for outside atmospheric pressure reference, the other is for sampling the space pressure.

• Duct Pressure Sensor

This sensor is required on all units that have duct pressure control through variable frequency drive control on the supply air blower. The sensor is to be mounted with the sensing probe inserted into the supply duct. The atmospheric pressure sampling tap is left open.

9MCP15-500.7

ELECTRICAL CONNECTIONS / GAS CONNECTIONS

• Space CO2 Sensor

This sensor is required on all units that have demand based ventilation control. The sensor is to be mounted in the space at a height of approximately 5 feet from the floor.

• Duct Mounted Smoke Detector

When ordered as a field installed accessory, the detector

should be mounted in the supply air or return air ductwork.

For further instructions on the above sensor(s), refer to the installation instructions that shipped with the sensor(s).

7. If the unit is a C-Cabinet sized unit with a Modine supplied Energy Recovery Module, Model ERM, the wiring connection between the MPR unit and the ERM unit must be made by extending the loose end of the wire drop located in the MPR unit outside air damper section, through the transition duct between units, and connected to the ERM control panel. Refer to the Installation & Service Manual that shipped with the ERM (Literature #MCP15-

520) for additional instructions. If the unit is a B-Cabinet sized unit with integral Energy Recovery, the unit is already factory wired to the Energy Recovery section.

8. The power supply to the unit must be protected with a fused or circuit breaker disconnect switch. Refer to the Figures on pages 32 through 35 for the location of the factory installed dead front disconnect option, if provided. Field installed disconnect switches should be mounted where required by the National Electric Code. Refer to the Model Serial plate for MCA and MOP values for the unit.

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

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

a. Supply power (120, 208, 240, 480, or 600 volts). b. Thermostats, building pressure sensors, or any other

accessory control devices that may be supplied (24 volts).

11. All outdoor electrical connections must be weatherized to prevent moisture from entering the electrical compartment.

12. Electrical connections are made in the controls cabinet and can be run through the bottom or side of the unit. Refer to the unit and base dimensional drawings for locations of wiring entrance. Refer to the wiring diagram for the terminal location of all low voltage wiring.

REVIEW BEFORE PROCEEDING

THIS SECTION APPLIES TO UNITS WITH

(MODEL DIGIT 17=2 OR 3).

IF THE UNIT DOES NOT HAVE GAS HEAT,

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 gas input to the appliance, as indicated on the serial plate, must not be less than 5% below the rated input, or 5% below the minimum rated input of dual rated units.

CAUtIoN

Purging of air from gas supply line should be performed as described in ANSI Z223.1 - latest edition “National Fuel Gas Code”, or in Canada in CAN/CGA-B149 codes.

IMPoRtANt

To prevent premature 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 11.1 to determine the cubic feet per hour (cfh) for the size of unit to be installed. Using this cfh value and the length of pipe necessary, determine the pipe diameter from Table 11.2. Where several units are served by the same main, the total capacity, cfh and length of main must be considered. While the gas connection(s) on the unit may be smaller than 1", do not use pipe sizes smaller than 1" leading up to the unit. At the unit, reduce the pipe size down to the appropriate size (refer to Table 11.1 for connection sizes). Table 11.2 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 should not drop below 6.0" W.C. when the unit is operating. 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.

OPTIONAL GAS HEAT

SKIP TO PAGE 15.

roltage.

10 MCP15-500.7

GAS

GAS CONNECTIONS

Furnace Size

(Btu/hr)

Gas Consumption

(CFH)

Gas

Connection

Table 11.1 - Natural Gas Heating Gas Consumption

Digit 6 Digit 18

F 150,000 143 1/2"

G 200,000 190 3/4"

H 250,000 238 3/4"

J 300,000 286 3/4"

K 400,000 381 3/4"

R 175,000 167 1/2"

S 225,000 214 3/4"

T 310,000 295 3/4"

J 300,000 286 3/4"

K 400,000 381 1"

C 

L 500,000 476 1"

L 600,000 571 1"

U 350,000 333 1"

V 450,000 429 1"

K 400,000 381 1.5" x 2

L 500,000 476 1.5" x 2

M 600,000 571 1.5" x 2

Q 800,000 762 1.5" x 2

D 

1 900,000 857 1.5" x 2

2 1,000,000 952 1.5" x 2

3 1,200,000 1143 1.5" x 2

4 1,400,000 1333 1.5" x 2

5 1,600,000 1524 1.5" x 2

j Natural gas consumption based on a heating value of 1050 Btu/cu. ft. k C-Cabinet units consist of two furnaces that together total the value shown in

Table 11.1.

l D-Cabinet units consist of two furnaces that together total the value shown

in Table 11.1 for sizes up to 800,000 Btu/hr. For sizes over 800,000 Btu/hr, the unit consists of four furnaces that together total the value shown in Table

11.1.



3. The gas piping to the unit can enter the unit from the side of the unit (refer to the unit dimensions) or from below (refer to the base dimensions). A drill locator sticker and dimple is located on the side of the unit to indicate the safe area for drilling the hole for side gas pipe entry on B- and C-Cabinet sized units. D-Cabinet sized units include a holes with grommets for side pipe entry. 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

11.1). Verify the manual shut-off valve is gas tight on an annual basis.

NOTE: For bottom piped units, some local codes may require

a manual shutoff valve external to the unit casing. In this case, the gas piping must exit the unit through the side, followed by the manual shut-off valve, piped back into the unit side, and lead to an additional union and manual shut-off valve.

4. Provide a sediment trap before each unit in the line where low spots cannot be avoided (see Figure 11.1).

5. When Pressure/Leak testing pressures above 14" W.C. (1/2 psi), close the field installed shut-off valve, disconnect the appliance and its combination gas control from the gas supply line, and plug the supply line before testing. When testing pressures 14" W.C. (1/2 psi) or below, close the manual shut-off valve on the appliance before testing.

Figure 11.1 - Recommended Sediment Trap/Manual

Shut-off Valve Installation

GAS

SUPPLY LINE

MANUAL GAS 

SHUT-OFF VALVE

GROUND JOINT

UNION WITH BRASS SEAT

Table 11.2 - Gas Pipe Capacities (Cu. Ft. per Hour) m

Pipe

Length

(feet)

1" 1-1/4" 1-1/2" 2"

10 520 1050 1600 3050 20 350 730 1100 2100 30 285 590 890 1650

40 245 500 760 1450 50 215 440 670 1270 60 195 400 610 1150 70 180 370 560 1050 80 170 350 530 990

90 160 320 490 930 100 150 305 460 870 125 130 275 410 780 150 120 250 380 710

m Gas pipe capacities based on gas pressure up to 14" W.C. through Schedule

40 pipe with a pressure drop of 0.3" W.C. for Natural gas with a specific gravity of 0.60.

Gas Pipe Diameter

TO GAS

CONTROLS

MIN.

PLUGGED

1/8" NPT TEST

GAUGE CONNECTION

Side Gas Connection

SEDIMENT

TRAP

CONTROLS

PLUGGED 1/8"

NPT TEST GAUGE

CONNECTION

Through hole

in bottom of unit.

(caulk hole to prevent

GROUND

JOINT UNION

W/ BRASS

SEAT

water leakage.)

MANUAL GAS

SEDIMENT

TRAP

SHUT-OFF VALVE

GAS

SUPPLY LINE

Bottom Gas Connection

j Valve is in the “OFF” position when handle is perpendicular to pipe.

MIN.

11MCP15-500.7

GAS HEATING OPTION VENT TERMINALS AND COMBUSTION AIR HOODS

Vent

Terminals

Combustion

Air Hoods

Type

Field Installe d Qty

(Btu/hr)

Vent Terminals and Combustion Air Hoods

1. Do not operate the units without the factory supplied (shipped loose) power exhauster vent system/vent termination(s) or combustion air hoods if applicable. Refer to Table 12.1 to determine how many terminals and hoods are required based on the model MPR nomenclature.

2. Do not modify or obstruct the combustion air inlet louvers or the power exhauster discharge cover terminations.

3. Do not add any vents other than those supplied by the manufacturer. For units that require vent extension kits, refer to Literature #MCP15-574, “Installation Instructions, Extended Vent Kit, Model MPR Gas Heat”.

Table 12.1 - Power Exhauster Vent Terminal and

Combustion Air Hood Quantity

Digit

Furnace Size

Digit

F 150,000

G 200,000

H 250,000

J 300,000

K 400,000

R 175,000

S 225,000

T 310,000

J 300,000

K 400,000

L 500,000

L 600,000

U 350,000

V 450,000

K 400,000

L 500,000

M 600,000

Q 800,000

1 900,000

2 1,000,000

3 1,200,000

4 1,400,000

5 1,600,000

Furnace

Non-

Condensing

Non-

Condensing

Non-

Condensing

Non-

Condensing

1 n/a

2 2

4 2

n/a

Non-Condensing Furnaces (B, C, or D-Cabinet)

For Non-Condensing furnace types, as determined from Table

12.1, refer to Figure 12.1 for vent termination installation details, otherwise skip to the section titled Condensing Furnaces. For units that require vent extension kits, refer to Literature #MCP15-574, “Installation Instructions, Extended Vent Kit, Model MPR Gas Heat”.

Figure 12.1 - Power Exhauster Vent Terminal for

Non-Condensing Gas Furnace Option

Note: Caulk mating surfaces before

Gas Furnace

Vent Outlet

k C-Cabinet sized unit shown with two vent terminals. B-Cabinet sized units

have only one and D-Cabinet with have either one on each side of the cabinet (two total) or two on each side of the cabinet (four total).

attaching to the unit

(6) Screws for Fastening Gas Furnace Vent Outlet Cover (supplied with kit)

For D-Cabinet units, the furnace doors must have the combustion air hoods field installed as shown in Figure 12.2,

using the screws included with the kit. Once complete, proceed to the “Start-Up” section.

Figure 12.2 - Combustion Air Hood Installation

(D-Cabinet only)

For specific instructions on each configuration in Table 12.1, refer to the appropriate section from the following sections titled:

• Non-Condensing Furnaces (B, C, or D-Cabinet), or

• Condensing Furnace (B-Cabinet), or

• Condensing Furnace (C-Cabinet)

12 MCP15-500.7

Note: Caulk mating surfaces before attaching to the unit.

Also shown are the vent terminals for reference.

(refer to

Instructions

Step 1)

(refer to Instructions Step 3)(refer to Instructions Step 2)

(refer to Instructions Step 1) (refer to Instructions Step 2)

GAS HEATING OPTION VENT TERMINALS AND COMBUSTION AIR HOODS

Condensing Furnaces (B-Cabinet)

For B-Cabinet units with Condensing furnace types, as determined from Table 12.1 on page 12, refer to Figures 13.1 and 13.2 for vent termination installation details. The installation steps are as follows:

Step 1: Insert short vent pipe length into the vent pipe

reducer. Insert that assembly into the rubber coupling on the power exhauster outlet. Tighten the clamp on the flexible coupling to secure the vent pipe.

Step 2: Insert the outer vent pipe with termination elbow

through the enclosure wall grommet and into the vent pipe section installed in Step 1.

Once complete, proceed to the “Condensate Drain and Trap Installation” section.

Condensing Furnaces (C-Cabinet)

Figure 13.1 - Power Exhauster Vent Terminal for

Condensing Gas Furnace Option

For C-Cabinet units with Condensing furnace types, as determined from Table 12.1 on page 12, refer to Figures 13.3 and 13.4 for vent termination installation details. The installation steps are as follows:

Step 1: Insert small diameter outside vent pipe termination

through enclosure wall grommet and into the flexible rubber coupling on the right side power exhaust outlet. Tighten the clamp on the flexible coupling to secure the vent pipe.

Step 2: Insert large diameter inner vent pipe assembly into

the flexible rubber coupling on the left side power exhaust outlet. Tighten the clamp on the flexible coupling to secure the vent pipe.

Step 3: Insert large diameter outside vent pipe termination

through enclosure wall grommet and into the interlocking joint of the inner vent pipe assembly from Step 2.

Step 4: Verify that the bird screens are inserted in the outlet

elbow.

Once complete, proceed to the “Condensate Drain and Trap Installation” section.

Figure 13.3 - Power Exhauster Vent Terminal for

Condensing Gas Furnace Option

Figure 13.2 - Orientation of Installed Vent Terminal for Condensing Gas Furnace Option (B-Cabinet)

Discharge Elbow must be

oriented to exhaust

straight down.

Figure 13.4 - Orientation of Installed Vent Terminal for Condensing Gas Furnace Option (C-Cabinet)

Discharge Elbows must

be oriented to exhaust

straight down.

13MCP15-500.7

3/4" Threaded Elbow on Heat Exchanger Drain Assembly (included with kit)

3/4" Male Threaded PVC Adapter (included with kit)

3/4" PVC Pipe (by others) with Sufficient Length to Reach the Heat Exchanger Drain Assembly from the Inside of the Building

3/4" Unions (by others) Recommended for Ease of Future Service

PVC "EZ-Trap" (included with kit) for Proper Drain Trapping (a 3/4" to 1" bushing by others may be required)

Note: The trap must be located in a heated space or protected to avoid freezing.

Vacuum Breaker and Drain Piping Components (by others)

To Building Drain System

From Heat

GAS HEATING OPTION CONDENSATE DRAIN AND TRAP INSTALLATION

Condensate Drain and Trap Installation (Condensing Furnace Type Only)

For Condensing furnace types, as determined from Table 12.1 on page 12, during heating operation, condensate is produced in the furnace sections. The installation requires condensate drain systems from each furnace section, as shown in Figures

14.1 and 14.2 and described below. Condensate trap kits are

provided with the unit.

1. For proper heating system performance, the condensate

drain system must include a trap for each furnace. B-Cabinet units have one furnace while C-Cabinet units have two furnaces.

2. All joints must be watertight to prevent leakage of

condensate. The drains must be extended down through the base of the unit and into the heated space below.

3. Each heat exchanger drain assembly includes a threaded

elbow that is oriented down. Once the male threaded PVC adapters, included with the kit, are glued to the PVC drain pipe (by others) that extends into the space, they are to be routed up through the holes in the unit base pan and screwed into the elbow connections. The threads must be sealed to prevent leaks.

4. Unions are recommended to permit maintenance of the

drains and to facilitate service of the heater. A union is shown on both sides of each trap.

5. A vacuum breaker is required after each trap. The vacuum

breaker should be constructed so that dirt and debris do not enter and clog the drain system.

6. Local code permitting, the condensate drain systems may

be joined after the traps and connected to a sanitary drain within the building. Because the condensate produced is acidic, some municipalities may require that the condensate be neutralized before being discharged into the sanitary sewer. A condensate neutralizer tube kit is available from Modine to reduce the pH of the condensate. A single tube can be used for drains that are joined after the traps providing the tube is installed after the junction. Refer to the instructions that come with the kit.

7. For proper operation, the traps must be primed with water.

The traps must be installed with the higher side connected to the heater and the lower side connected to the drain.

8. If there is an opportunity that the temperature in the space

will fall below freezing during non-operating periods, the condensate drain systems and secondary heat exchanger must be completely drained to prevent freeze damage. Alternately, heat tape can be applied to the drain pipe system in accordance with the heat tape manufacturers instructions.

Figure 14.1 - Furnace Condensate Drain/Trap

System j

j C-Cabinet sized unit shown with two condensate drain systems. B-Cabinet

sized units require only one drain system.

Figure 14.2 - Drain System Trap/Vacuum Breaker

Exchanger Drain Assembly on Unit

Note: Drain pipe from unit

Vacuum Breaker

To Building Drain System

Note: Refer to figure above for determination of parts supplied by others.

must enter the high side of the drain trap.

14 MCP15-500.7

HOT WATER PIPING CONNECTIONS

REVIEW BEFORE PROCEEDING

THIS SECTION APPLIES TO UNITS WITH

OPTIONAL HOT WATER HEAT

(MODEL DIGIT 17=4).

IF THE UNIT DOES NOT HAVE HOT WATER

HEAT, SKIP TO PAGE 16.

CAUtIoN

1. Units not approved for use in potable water systems.

2. Do not operate the unit with steam. The coil is not designed for steam condensate removal which can damage the unit.

3. Hot water supplied to the hot water heating option must not exceed 180°F temperature or 75 PSIG pressure.

1. Models with a factory installed hot water heating coil (for use with water or propylene glycol fluids) are supplied with 1-1/2" sweat connections (1.625").

Figure 15.1 - Hot Water Coil Connections

 •On3-wayvalvecontrolconfigurations,includeabalancing

valve between the supply line and control valve to balance the system.

 •Includeahosebibdrainvalveonthebottomofthesupply

manifold to allow for periodic flushing of the system to remove sediments from the coil.

 •Includeapipelinestraineronthesupplylinetoprevent

sediment from reaching the coil.

 •Includeanairventatthetopofthereturnmanifoldtobleed

off accumulated air in the system. Air in the system will generate noise and may cause water hammer that can damage the joints of the piping and coil.

 •Includeeithera2-wayor3-waymodulatingcontrolvalve

designed for a 0-10VDC control signal. The valves will be automatically modulated by the unit’s Carel controller to maintain the supply air temperature setpoint. Note that the control valve must be a normally open, spring return type valve. This is to allow hot water to flow through the coil for freeze protection when the unit is shut down. Refer to the Freeze Stat Option section for additional detail.

 •Hotwaterpipesshouldbeinsulatedtoreduceheatlossand

to prevent overheating of the end compartment.

9. Leak test the coil and connections as outlined in the Start-Up section.

Figure 15.2 - Typical 2-Way Piping Installation (piping and components by others)

Supply Connection Return Connection

2. The entering water temperature (EWT) supplied to the heating coil must not exceed 180°F.

3. The fluid flow rate must not exceed 50 gallons/minute (GPM) and fluid pressure must not exceed 75 psi.

4. It is recommended to use an inhibited glycol solution that is designed for HVAC applications for corrosion protection and freeeze protection for the lowest possible outside air temperatures for the installed location. Failure to protect against freezing can result in damage to the coil and property.

5. Provide adequate pipe hangers, supports, or anchors to secure the piping system independently of the coil to prevent excess vibration and stress that can damage the piping and joints.

6. 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.

7. System piping should be flexible enough to allow for thermal expansion and contraction of the coil and piping components.

8. Refer to Figures 15.2 and 15.3 for typical piping system design and the following recommended items:

 •Installshut-offvalvesinlinestoandfromtheunittoallow

for maintenance or replacement of the coil without shutting down and draining the entire system.

 •Installunionsforeaseofpipingcomponent/coilremoval.  •Includeacircuitsetterinthereturnlinetoregulateflow.

HOSE BIB DRAIN

SHUT-OFF

VALV E

SHUT-OFF

VALV E

SUPPLY

RETURN

HOT WATER

COIL

AIR VENT

UNION

2-WAY CONTROL

VALV E

STRAINER

UNION

CIRCUIT SETTER

Figure 15.3 - Typical 3-Way Piping Installation

(piping and components by others)

HOSE BIB DRAIN

SHUT-OFF

VALV E

SHUT-OFF

VALV E

SUPPLY

RETURN

HOT WATER

COIL

AIR VENT

UNION

BALANCING

VALV E

3-WAY CONTROL

VALV E

UNION

STRAINER

UNION

CIRCUIT SETTER

Optional Factory Installed Freeze Stat

When equipped with the optional Coil Freeze Stat, an autoresetting capillary type freeze stat (see Figure 50.1) is factory installed immediately below and across the face of the hot water coil. The stat is set to trip at 40°F (adjustable) and will automatically reset when the coil temperature rises 5°F above the setpoint. If the stat has tripped, the unit controls would respond by closing the outdoor air damper, opening the return air damper (if applicable), de-energize the supply air fan, open the hot water coil valve 100%, and log the alarm on the controller. The freeze stat can be removed from the unit for servicing as discussed in the Maintenance section.

15MCP15-500.7

START-UP PROCEDURE

General

1. When the dead front disconnect switch(es) (for main unit and/or powered convenience outlet option) is in the “OFF” position, supply power remains energized at the line (supply) side of the dead front disconnect switch(es). The switch body is located inside of another junction box to protect against contact with the live wiring. The junction box must not be disassembled unless the main power supply from the building to the unit is de-energized.

2. For units equipped for dual power supply sources, both sources of power must be disconnected to prevent electrical shock and equipment damage.

WARNING

CAUtIoN

When servicing the unit, some components may be hot enough to cause pain or injury. Allow time for cooling of hot components before servicing.

IMPoRtANt

1. To prevent premature heat exchanger failure, check to be sure the blower has been set to deliver the proper airflow for the application. Refer to page 17 for Blower Adjustments.

2. Start-up and adjustment procedures must be performed by a qualified service agency.

3. All scroll compressors requires the correct supply power phase rotation. Phase reversal may result in compressor failure not covered under warranty. Refer to the Start-Up Procedure section.

4. The exhaust fan is not designed for high temperature or smoke control exhaust applications. Exhaust air temperature must not exceed 104°F. Operating the exhaust fan above 104°F will result in failure of the exhaust fan.

1. Turn off power to the unit at the disconnect switch. If equipped with gas heating option, turn all hand gas valves to the “OFF” position.

Note: The dead front disconnect switch, if included, is factory installed in the controls/compressor compartment section (refer to the figures on pages 32 through 35). The disconnect switch is designed so that it must be turned “OFF” before entry to the compartment can be obtained. When in the “OFF” position, power is disconnected to all unit wiring electrically following the switch (see WARNING).

2. For units equipped for dual power supply sources, both sources of power must be disconnected to prevent electrical shock and equipment damage.

3. Open the power compartment, controls compartment, and blower access doors.

4. Check that the supply voltage matches the unit supply voltage listed on the Unit Serial Plate. For units equipped for dual power supply sources, the voltage on both the main feed and the auxiliary feed must match the unit supply voltage listed on the Unit Serial Plate.

5. Check that fuses or circuit breakers are in place and sized correctly.

6. Verify that all wiring is secure and properly protected. Trace circuits to ensure that the unit has been wired according to the wiring diagram.

7. Check that all electrical and gas connections are weatherized.

8. For C-Cabinet sized units, if the unit is installed with a Modine supplied Energy Recovery Module, Model ERM, verify that the wiring connection between the MPR unit and the ERM unit has been properly installed. If the unit is a B-Cabinet sized unit with integral Energy Recovery, the unit is already factory wired to the Energy Recovery section.

9. For units with gas heating, check to ensure that the combustion air inlet louvers and the power exhauster discharge cover (Non-Condensing as determined from Table 12.1 on page 12) or the vent elbow terminations (Condensing as determined from Table 12.1 on page 12) are free from obstructions.

10. For units with condensing gas heating, check that the condensate drain system is properly installed and the trap has has been primed with water.

11. For units with Hot Water Heat (Digit 17=4), check the following:

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

• Open all required valves to fill the coil. Once the coil is full, close all air vents.

• Perform an initial hydrostatic leak test of all brazed, threaded or flanged joints, valves and interconnecting piping, and the hot water coil. Recheck the coil level and correct if necessary.

• When the setup is found to be leak free, flush the coil through the drain valve to eliminate grease, oil, flux and sealing compounds present from the installation.

• Recheck the coil and all connections for water leaks.

• Check water flow rates and pressure drops and compare

to design.

• Check that the hot water supplied to the coil does not exceed 180°F temperature or 75 PSIG pressure. Verify that the appropriate glycol mixture is used for freeze protection.

12. Check to see that there are no obstructions to the intake and discharge of the unit.

13. Verify that the belts are aligned in the sheave grooves properly and are not angled from sheave to sheave.

14. On belt driven blowers, blower bearings are permanently lubricated unless they are pillow block bearings or if they have grease fittings. For motors or blower bearings that are not permanently lubricated, lubricate according to the manufacturer’s instructions. Refer to the Maintenance section on page 48.

15. Check to make sure that all filters are in place and that they are installed properly according to direction of air flow. Pleat direction must be vertical to ensure optimum performance.

16. Perform a visual inspection of the unit to make sure no damage has occurred during installation.

16 MCP15-500.7

START-UP PROCEDURE - CONTINUED

17. Check that the evaporator drain pan drain trap has been primed with water.

18. Turn on power to the unit at the disconnect switch. Note: Units include one blower door switch per access door (one on B- and C-Cabinet, two on D-Cabinet) that are factory installed inside the blower access section door(s). When a blower section door is opened, the switch is opened and interrupts power to the low voltage circuit and de-energizes the blower motor controller. D-Cabinet units also have the same switches on the evaporator/hot gas reheat coil access sections.

19. Check the Carel microprocessor controller and supply fan blower motor for electrical operation. If the unit is equipped with the optional building power exhauster module (with or without energy recovery), check the blower motor for electrical operation. If these do not function, recheck the wiring diagram. Check to ensure that none of the Control Options (for example, smoke detector, etc.) have tripped.

20. Check to make sure that the damper(s) operate properly without binding.

21. Check that the supply power wiring is wired with the correct phase rotation. For units equipped for dual power supply sources, correct phase rotation must be verified on both the main feed and the auxiliary feed. Incorrect phase rotation can damage the equipment. Check the phase rotation as follows:

• For units equipped with single speed motor starters on the supply fan: 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 insufficient air will be delivered if the blower wheel is running backwards. If the blower wheel is rotating in the opposite direction, the phase reversal must be corrected by changing the incoming power feed legs at the supply to the unit, NOT the individual components on the unit. Recheck for proper rotation.

• For units equipped with a variable frequency drive on the supply fan: The VFD will correct the phase

rotation for the supply fan, but will not correct the phase rotation for the rest of the unit, therefore observing the supply blower wheel rotation direction is not an accurate indicator of correct phase rotation. Scroll compressors will only compress in one rotational direction. Verification of proper rotation direction is made by observing that suction pressure drops and discharge pressure rises when the compressor is energized. Reverse rotation will result in no pressure differential as compared to normal values. There is no negative impact on durability caused by operating the compressors in the reversed direction for a short period of time (under one hour) but should not be allowed to operate longer than the time it takes to verify rotation. If the compressor is rotating in the opposite direction, the phase reversal must be corrected by changing the incoming power feed legs at the supply to the unit, NOT at the compressor. Recheck for proper rotation.

22. Check the blower speed (rpm). Refer to Blower Adjustments for modification.

23. Check the motor speed (rpm).

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

25. Check the motor amp draw to make sure it does not exceed the motor nameplate rating. Check all legs to ensure system is balanced.

26. For units equipped for dual power supply sources, the unit should be started separately on the main power feed and again on the auxiliary power feed to verify proper unit and control operation.

Note: Units equipped for dual power supply sources have the unit power wiring separated into two circuits as follows:

Circuit #1

• Compressors

• Condenser fans

• Electric heating section (if applicable).

• Energy recovery wheel (if applicable)

Circuit #2

• Main unit controller

• Supply fan

• Dampers

• Gas heating section (if applicable)

• Exhaust fan (if applicable)

• Energy recovery wheel bypass damper (if applicable)

When operating in a full power state with the main power feed, both Circuit #1 and Circuit #2 should be powered. When operating in a low power state with the auxiliary power feed, only Circuit #2 should be powered.

Blower Adjustments

The units are designed for ease of airflow adjustments, within a range, for field balancing against actual external static pressure conditions. If the static pressure external to the unit is above or below the original design point for the unit, the blower will deliver an airflow volume that is lower or higher than required. When equipped with the building exhaust option (with or without energy recovery), the air balancing must be performed for both the main unit supply fan, as well as the exhaust fan.

The blower speed (supply and/or exhaust blowers) may be adjusted to achieve the desired air volume, provided:

• The allowable temperature rise range and the maximum supply air temperature for heating is not exceeded as shown in Table 18.1, and

• The airflow is within the allowable limits shown on the serial plate for both heating and cooling, and

• The total static pressure does not exceed the limit shown on the unit serial plate, and

• It is within the range of adjustability for the unit, and

• The motor amp draw must not exceed the motor

nameplate rating.

The blower speed adjustment method is dependant on the following configurations:

• Direct Drive where the blower is driven directly by the motor as seen in Figure 18.1. This is the current standard supply fan configuration for all units.

• Belt Drive where the blower is driven by the motor with a belt and sheaves as seen in Figure 18.2. This is the current standard exhaust fan configuration (if equipped) for all units. It was also used on supply fans for units shipped before 2018.

Once the blower/motor configuration of the unit is determined, follow the appropriate instructions in the sections on the following pages.

17MCP15-500.7

START-UP PROCEDURE - CONTINUED

Figure 18.1 - Direct Drive Blower Example

Direct Driven Blower

(dual blower shown)

Figure 18.2 - Belt Drive Blower Example

Motor Sheave (adjustable)

Blower Sheave (non-adjustable)

Automatic Belt Tensioner

Blower Adjustments – Direct Drive Fans

All direct drive supply fan speed adjustments can be performed with the Modine Control System programmable microprocessor controller. There are two ways to access the menus:

1. Using the user interface on the main unit controller.

2. Using the pGD1 Digital Display/Interface Module.

For guidance on either method above, refer to the latest revision of the following documents for additional warnings, cautions, controller location, instructions, and menu navigation:

• ControlsManual,MCP15-525.

• pGD1DigitalDisplay/InterfaceModuleInstallation

Instructions, MCP15-543.

The blower adjustments are made as follows:

1. Ensure unit is running at the maximum airflow setting for the control type selected. For example, if the unit has Multi-Speed or Variable Speed fan control, ensure the unit is operating at the highest speed setting.

2. On the keypad navigate to menu “G. Service -> f. SERVICE SETTINGS”. At this menu, you will be prompted to enter the Service password of 1500.

3. Navigate to “c. Control Settings” and scroll to the “Supply Fan Control (CS6)” screen. See Figure 18.3.

Table 18.1 - Allowable Temperature Rise Range and

Maximum Supply Air Temperature

Casing

Size

Heat Type Rating

(for formula)

1 A, B, C, D 1.00 N 1 - 100°F 100°F

F, G, H, J, K 0.81

2 or 3

R, S, T 0.94 N 30 - 100°F 100°F

1 A, B, C, D, E 1.00 N 1 - 100°F 100°F

J 0.81 N 30 - 75°F

K, L, M 0.81

U, V 0.81

1 A, B, C, D, E 1.00 N 1 - 100°F 100°F

K 0.81 L 30 - 75°F

L, M, Q 0.81

1, 4

2, 3, 5 H 60 - 120°F

Eff

0.81

Temp Rise

Allowable

Temp Rise

Range

L 30 - <70°F H 70 - 100°F

L 30 - <70°F H 70 - 100°F L 30 - <70°F H 70 - 100°F

L 30 - <70°F H 70 - 100°F H 70 - 120°F

Max Supply

Air TempDigit 6 Digit 17 Digit 18 Digit 19

130°F

100°F

130°F

Figure 18.3 - Control Settings Screen CS6

4. Adjust the Air Balance Adj parameter up or down to obtain the design airflow given the actual static pressure.

5. In the event you are unable to increase or decrease the motor speed to the desired air balance please consult your factory representative.

6. Check the motor amps to ensure the maximum motor amp rating is not exceeded. For units equipped with a VFD, measure the amps at the incoming lines to the motor. If the unit has dual supply fans, measure each motor individually. Verify airflow volume and repeat steps above for further adjustment.

7. If equipped with gas heat, turn on the gas and initiate burner operation. For guidance, refer to the Controls Manual.

8. Verify the temperature rise and supply air temperature of the heating section do not fall outside the range or exceed the maximums shown in Table 18.1. Airflow can be approximated with the following formula:

CFM = (Input Btu/hr x Eff) / (1.08 x Temp Rise) where Eff (Efficiency) is determined from Table 18.1

18 MCP15-500.7

START-UP PROCEDURE - CONTINUED

Toward Motor

Set Screw

Adjustable Half

of Sheave

Blower Adjustments – Belt Drive Fans

All belt drive supply fan and, if applicable, exhaust fan speed adjustments can be made with the adjustable sheave on the blower motor as follows:

1. Turn off power to the unit at the disconnect switch. If equipped with gas heat option, turn all hand gas valves to the “OFF” position.

2. Loosen the belt tension and remove the belt.

3. On the motor sheave, loosen the set screw on the side away from the motor (see Figure 19.1).

Figure 19.1 - Motor Sheave Adjustment

4. To increase the blower speed, turn the adjustable half of the sheave inward. To decrease the blower speed, turn the adjustable half of the sheave outward. The sheave half is

adjustablein½turn(180°)increments.Each½turn

represents approximately a 2-5% change in blower speed and airflow volume.

5. Tighten the set screw on the flat portion of the sheave shaft.

6. Replace the belt and verify that the belts are aligned in the sheave grooves properly and are not angled from sheave to sheave.

7. Turn on power to the unit and initiate blower motor operation. For guidance, refer to the Controls Manual.

8. Check the motor amps to ensure the maximum motor amp rating is not exceeded. Verify airflow volume and repeat steps above for further adjustment.

9. If equipped with gas heat, turn on the gas and initiate burner operation. For guidance, refer to the Controls Manual.

10. Verify the temperature rise and supply air temperature of the heating section do not fall outside the range or exceed the maximums shown in Table 18.1. Airflow can be approximated with the following formula:

CFM = (Input Btu/hr x Eff) / (1.08 x Temp Rise) where Eff (Efficiency) is determined from Table 18.1

Air Flow Proving Switch / Optional Dirty Filter Switch

The air flow proving switch is factory installed in the blower compartment. The purpose of the air flow proving switch is to cut power to the controls if a positive pressure is not measured by the switch. This could be caused by a lack of air movement through the evaporator coil or heat exchanger.

The optional dirty filter pressure switch is factory installed in the filter section. The dirty filter pressure switch monitors the pressure differential between the two sides of the filters. When the filters become dirty, the differential pressure increases and trips the pressure switch which initiates an alarm from the Carel controller. The pressure differential switch must be field set because setting the switch requires the blower to be inoperation and the ductwork to be installed.

Setting the Air Flow Proving or Dirty Filter Switch

1. Ensure that the unit filters are clean. Replace if necessary.

2. Using the Modine Control System controller interface, start blower operation.

3. Turn the set screw of the pressure switch clockwise until it stops.

4. With the wires removed from the common and normally open terminals of the switch, measure continuity and turn the adjustment screw counter-clockwise until the switch makes. Then turn the adjustment screw one additional turn counter-clockwise to account for dirty filters or other system static changes.

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 50 and 100% of the full speed air flow depending on the controls selection of the unit, but never less than the following:

• B-Cabinet units: 1100 CFM

• C-Cabinet units: 3000 CFM

• D-Cabinet units: 4000 CFM

• All units with Gas Heat: Minimum airflow as listed on the

Gas Heat Serial Plate

Refer to the Controls Manual for additional information.

11. After 24 hours of operation, retighten the setscrews to the torque listed in the owners manual on the bearing, sheave, and blower wheel to avoid damage to the unit.

19MCP15-500.7

START-UP PROCEDURE - CONTINUED

Checking Refrigerant Charge

Do not overcharge the refrigeration system. This can lead to elevated compressor discharge pressure and possibly flooding the compressor with liquid.This may result in compressor failure not covered under warranty.

WARNING

CAUtIoN

IMPoRtANt

1. All refrigeration checks must be made by a qualified R-410A refrigeration technician.

2. Do not release refrigerant to the atmosphere. When

adding or removing refrigerant, all National, State/ Province, and local laws must be followed.

Refrigerant charge can be verified by checking both superheat and subcooling. B- and C-Cabinet units have one circuit and D-Cabinet units have two circuits. The following procedure is to be done for each refrigeration circuit.

1. Check the evaporator coil to be sure there are no obstructions to airflow.

2. From the Modine Control System controller interface, create a call for cooling. If the unit has the hot gas reheat option, the hot gas reheat valves must be closed.

3. The unit must be operated at near to full load operation before checking the refrigerant charge. The unit operation should be stabilized, typically after 10-15 minutes of operation.

4. Measure subcooling as follows:

a. Read the gauge pressure at the liquid line test port (refer

to the figures on pages 32 through 35). Note the saturation temperature on the gauge.

b. Measure the temperature of the liquid line at a point

near where the pressure reading was taken.

c. Subtract the measured liquid line temperature from the

saturation temperature to determine the liquid subcooling. For units without the hot gas reheat option, the subcooling should be 10-15°F. For units with the hot gas reheat option, the subcooling should be 5-15°F.

5. Measure the superheat as follows:

a. Read the gauge pressure at the suction line close to the

compressor. Note the saturation temperature on the gauge.

b. Measure the temperature of the suction line at a point

near where the pressure reading was taken.

c. Subtract the saturated temperature from the measured

suction line temperature to determine the evaporator superheat. The superheat should be 8-12°F.

6. Determine if the system is undercharged or overcharged and correct as follows:

a. Undercharged: Typically, superheat is too high and

subcooling is too low. Refrigerant should be added.

b. Overcharged: Typically, superheat is too low and

subcooling is too high. Refrigerant should be removed.

7. After adding or removing refrigerant, allow the system to stabilize for 10-15 minutes before making any other adjustments.

8. Repeat the steps above until the subcooling and superheat are within the range specified.

9. Repeat the above procedure for the 2nd circuit on D-Cabinet units.

10. Once the correct charge has been established, operate the unit reheat mode to verify correct operation.

Table 20.1 - Refrigerant Charge

Casing Size Unit Tons

Hot Gas

Reheat

0 17.0

1 or 2 20.0

0 17.0

1 or 2 20.5

0 23.0

1 or 2 28.5

0 24.0

1 or 2 28.5

0 28.5

1 or 2 35.5

0 35.0

1 or 2 39.0

0 37.0

1 or 2 42.0

0 38.0

1 or 2 44.0

0 39.0

1 or 2 46.0

0 34.5

1 or 2 45.0

0 36.0

1 or 2 46.5

0 Future

1 or 2 Future

0 Future

1 or 2 Future

Refrigerant Charge per

Circuit (lbs.) # of CircuitsDigit 6 Digits 4-5 Digit 10

20 MCP15-500.7

START-UP PROCEDURE - CONTINUED

REVIEW BEFORE PROCEEDING

THIS SECTION APPLIES TO UNITS WITH

OPTIONAL GAS HEAT

(MODEL DIGIT 17=2 OR 3).

IF THE UNIT DOES NOT HAVE GAS HEAT,

SKIP TO PAGE 28.

Gas Heating Option

The Gas Heating Option requires gas pressure be measured

and adjusted as required at several points on the unit. The following steps must be completed:

Identify the Gas Control Type

Before you begin, review the furnace serial plate to determine the model installed. The serial plate is located on the right hand access door for the furnace section. Refer to Pages 56 through 59 for Serial Plate and Model Nomenclature information. Note that the furnace serial plate is separate from the unit (model MPR) serial plate.

Digit 11 of the furnace model number denotes the type of gas control used. These are defined below:

4 - Indicates two heat exchangers using basic modulating

controls with United Technologies ignition. Manifold pressure of both heat exchangers is varied simultaneously based on demand. Power exhausters operate at a constant speed.

6 - Indicates a single heat exchanger with Beckett advanced

modulation control which varies the manifold pressure and power exhauster speed based on demand. High turn down and more consistent efficiency are possible with this control.

8 - Indicates two or more heat exchangers; one equipped

with advanced Beckett modulation master control and the other(s) equipped with non-modulating single input slave control. The slave heat exchanger(s) is controlled and monitored by the master control and will turn on or off depending on demand.

Check/Adjust Pressure Upstream of Unit

With the field installed manual gas shut-off valve in the “OFF” position, recheck the gas supply pressure at the field installed manual shut-off valve. The inlet pressure should be 6"-7" W.C. on natural gas, while all the burners are operating, but never more than 14" W.C when the burners are off. If inlet pressure is too high, install an additional pressure regulator upstream of the combination gas control.

Check/Adjust Pressure at Combination Gas Valve

1. Open the field installed manual gas shut-off valve and set the combination gas control valve to the “ON” position. Note for C- and D-Cabinet sized units, the Gas Heating Option consists of two or more heating sections. For this step, only one combination gas valve is to be set to the “ON” position.

2. Enable the unit controls. For furnace models with furnace model Digit 11=6, the LED readout on the furnace control board (Figure 23.1) will briefly display the furnace size. Verify that the model readout is correct for the unit being started.

3. Ensure that the supply fan blower is operating at the proper airflow and adjust the Modine Control Systemc control setpoint to create a call for heat. Refer to the Controls Manual for instructions on changing the setpoint.

4. Check the ignition control and gas valve for electrical operation.

5. Check to make sure that the main gas valve opens while the supply fan blower is operating.

6. Check the gas pressure at the INLET to the combination gas control valve (refer to figures on pages 24 through

26) and adjust as needed to maintain 6"-7" W.C while the burners are operating at high fire. This pressure is required for proper ignition and to attain the rated input of the unit. If this pressure cannot be obtained, the gas supply is undersized and needs to be corrected or the gas supplier must be contacted.

7. Check gas pressure on the OUTLET of the combination gas control valve (refer to figures on pages 24 through 26) when the burners are functioning. This should be set to 4.0" W.C. for all furnaces with furnace model Digit 11=4, or 6. For C-Cabinet furnaces with furnace model Digit 11=8, only the right hand modulated heat exchanger is set to 4.0”W.C. The left hand fixed input heat exchanger is set to 3.5”W.C. Adjust the gas control valve regulator as needed (see gas valve instruction sheet for location.)

8. Check to ensure that gas controls sequence properly (see Controls Manual).

9. For units with multiple heat exchangers, repeat steps 3 through 8 for each heat exchanger before proceeding to the next step.

Check/Adjust Pressure at Manifold

The following steps are required to check/adjust the manifold

pressure on modulated heat exchangers. For units with furnace model Digit 11=4, this process applies to both heat exchangers and is conducted on one heat exchanger at a time. For all other units, this process applies to only one heat exchanger, normally the lower right heat exchanger on multiple heat exchanger units.

1. Move the field installed manual shut-off valve to the “OFF” position.

2. Remove the 1/8" pipe plug in the pipe tee of the furnace.

3. Attach a digital or “U” tube type water manometer which is at least 12" high and capable of reading to 0.1" W.C.

4. The Maxitrol EXA modulating valve series (refer to figures on pages 24 through 26) has a cover secured with two screws that must be removed. Once removed, there are a bank of (3) DIP switches and two buttons and a communication LED for the user interface as shown in Figure 22.1.

5. Verify that the DIP switches are properly set to the settings shown in Figure 22.1.

6. Move the field installed manual gas shut-off valve to the “ON” position.

7. Adjust the High Fire Setting as follows:

a. Enable the unit controls. b. For units with furnace model Digit 11=6 or 8, place

the furnace control into the “Checkout Test Mode” as described on the next page and set the Fire Rate Input to 10.0.

c. Press and hold Button #1 on the modulating valve until

the LED lights solid red, then release.

d. With the valve now in the high fire setting mode, confirm

21MCP15-500.7

START-UP PROCEDURE - CONTINUED

or adjust the high fire manifold pressure to be 3.5" W.C. If the pressure needs to be adjusted, press or hold Button #1 to increase gas flow and press or hold Button

10. For furnace models with Digit 11=6 or 8, verify the furnace

#2 to decrease gas flow.

e. If 3.5" W.C. cannot be attained, recheck the inlet gas

pressure as described previously. After addressing any issues, if 3.5" W.C. still cannot be attained, step the valve closed using button #2 to the point where manifold pressure begins to be impacted. If the pressure at that

 • Thehighfiremanifoldpressuremaybeintherangeof

 • Thelowfiremanifoldpressuremustnotgobelow

point is less than 3.3" W.C., corrective action is required.

f. Save the setting by simultaneously holding Buttons #1

and #2 until the LED turns OFF. If this is not performed within 5 minutes, the control will default to the previously saved settings and return to normal operating mode.

11. Once the setting of the modulating valve has been

Figure 22.1 - Maxitrol Modulating Valve Adjustments

BUTTON #2

SUPPLY POWER

WIRING TERMINALS

CONTROL SIGNAL

WIRING TERMINALS

3 4

1 2

1 2 3

(ONLY ON UNITS WITH FURNACE

Furnace Model

Digit 11

(Capacity Control)

6 or 8

BUTTON #1

POSITION FEEDBACK

WIRING TERMINALS

MODEL DIGIT 10=6, 7, OR 8)

DIP SWITCHES

(SEE TABLE FOR SETTINGS)

LED INDICATOR

DIP Switch

Settings

SW #1 OFF

SW #2 OFF

SW #3 OFF

SW #1 OFF

SW #2 ON

SW #3 OFF

8. Adjust the Low Fire Setting as follows: a. For units with furnace model Digit 11=6 or 8, place

the furnace control into the “Checkout Test Mode” as instructed in the next section and set the Fire Rate Input to 2.0.

b. Press and hold Button #2 on the modulating valve until

the LED light blinks red, then release.

c. With the valve now in the low fire setting mode, confirm

or adjust the low fire manifold pressure to be no less than the minimum shown on the furnace serial plate in the box called “Min. Manifold Pressure”. If the pressure needs to be adjusted:

Press or hold Button #1 to increase gas flow and press

Button #2 to decrease gas flow. It is best to push and release button #2 to single step the valve to the minimum manifold pressure. Pressing and holding the button is likely to cause the valve to close too far and lose flame.

d. Save the setting by simultaneously holding Buttons #1

and #2 until the LED turns OFF. If this is not performed within 5 minutes, the control will default to the previously saved settings and return to normal operating mode.

9. For furnace models with Digit 11=6 or 8, if no errors or alerts were recorded by the board (these will be on the 3 LED displays as an “A” or “E” followed by a number), proceed to the next step. If any alerts or errors were logged by the board, refer to the “Clearing Furnace Control Board

22 MCP15-500.7

12. Move the field installed manual shut-off valve to the “OFF”

13. After the plug is in place, move the field installed manual

14. For units with furnace model Digit 11=4, repeat the entire

Placing Furnace Control Into “Checkout Test Mode”

(Applies to furnace models with Digit 11=6 or 8)

The furnace control board (Figure 23.1) has functionality to be

put it in a manual operation “Checkout Test Mode” for testing purposes as noted in the previous sections for checking and setting gas pressure. To enter that mode, perform the following steps:

1. The Checkout Test mode is only available when the furnace

2. Press the MODE button for at least 4 seconds until the LED

3. Press the DOWN button briefly to change the display to

4. When the Checkout Test mode is entered, the control board

5. If a lockout error condition occurs, or the MODE button is

Clearing Furnace Control Board Error Codes

1. Fault codes can be reviewed by pressing the MODE button

2. Briefly press the MODE button again to review the fault

Error Codes” section in the next column to clear the errors.

control board and modulating valve is communicating properly by adjusting the Fire Rate Input on the control board from 10.0 to 2.0 with the up and down buttons.

3.3" W.C to 3.5" W.C. at the 10.0 Fire Rate Input setting.

0.2" W.C. at the 2.0 Fire Rate Input setting. If the manifold pressure drops below 0.2”W.C. or flame is lost, repeat the "Check/Adjust Pressure at Combination Gas Valve" section on the previous page and then repeat the “Low Fire Setting” sequence described above.

completed, replace the valve cover that was removed earlier.

position, remove the manometer, and replace the 1/8" pipe plug.

shut-off valve to the “ON” position and recheck the pipe plug for gas leaks with soap solution.

process for the 2nd furnace.

control board detects an “E09” error condition (No Firing Rate Input). To accomplish this, temporarily disconnect wire #804 from the furnace control board and create a call for heat from the main Carel controller. Be sure to insulate the end of the signal wire so it cannot cause a short.

display changes to display “Lo9”.

“tSt”, and then briefly press the MODE button to enter the Checkout Test mode.

will initiate a normal ignition sequence with the Firing Rate Input set to a simulated 10.0 VDC. The simulated Firing Rate Input can be set to different 1.0 VDC step values from 10V to 2V. A 10V signal will give maximum fire rate while a 2V signal will give the minimum fire rate. Once burner ignition has been achieved and the control enters the RUN mode, the normal runtime data parameters, including the Firing Rate, will be continuously displayed on the furnace control board LED indicators.

depressed for more than 4 seconds, or there is no push button activity for 30 minutes, then the Checkout Test mode will be exited.

for at least 4 seconds until the LED display changes to display “Lo9”. Refer to Figure 23.1 for location of buttons and LED display.

codes. Up to 15 fault codes are stored and can be reviewed

START-UP PROCEDURE - CONTINUED

by pressing the UP or DOWN buttons. Codes will be displayed followed by the number of days since the fault was detected.

3. To clear the fault codes from memory, press the DOWN button until “CLr” is displayed. Press and hold the MODE button to clear the memory. The board will then revert to normal operation.

Figure 23.1 - Furnace Master Control Board (Furnace models with Digit 11=6 or 8 only)

R W

OUTPUT

ALARM

FUSE

PRESSURE

SENSOR

J13

NOTE: FOR ACTUAL WIRING TO THE FURNACE CONTROL BOARD, PLEASE REFER TO THE WIRING DIAGRAM LOCATED IN THE FURNACE CONTROL COMPARTMENT.

VB1200

CONTROL BOAR D

PLUG

J12

7-SEGMENT

LED DISPLAY

GND

MODE BUTTON

GND

IND-L1

IND-L2

AUX-L1

AUX-L2

FLAME ROD

DOWNUPMODE

UP/DOWN BUTTONS

FLAME VOLT

Figure 23.3 - Furnace Master/Slave Locations

SLAVE A MASTER

C-CABINET SIZE UNIT

(ALL GAS HEAT SIZES)

D-CABINET SIZE UNIT

SLAVE A MASTER

(UP TO 800,000 BTU/HR)

1.0VDC=1MCIROAMP

Figure 23.2 - Furnace Slave Control Board (Furnace models with Digit 11=8)j

IND-L2

VB1201

IND-L1

FLAME ROD

GND

JUMPER SETTING MUST MATCH FURNACE SLAVE DESIGNATION. 1

NOTE: FOR ACTUAL WIRING TO THE FURNACE CONTROL BOARD, PLEASE REFER TO THE WIRING DIAGRAM LOCATED IN THE FURNACE CONTROL COMPARTMENT.

GND

FLAME VOLT

1.0VDC=1MCIROAMP

CONTROL BOAR D

ABCD SLAVE

j This applies to C- and D-Cabinet sized units with furnace model Digit 11=8.

Refer to Figure 23.3 for identifying which furnace is the Master and which furnace(s) are the Slave(s).

GND

FUSE

WHITE

D-CABINET SIZE UNIT

(OVER 800,000 BTU/HR)

SLAVE A

SLAVE C

SLAVE B

MASTER

k Furnace locations are shown for reference, not the location of the furnace

controls. Refer to the figures on pages 25 through 27 for controls location.

Final Check

1. Operate furnace (all furnaces for units with multiple heat exchangers) at high fire and verify that gas pressure to the INLET of the combination gas control valve is maintained at 6”-7” W.C. If the pressure cannot be maintained at 6”-7” W.C. while operating at high fire, the gas supply system is undersized and must be corrected and the entire check and adjustment of gas pressures section must be repeated.

2. Once all gas pressures have been checked and are at the proper settings, shut the unit down and move the field installed manual shut-off value to the “OFF” position.

3. Remove all testing equipment and replace any hardware (plugs, covers, etc.). For furnace models with Digit 11=6, replace wire #804 that was temporarily removed when the control was placed in the “Checkout Test Mode”.

4. Close the unit access doors.

23MCP15-500.7

START-UP PROCEDURE - CONTINUED

Figure 24.1 - Gas Heat Option Gas Controls - B-Cabinet Sized Units

81% Efficiency Gas Heat Option (Digit 18 = F,G,H, J or K)94% Efficiency Gas Heat Option (Digit 18 = R, S or T)

1 Power exhauster 2 Maxitrol EXA STAR modulating

gas valve

3 Main combination gas valve 4 High limit control

(hidden behind Item #2 on 80% efficiency furnace)

5 Solid state ignition control board 6 Furnace control board 7 Vent differential pressure proving switch 8 Direct spark ignitor 9 Manifold pressure tap on manifold tee 10 Flame sensor 11 Manifold piping with gas orifices

24 MCP15-500.7

12 Condensate drain float switch

(94% efficiency furnace only) 13 Compartment strip heater/thermostat

(94% efficiency furnace only - not pictured)

15 Heat exchanger tube drain tray with

drain line (80% efficiency furnace only not pictured)

16 Convenience outlet (optional feature)

START-UP PROCEDURE - CONTINUED

Figure 25.1 - Gas Heat Option Gas Controls - C-Cabinet Sized Units

Left Furnace

(Slave)

1 Power exhauster 2 Maxitrol EXA STAR modulating

gas valve (right-hand furnace only)

3 Main combination gas valve 4 High limit control

81% Efficiency Option (Digit 18 = J, K, L or M)

5 VB1200 master furnace control board (for right-side furnace) 6 VB1201 slave furnace control board (for left-side furnace) 7 Direct spark ignition control board

NOTE: For this option, only the leftside furnace is shown. The right-side furnace will be nearly identical.

Right Furnace

(Master)

8 Not Applicable

9 Vent differential pressure proving switch 10 Direct spark ignitor 11 Manifold tee pressure tap

12 Flame sensor 13 Manifold piping with gas orifices 14 Not applicable 15 Heat exchanger tube drain tray with drain line

1 Power exhauster 2 Maxitrol EXA STAR modulating

gas valve 3 Main combination gas valve

(hidden behind Item #5)

4 High limit control 5 Solid state ignition control board 6 Valve state relay to Carel controller 7 Not applicable 8 Not Applicable

9 Vent differential pressure proving switch 10 Direct spark ignitor 11 Manifold tee pressure tap

12 Flame sensor 13 Manifold piping with gas orifices 14 Condensate drain float switch

90% Efficiency Option (Digit 18 = U or V)

25MCP15-500.7

START-UP PROCEDURE - CONTINUED

Figure 26.1 - Gas Heat Option Gas Controls - D-Cabinet Sized Units - 800,000 Btu/hr and Smaller (81% Eff)

Master FurnaceSlave Furnace (Opposite Side of Cabinet)

1 Power exhauster 2 Maxitrol EXA STAR modulating gas valve 3 Main combination gas valve 4 High limit control (hidden behind piping as shown) 5 Solid state ignition control board 6 Furnace control board

7 Vent differential pressure proving switch 8 Direct spark ignitor 9 Manifold pressure tap on manifold tee 10 Flame sensor 11 Manifold piping with gas orifices 12 Heat exchanger tube drain tray with drain line

26 MCP15-500.7

START-UP PROCEDURE - CONTINUED

Figure 27.1 - Gas Heat Option Gas Controls - D-Cabinet Sized Units - 900,000 Btu/hr and Larger (81% Eff)

Slave Furnace “B” k

Master Furnace k

Stacked Master/Slave Furnaces jStacked Slave Furnaces (Opposite Side of Cabinet) j

j Refer to Figure 23.3 for location of furnace positions. k Refer to Figure 26.1 for idenfication of furnace

components.

Slave Furnace “A” k

Slave Furnace “C” k

j Refer to Figure 23.3 for location of furnace positions. k Refer to Figure 26.1 for idenfication of furnace

components.

27MCP15-500.7

START-UP PROCEDURE - CONTINUED

THE FOLLOWING SECTION APPLIES ONLY TO B-CABINET SIZED

REVIEW

BEFORE

PROCEEDING

Energy Recovery Exhaust Option

UNITS WITH OPTIONAL ENERGY RECOVERY EXHAUST OPTION

(MODEL NOMENCLATURE DIGIT 6=B AND DIGIT 21=A, B, OR C).

IF THE UNIT DOES NOT HAVE THIS OPTION, SKIP TO PAGE 30.j

j If the unit is a C-cabinet size and has energy recovery exhaust, refer to the latest revision of literature #MCP15-520 for the

Start-Up Procedure for the Model ERM Energy Recovery Module.

1. The power supply wiring for the Energy Recovery Section comes from a single point power connection on the unit. Disconnect power supply at model MPR before making wiring connections to prevent electrical shock and equipment damage.

2. For units equipped for dual power supply sources, both sources of power must be disconnected to prevent electrical shock and equipment damage.

WARNING

IMPoRtANt

1. On units with the electric preheat option, to prevent premature heat exchanger failure, check to be sure the blower has been set to deliver the proper airflow for the application. Refer to page 17 for Blower Adjustments.

2. The exhaust fan is not designed for high temperature or smoke control exhaust applications. Exhaust air temperature must not exceed 104°F. Operating the exhaust fan above 104°F will result in failure of the exhaust fan.

1. Turn off power to the unit at the disconnect switch. If equipped with gas heating option, turn all hand gas valves to the “OFF” position.

2. For units equipped for dual power supply sources, both sources of power must be disconnected to prevent electrical shock and equipment damage.

3. Open the power compartment, controls compartment, and blower access doors. Refer to Figure 29.1 for location of doors and internal components.

4. Check that the supply voltage matches the unit supply voltage listed on the Unit Serial 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.

5. Check that fuses or circuit breakers are in place and sized correctly.

6. Check to see that there are no obstructions to the intake and discharge of the unit.

7. Check the belt tension and sheave alignment for the exhaust blower.

8. Most motors are permanently lubricated for long life and are identified as such on the motor nameplate. Most blower bearings are permanently lubricated as well, except for pillow block bearings or those identified with grease fittings. For motors or blower bearings that are not permanently lubricated, lubricate according to the manufacturer’s instructions.

9. Check to make sure that all filters are in place and that they are installed properly according to direction of air flow.

10. Perform a visual inspection of the unit to make sure no damage has occurred during installation.

11. Turn on power to the unit at the disconnect switch. Note: The unit includes a blower door switch that is factory installed inside the blower section door on the access side of the unit. When the blower section door is opened, the switch is opened and interrupts power to the low voltage circuit and de-energizes the motor starter that controls blower motor operation.

12. Check the Modine Control System controller and exhaust fan blower motor for electrical operation. If this does not function, recheck the wiring diagram. Check to insure that none of the Control Options have tripped.

13. Check to make sure that the economizer wheel bypass damper (if equipped) 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 insufficient air will be delivered 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. 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. Check all legs to insure system is balanced.

19. Check that the energy recovery wheel rotates. The wheel is factory set to rotate at approximately 20RPM to maximize latent heat transfer.

20. Check the energy recovery wheel voltage and amp draw to make sure it does not exceed the motor nameplate rating.

28 MCP15-500.7

UNIT COMPONENT IDENTIFICATION / LOCATION

Figure 29.1 - Controls Cabinet - Energy Recovery Section (B-Cabinet only, if equipped) j

786

2 (S) Controls compartment with side wiring entrance

3 (S) Power distribution block

4 (S) Carel pCOxs microprocessor controller

5 (O) Exhaust fan motor starter (unless VFD controlled, see #19)

6 (S) Exhaust fan motor circuit breaker

7 (S) Energy recovery wheel drive motor circuit breaker

8 (S) Energy recovery wheel drive motor motor starter

9 (S) High and low voltage wiring terminal strip with ground

terminals

10 (O) Exhaust air filters

11 (O) Exhaust air filters pressure drop switch

12 (S) Energy recovery wheel

13 (O) Energy recovery wheel pressure drop switch

14 (O) Energy recovery wheel electric preheat assembly

with control compartment

j Location of components is typical, but may change depending on the unit configuration.

15 (S) Outside air filters

16 (O) Outside air filters pressure drop switch

17 (S) Blower door switch

18 (S) Outside air enthalpy sensor

19 (O) Exhaust fan variable frequency drive (unless motor

20 (S) Exhaust fan motor

21 (S) Exhaust fan plenum fan

22 (S) Exhaust fan belt drive/auto belt tensioner access (access

23 (O) Inlet hood

24 (S) Exhaust hood (not pictured)

25 (O) Economizer bypass damper actuator compartment

26 (O) Energy recovery wheel rotation detection sensor

(not pictured)

(S) = standard (O) = optional

starter controlled, see #5)

door removed)

29MCP15-500.7

UNIT COMPONENT IDENTIFICATION / LOCATION

ALL FIGURES ON THIS PAGE ARE FOR B- AND C-CABINET SIZED UNITS

Figure 30.1 - Blower/Evaporator/Filter/Damper Sections j Figure 30.2 - Condenser Section j

8910

20 21

1 (O) GFCI convenience outlet (not shown here, refer to Figure 24.1)

2 (S) Blower door switch

3 (S) Airflow proving switch

4 (S) Supply fan motor with direct drive fan

5 (O) Hot gas reheat circuit shut-off valves (one located in controls compartment

for C-Cabinet sized units)

6 (S) Electronic expansion valve

7 (S) Refrigeration circuit sight glass

8 (O) Hot gas reheat coil

9 (S) Distributor and distributor piping (not all distributor tubes shown)

10 (S) High capacity evaporator coil

11 (O) 4" secondary filters, MERV 13 or 16

12 (S) 2" primary filters, MERV 10 (standard), 13, or 15

13 (O) Dirty filter pressure switch (not shown)

14 (S/O) Outside air damper (standard on units with outside air)

15 (S/O) Modulating damper actuator (standard on units with outside air)

16 (S) Mixed air temperature sensor (standard on all units with outside and return air dampers)

17 (S) Outside air enthalpy sensor

18 (O) Return air damper

19 (O) Modulating damper actuator

20 (O) Return air enthalpy sensor

21 (O) Return air smoke detector

22 (S) Evaporator drain pan drain connection

23 (O) Gas or electric heat module (gas shown)

24 (O) Gas heating high limit control (standard if gas heat)

25 (O) Gas heating power exhauster outlet (standard if gas heat)

26 (O) Gas heat auxiliary electric heat (not pictured)

1 (S) Condenser fan housing

2 (S) Condenser fan motors

3 (S) Refrigerant filter/dryer assembly

4 (S) Liquid line pressure transducer

5 (S) PF™ aluminum microchannel coils

6 (S) Schraeder valve pressure test port

(S) = standard (O) = optional

j Pictured is the C-Cabinet sized unit. Component

locations are similarly placed on the B-Cabinet sized unit. Location of components is typical, but may change depending on the configuration of the unit.

Figure 30.3 - Optional Data Port k

(S) = standard (O) = optional

30 MCP15-500.7

k Pictured is the OPTIONAL weatherproof RJ-11 jack for

connection of the Remote User Interface Module (optional accessory) to the unit to allow real-time diagnostics without opening the cabinet or shutting the unit off.

UNIT COMPONENT IDENTIFICATION / LOCATION

ALL FIGURES ON THIS PAGE ARE FOR D-CABINET SIZED UNITS

Figure 31.1 - Compressor/Condenser/Blower/Evaporator/Filter/Damper Sections j

1. (S) Blower door switch

2. (S) Airflow proving switch (not shown, located on opposite side)

3. (S) Direct drive supply fan(s)/motor(s)

4. (O) Hot gas reheat valves

4A. Circuit #1 and #2 shut-off valves

4B. Circuit #1 and #2 3-way modulating valves

5. (S) Electronic expansion valves

6. (S) Refrigeration circuit sight glasses

7. (O) Hot gas reheat coil

8. (S) Distributor and distributor piping (not all distributor tubes shown)

9. (S) High capacity evaporator coil

10. (O) 4" secondary filters, MERV 13 (not shown)

11. (S) 2" primary filters, MERV 10 (standard), 13, or 15

12. (O) Dirty filter pressure switch (not shown)

13. (S/O) Outside air damper (standard on units with outside air)

14. (S/O) Damper actuator (standard on units with outside air)

15. (S/O) Mixed air temperature sensor (standard on units with outside and return air dampers)

16. (S) Outside air enthalpy sensor

17. (O) Return air damper

18. (O) Modulating damper actuator

19. (O) Return air enthalpy sensor

20. (O) Return air smoke detector

21. (S) Evaporator drain pan drain connection

22. (O) Gas or electric heat module (gas shown)

23. (O) Gas heat auxiliary electric heat (not pictured)

24. (O) Gas supply connection point

25. (S) Condenser fans/motors

26. (S) Refrigerant filter/dryer assembly (located behind panel)

27. (S) Liquid line pressure transducer

28. (S) PF™ aluminum microchannel coils (one displayed clear for purposes of providing condenser fan/motor detail)

29. (S) Schraeder valve pressure test ports

30. (S) Tandem Compressor Set #1 (Digital Modulating-On/Off)

31. (S) Tandem Compressor Set #2 (On/Off-On/Off)

32. (S) Power Cabinet (refer to page 35)

33. (O) Deadfront Disconnect Switch Handle

Standard (O) = Optional

j Location of components is typical, but may change depending on the configuration of the unit.

31MCP15-500.7

UNIT COMPONENT IDENTIFICATION / LOCATION

Figure 32.1 - Controls Cabinet - B-Cabinet Sized Units j

6 6

1 Not applicable

2 (S) Condenser fan motor circuit breakers

3 (O) Hot gas reheat circuit shut-off valves

(not shown, located in coil compartment)

4 (O) Hot gas reheat modulating valves

5 Not applicable

6 (S) Tandem digital scroll compressor set

(7 ton nominal units feature a single modulating digital compressor, all others are tandem)

7 (S) Carel EVD superheat/electronic expansion valve controller

8 (S) Carel microprocessor controller (main)

9 (S) Carel Ultracap for EVD controller

10 (S) Low voltage wiring terminal strip with ground terminals

11 (S) Low voltage wiring channels

12 (S) Low voltage transformer for Carel microprocessor

controller (behind item 33)

13 Not applicable

14 (S/O) Double pole, double throw relay(s)

15 (S) High voltage wiring channels

16 (O) Supply voltage/phase monitor

17 (S) Condenser fan variable frequency drive circuit breaker

(not pictured, only applies to Model Digit 11=A or B)

18 (O) Supply fan variable frequency drive circuit breaker

7 9

18 22 23

27 28

2 2 2 19

19 (O) Power exhaust fan contactor/variable frequency drive

circuit breaker

20 (S) Main controls step-down transformer primary circuit

breaker

21 (O) Gas heating circuit step-down transformer primary circuit

breaker

22 (O) Convenience outlet step-down transformer primary circuit

breaker (if factory powered)

23 (O) Convenience outlet step-down transformer secondary

circuit breaker (if factory powered)

24 (S) Main controls step-down transformer secondary circuit

breaker

25 (S) High voltage wiring terminal strip with ground terminals

26 (S) High voltage power distribution block

27 (S) Compressor #1 contactor

28 (S) Compressor #2 contactor

29 (S) Condenser fan variable frequency drive

(not pictured, only applies to Model Digit 11=A or B)

30 (O) Supply fan variable frequency drive

31 (O) Gas heating circuit step-down transformer (behind item 33)

32 (O) Factory powered convenience outlet disconnect switch

33 (O) Main unit deadfront disconnect

(S) = standard (O) = optional

j Location of components is typical, but may change depending on the configuration of the unit.

32 MCP15-500.7

UNIT COMPONENT IDENTIFICATION / LOCATION

Figure 33.1 - Controls Cabinet - C-Cabinet Sized Units j For units where unit serial number Digit 12=2 (Carel EVD Superheat Controller)

6 6

1 (S) High voltage power distribution block

2 (S) Condenser fan motor circuit breakers (qty. 2 on 15 ton,

3 on 20-30 ton)

3 (O) Hot gas reheat circuit shut-off valve

(not shown, located in coil compartment)

4 (O) Hot gas reheat modulating valves

5 Not applicable

6 (S) Tandem digital scroll compressor set

7 (S) Carel EVD superheat/electronic expansion valve controller

with Carel Ultracap

8 (S) Carel microprocessor controller (main)

9 (S) Carel microprocessor controller (expansion module)

10 (S) Low voltage wiring terminal strip with ground terminals

11 (S) Low voltage wiring channels

12 (S) Low voltage isolation transformer for Carel microprocessor

controller

13 Not Applicable

14 (S/O) Double pole, double throw relay(s)

(ex: smoke detector interlock, exhaust fan interlock, etc.)

15 (S) High voltage wiring channels

16 (O) Supply voltage/phase monitor

17 (S) Condenser fan variable frequency drive circuit breaker

18 (O) Supply fan variable frequency drive circuit breaker

2 2 217 20 21 25

78 9

19 (O) Power exhaust fan contactor/variable frequency drive

circuit breaker

20 (S) Main controls step-down transformer primary circuit

breaker

21 (O) Gas heating circuit step-down transformer primary and

secondary circuit breakers

22 (O) Convenience outlet step-down transformer primary

circuit breaker (if factory powered)

23 (O) Convenience outlet step-down transformer secondary

circuit breaker (if factory powered)

24 (S) Main controls step-down transformer secondary circuit

breaker

25 (S) High voltage wiring terminal strip with ground terminals

26 (S) Compressor crankcase heater circuit breaker

27 (S) Compressor contactors

28 (O) Condensing gas heating strip heater contactor

29 (S) Condenser fan variable frequency drive

30 (S) Supply fan motor starter

(O) Supply fan variable frequency drive

31 (S) Solid state relay for Carel controller

32 (O) Factory powered convenience outlet disconnect switch

33 (O) Main unit deadfront disconnect

34 (O) Auxiliary / Supplementary electric heat circuit breaker

(S) = standard (O) = optional

j Location of components is typical, but may change depending on the configuration of the unit. For units where unit serial number Digit 12=1 (Emerson EC3

Superheat Controller), refer to previous version Installation & Service Manual MCP15-500.6 for location of components.

33MCP15-500.7

UNIT COMPONENT IDENTIFICATION / LOCATION

Figure 34.1 - Controls Cabinet - D-Cabinet Sized Units j

1. (O) Remote shutdown relay (CR1)

2. (O) Supply fan enable relay (CR4) [for units with two supply fan VFD’s]

3. (S) Carel EVD Ultracap - Circuit #1

1 3 4 5

7 8

9 10

4. (S) Carel EVD Ultracap - Circuit #2

5. (S) Low voltage terminal strip

6. (S) Controls secondary circuit breaker (CB5)

7. (O) 4-pole relays

8. (S) Low voltage terminal strip

9. (S) Solid state relay unloader (SSR1)

10. (S) Carel PCO5+ microprocessor controller

11. (S) Carel PCOe microprocessor controller (expansion module)

12. (S) Carel EVD electronic expansion valve controller - Circuit #1

13. (S) Carel EVD electronic expansion valve controller - Circuit #2

14. (S) Low voltage terminal strip

15. (O) GFCI convenience outlet

(S) = standard (O) = optional

11 121413

j Location of components is typical, but may change depending on the configuration of the unit.

34 MCP15-500.7

UNIT COMPONENT IDENTIFICATION / LOCATION

Figure 35.1 - Power Cabinet - D-Cabinet Sized Units j

9 10

7c7b7a 7d

1. (O) Gas Heat Control Transformer Secondary Circuit Breaker

2. (O) Wiring Terminals for Item #1

3. (O) Phase Monitor Relay

4. (O) Gas Heat Control Transformer

5. (S) 24V Control Transformer

6. (O) Auxiliary Electric Heat (Gas Heat Option) Fuses

7. (O) Powered GFCI Convenience Outlet Option consisting of:

a. Disconnect Switch

b. Transformer Primary Fuses

c. Secondary Circuit Breaker

d. Terminal Strip

e. Transformer

f. Convenience Outlet Junction Box (outlet accessible from

Low Voltage Control Cabinet (see Figure 34.1))

8. (S) Main High Voltage Power Distribution Block

9. (O) Supply Fan VFD #2 Fuses (dual blower 15 or 20HP only)

10. (S) Compressor Power Distribution Block

11. (S) Supply Fan VFD #1 Fuses

12. (S) Compressor Circuit Breakers

13. (S) Compressor Contactors

21 22

24 25

26 27

14. (O) Main Factory Mounted Disconnect Switch

15. (S) Supply Fan Power Distribution Block (dual blower

1-10HP)

16. (S) Supply Fan VFD #1 (not pictured is Supply Fan VFD #2

for dual blower 15 or 20HP)

17. (S) Supply Fan Overloads (dual blower 1-10HP)

18. (S) Ground Lug

19. (S) Main Ground Bus Bar

20. (S) Sub Feeder Fuses

21. (S) Terminal Strip for Power Distribution

22. (S) Ground Terminal Blocks

23. (S) Condenser Fan Fuses and Bus Bar

24. (S) Compressor Crankcase Heater Fuses

25. (S) Control Transformer Primary Fuses

26. (O) Gas Heat Control Transformer Primary Fuses

27. (O) Phase Monitor Relay Fuses

28. (S) Cabinet Cooling Device

(S) = standard (O) = optional

j Location of components is typical, but may change depending on the configuration of the unit.

35MCP15-500.7

DIMENSIONS - B-CABINET SIZE UNIT (NO ENERGY RECOVERY)

Figure 36.1 - Unit Dimensions (inches)

CONDENSING SECTION

FAN QUANTITY:

(2) FOR 7 AND 10 TON UNITS

(3) FOR 13 , 15, AND 20 TON UNITS

(4) 1.5" LIFTING EYE BOLTS

(EACH CORNER OF UNIT)

ACCESSORY RAINHOOD

AND BIRDSCREEN

(FIELD INSTALLED ACCESSORY )

55.90

6.93

71.90

64.97

CONDENSING

SECTION

ACCESS PANEL

(ALSO OTHER SIDE)

85.78

54.6031.18

COMPRESSOR

COMPARTMENT

ACCESS DOOR

GAS/ELECTRIC

HEAT (OPTION) COMPARTMENT ACCESS DOORS

54.00

(BASE)

1.33 100.25

CONTROLS

COMPARTMENT

ACCESS DOOR

APPROXIMATE AREA

FOR SIDE ELECTRICAL

SERVICE ENTRANCE

(refer to Warning label

on unit for exact location)

APPROXIMATE AREA

FOR SIDE GAS

SERVICE ENTRANCE

(refer to Warning label

on unit for exact location)

SUPPLY AIR BLOWER

& EVAPORATOR/

HOT GAS REHEAT COIL

ACCESS DOOR

EVAPORATOR &

HOT GAS REHEAT COIL

SERVICE ACCESS PANEL

100.00 (BASE)

133.75

FILTER & DAMPERS

ACCESS DOOR

1" NPT EVAP

COIL DRAIN

PAN PIPE

CONNECTION

32.17

36 MCP15-500.7

DIMENSIONS - B-CABINET UNIT BASE/ROOF CURB (NO ENERGY RECOVERY)

(CONDENSING FURNACES ONLY)

SUPPLY AIR

OPENING

LOCATION

RETURN AIR

OPENING

LOCATION

RETURN AIR DUCT

CONNECTOR ACCESSORY

(OPTIONAL)

SUPPLY AIR DUCT

CONNECTOR ACCESSORY

(OPTIONAL)

10.62 28.25 36.36 14.00

35.00

44.25

INSIDE

1.751.03

1.03

1.75

8.23

3.22

47.75

93.75

90.25

INSIDE

1.12

14.0 OR 24.0

SEE SCHEDULE

40.00

Figure 37.1 - Unit Base Dimensions (inches)

100.00

UNIT ACCESS

SIDE

95.22

2.39

2.00" DIA. GAS FURNACE PIPING HOLE

(IF EQUIPPED)

1.75" DIA.

FURNACE CONDENSATE

DRAIN LINE HOLE

2.00" DIA. ELECTRICAL POWER PIPING HOLES

2.39

1.37

9.76

10.50

5.50

6.78

CONDENSING

SECTION SIDE

LANDING AREA

FOR ROOF CURB

INSIDE BASE ASSEMBLY DETAIL

VIEW AS VIEWED FROM SIDE

Figure 37.2 - Roof Curb Dimensions (inches)

10.73

SUPPLY AIR

OPENING

3.50

28.25 36.36 14.0013.11

35.00

2.39

40.00

BASE ASSEMBLY AS

VIEWED FROM BOTTOM

5.72

RETURN/ EXHAUST

AIR

OPENING

(if applicable)

3.50

2.39

49.22

54.00

Table 37.1 - Roof Curb Weight (approx) - lbs.

Section Description Weight

14” - Insulated 174

Roof Curb

14” - Uninsulated 179

24” - Insulated 268

24” - Uninsulated 273

37MCP15-500.7

DIMENSIONS - B-CABINET SIZE UNIT (WITH ENERGY RECOVERY)

Figure 38.1 - Unit Dimensions (inches)

71.89

6.93

64.96

(ALSO OTHER SIDE)

31.30 54.63

CONDENSING

SECTION

ACCESS PANEL

85.93

COMPRESSOR

COMPARTMENT

ACCESS DOOR

GAS/ELECTRIC

HEAT (OPTION) COMPARTMENT ACCESS DOORS

54.00 (BASE)

CONDENSING SECTION

FAN QUANTITY:

(2) FOR 7 AND 10 TON UNITS

(3) FOR 13, 15, AND 20 TON UNITS

(4) 1" LIFTING ANGLES

(EACH CORNER)

CONTROLS

COMPARTMENT

ACCESS DOOR

APPROXIMATE AREA

FOR SIDE ELECTRICAL

SERVICE ENTRANCE (refer to Warning label

on unit for exact location)

APPROXIMATE AREA

FOR SIDE GAS SERVICE ENTRANCE (refer to Warning label

on unit for exact location)

4.00

43.72

SUPPLY AIR BLOWER

& EVAPORATOR/

HOT GAS REHEAT COIL

ACCESS DOOR

EVAPORATOR &

HOT GAS REHEAT COIL

SERVICE ACCESS PANEL

(2) 1" LIFTING ANGLES

(EACH SIDE)

FILTER & DAMPERS

ACCESS DOOR

1" NPT EVAP

CONNECTION

ENERGY RECOVERY

WHEEL ECONOMIZER

BYPASS DAMPER

ACCESSORY RAINHOOD

AND BIRDSCREEN

(FIELD INSTALLED ACCESSORY)

ENERGY RECOVERY

EXHAUST AIR

RAINHOOD

204.30

168.38 32.16

ENERGY RECOVERY

WHEEL & CONTROLS

COMPARTMENT

ACCESS DOORS

ACCESS PANEL

COIL DRAIN

PAN PIPE

168.00

EXHAUST FAN BELT DRIVE &

AUTO BELT TENSIONER

4.00

38 MCP15-500.7

DIMENSIONS - B-CABINET UNIT BASE/ROOF CURB (W/ ENERGY RECOVERY)

Figure 39.2 - Unit Base Dimensions (inches)

176.00

172.50

102.25

UNIT ACCESS

SIDE

168.00

2.39

1.37

9.76

10.50

5.50

6.78

CONDENSING SECTION SIDE

LANDING AREA

FOR ROOF CURB

10.73

SUPPLY AIR

OPENING

3.50

28.25 36.36 14.0013.11

35.00

104.19

BASE ASSEMBLY AS

VIEWED FROM BOTTOM

2.00" DIA.

GAS FURNACE

PIPING HOLE

(IF EQUIPPED)

CONDENSATE

DRAIN LINE HOLE

(CONDENSING

FURNACES ONLY)

ELECTRICAL

PIPING HOLES

INSIDE BASE ASSEMBLY DETAIL

VIEW AS VIEWED FROM SIDE

1.75" DIA.

FURNACE

2.00" DIA.

POWER

2.39

Figure 39.2 - Unit Roof Curb Dimensions (inches)

1.75

1.03

40.00

163.22

RETURN/

EXHAUST

AIR

OPENING

1.03

5.72

3.50

2.39

49.22

2.39

43.72

54.00

1.75

47.75

14.0 OR 24.0

SEE SCHEDULE

SUPPLY AIR

OPENING

LOCATION

10.62 28.25 36.36 14.00

8.23

CONNECTOR ACCESSORY

35.00

SUPPLY AIR DUCT

(OPTIONAL)

Table 39.1 - Roof Curb Weight (approx) - lbs.

Section Description Weight

14” - Insulated 259

Roof Curb

14” - Uninsulated 266

24” - Insulated 394

24” - Uninsulated 401

RETURN/

EXHAUST AIR

OPENING

LOCATION

3.22

161.75

158.25 INSIDE

RETURN AIR DUCT

CONNECTOR ACCESSORY

(OPTIONAL)

40.00

44.25 INSIDE

1.75

1.12

39MCP15-500.7

DIMENSIONS - C-CABINET SIZE UNIT

Figure 40.1 - Unit Dimensions (inches)

CONDENSING SECTION FAN QUANTITY:

(2) FANS FOR 15 TON UNIT

(3) FANS FOR 20 THRU 30 TON UNITS

(4) 1.50" LIFTING EYE BOLTS

(EACH CORNER OF UNIT)

101.53

60.11

107.12

ACCESSORY RAINHOOD

AND BIRDSCREEN

(FIELD INSTALLED ACCESSORY)

148.49

65.92

75.66

CONDENSING

ACCESS PANEL

(also other side)

COMPRESSOR

COMPARTMENT

ACCESS DOOR

SECTION

64.6136.91

CONTROLS COMPARTMENT ACCESS DOOR

64.28

(BASE)

GAS/ELECTRIC

HEAT (OPTION) COMPARTMENT ACCESS DOORS

4.00

APPROXIMATE AREA FOR SIDE ELECTRIC SERVICE ENTRANCE (refer to Warning label

70.14

on unit for exact location)

APPROXIMATE AREA

SERVICE ENTRANCE (refer to Warning label

on unit for exact location)

FOR SIDE GAS

SUPPLY AIR BLOWER

& EVAPORATOR/

HOT GAS REHEAT COIL

ACCESS DOOR

EVAPORATOR &

HOT GAS REHEAT COIL

SERVICE ACCESS PANEL

74.34

111.71

FILTER & DAMPERS

ACCESS DOOR

111.28

(BASE)

1" NPT EVAP

COIL DRAIN

PAN PIPE

CONNECTION

36.78

31.96

40 MCP15-500.7

DIMENSIONS - C-CABINET SIZE UNIT BASE / ROOF CURB

SUPPLY AIR

OPENING

LOCATION

RETURN/

EXHAUST AIR

OPENING

LOCATION

(if applicable)

1.12

14.0 OR 24.0

SEE SCHEDULE

104.75

21.50 36.75 21.0019.90

101.25

INSIDE

50.0054.25

INSIDE

1.75

2.12

2.132.13

2.12

57.75

1.75

Figure 41.1 - Unit Base Dimensions (inches)

2.00" DIA.

ELECTRICAL POWER

BOTTOM PIPING HOLES

PIPING ENTRANCE

(UNITS WITH HOT

WATER HEAT ONLY)

HOT WATER

2.00" DIA.

ELECTRICAL POWER

BOTTOM PIPING HOLES

UNIT ACCESS

SIDE

106.22 2.53

2.53

9.24

17.09

11.93

DETAIL "A" FOR

UNITS WITH HOT

WATER HEAT

4.09

2.53

6.60

WATER HEAT ONLY)

HOT WATER PIPING EXIT

(UNITS WITH HOT

LANDING AREA

1.37

FOR ROOF CURB

2.00" DIA. GAS

FURNACE BOTTOM

PIPING HOLE

(UNITS WITH

GAS HEAT ONLY)

1.25" DIA. FURNACE

CONDENSATE DRAIN

LINE HOLES

(UNITS WITH

CONDENSING

FURNACES ONLY)

2.53

SEE DETAIL "A" FOR DIMENSIONS FOR UNITS WITH HOT WATER HEAT

9.24

17.07

11.93

Figure 41.2 - Roof Curb Dimensions (inches)

4.61

3.30

SUPPLY AIR

3.30

22.38 36.75

OPENING

CONDENSING SECTION SIDE

21.50

50.00

4.61

BASE ASSEMBLY AS

VIEWED FROM BOTTOM

LOOKING UP

111.28

BASE ASSEMBLY AS

VIEWED FROM SIDE

50.00

RETURN/

EXHAUST AIR

OPENING

(if applicable)

21.00

4.61

59.22

4.61

Table 41.1 - Roof Curb Weight (approx) - lbs.

Section Description Weight

Roof Curb

14” - Insulated 210

14” - Uninsulated 205

24” - Insulated 318

24” - Uninsulated 310

41MCP15-500.7

DIMENSIONS - D-CABINET SIZE UNIT

180.00 (BASE)

EVAPORATOR &

HOT GAS REHEAT COIL

SERVICE ACCESS PANEL

1-1/2" NPT EVAP

COIL DRAIN

PAN PIPE

CONNECTION

137.16

SUPPLY AIR

BLOWER DOOR

FILTER & DAMPERS

ACCESS DOOR

180.63 40.36

29.45

CONDENSING

SECTION

COMPRESSOR

COMPARTMENT

ACCESS DOOR

HIGH VOLT CONTROLS

COMPARTMENT

ACCESS DOOR

GAS/ELECTRIC

HEAT (OPTION) COMPARTMENT ACCESS DOORS

97.60

104.25

(LUGS)

GAS SERVICE

ENTRANCE

GAS SERVICE

ENTRANCE

(4) 1.00" LIFTING LUGS

(EACH CORNER OF UNIT)

(4) TIE DOWN POINTS

(EACH CORNER OF UNIT)

APPROXIMATE AREA

FOR SIDE ELECTRIC

SERVICE ENTRANCE

(refer to Warning label

on unit for exact location)

LOW VOLT CONTROLS

COMPARTMENT

ACCESS DOOR

EVAPORATOR &

HOT GAS REHEAT COIL

SERVICE ACCESS PANEL

100.51

100.75

(BASE)

CONDENSING SECTION FAN QUANTITY:

(4) FANS FOR 30 AND 40 TON UNIT

(6) FANS FOR 52 AND 60 TON UNITS

103.07

ACCESSORY RAINHOOD

AND BIRDSCREEN

(FIELD INSTALLED ACCESSORY)

43.56

(LUGS)

120.94

(LUGS)

Figure 42.1 - Unit Dimensions (inches)

42 MCP15-500.7

DIMENSIONS - D-CABINET SIZE UNIT BASE / ROOF CURB

Figure 43.1 - Unit Base Dimensions (inches)

180.00

172.00

4.00

18.26

SUPPLY AIR

4.00

21.89 34.24

4.00

INSIDE BASE ASSEMBLY DETAIL

VIEW AS VIEWED FROM SIDE

OPENING

14.38

LOW VOLT CONTROL PANEL ON THIS SIDE

2.11

LANDING AREA

FOR ROOF CURB

Figure 43.2 - Roof Curb Dimensions (inches)

60.12

BASE ASSEMBLY AS

VIEWED FROM BOTTOM

1.75

8.52

RETURN AIR OPENING (IF

SELECTED)

3.52

4.3925.00

92.75

1.25

100.75

1.75

91.75

14.0 OR 24.0

SEE SCHEDULE

SUPPLY AIR

OPENING

LOCATION

34.2519.64

21.81 33.40

CONNECTOR ACCESSORY

12.12

60.12

16.00

SUPPLY AIR DUCT

(OPTIONAL)

171.00

167.50

INSIDE

171.50

88.25 INSIDE

86.48

1.75

RETURN AIR DUCT

CONNECTOR ACCESSORY

(OPTIONAL)

1.75

RETURN AIR OPENING (IF

SELECTED)

25.00 2.14

6.25

4.3124.15

1.12

43MCP15-500.7

BASE MODEL WEIGHTS

Table 44.1 - Approximate Base Model Weight - (lbs.)

Section Description

MPR07 2377

MPR10 2489 40kW 174 174 328

MPR13 2570 60kW 185 185

MPR15 2585 2710 80kW 195 195 348

Base Unit

Dampers

Hot Gas

Reheat

Supply Air

Blower (Direct

Drive)

Motors

(most

common)

Power

Option

Deadfront

Disconnect

60A & 100A

200A & 400A

600A

None

MPR20 2685 2894 100kW 205 205

MPR26 2898 120kW 370

MPR30 2907 6464 160kW 390

MPR40 6656 200kW 410

MPR52 6862

MPR60 6862 200MBH 154

Fresh Air Only 40 45 200 250MBH 154

Fresh and Return Air 80 95 362 300MBH 234 256

MPR07 22 400MBH 234 308 308

MPR10 22 500MBH 308 308

MPR13 26 600MBH 313 468

MPR15 26 64 800MBH 468

MPR20 26 64 900MBH 616

MPR26 64 1000MBH 616

MPR30 64 70 1200MBH 936

MPR40 70 1400MBH 936

MPR52 80 1600MBH 936

MPR60 80 175 MBH - 94% 158

ANPL 11” 33 225 MBH - 94% 160

ANPL 12” 34 310 MBH - 94% 173

ANPA 12” 35 350 MBH - 90% 316

ANPA 14” 51 450 MBH - 90% 320

ANPA 16” 57 57

ANPA 16” Dual 114 40kW 328

ANPA 20” 97 97

ANPA 25” 163 28” Wheel 1002

ANPA 25” Dual 326 36” Wheel 1041

1HP 40 40 40 48” Wheel 1200

1-1/2HP 40 40 40

2HP 50 50 50 11” 114

3HP 80 80 80 16” 126

5HP 95 95 95 20” 148

7-1/2HP 160 160 160

10HP 220 220 220 1-1/2HP 40

15HP 310 310 310 2HP 50

Convenience

Outlet

None 5 5 5 7-1/2HP 160

None 10 10 10 20kW Nominal 164

None 15

None 0 0 0

Cabinet Size

B C D B C D

Section Description

20kW 164 164

Electric

150MBH 128

Heat Option



Natural Gas

Auxiliary Electric

Heat Adder

Energy Recovery

Wheel Section

Exhaust Air

Integral

Energy

Recovery

Wheel

Option 

j If equipped with the hot water heat option, please consult the Breeze

AccuSpec selection program for the option weight.

k For weights of Energy Recovery Module on C-Cabinet (if applicable), refer to

the latest revision of literature #MCP15-520.

l 20kW electric preheat is derated for 208V and 230V. m Auxiliary Electric Heat Adder is available for certain Natural Gas heat ratings

and is additive to the Natural Gas heat weight.

Blower

Motors

(most common)

Energy Wheel

Electric Preheat

20kW 164 164

None 0

1HP 40

3HP 80

5HP 95

None 0

Cabinet Size

 

44 MCP15-500.7

OPTION AND ACCESSORY PRESSURE DROP TABLES

Table 45.1 - Pressure Drop Data - B-Cabinet Sized Unit Supply Fan j

Feature

Evaporator

Coil

Unit

Hot Gas

Reheat Coil

2” Primary

Filters

4”

Secondary

Air

Control

Heat

Electric

150MBH

200MBH

250MBH

300MBH

Gas Heat

400MBH

150MBH

200MBH

250MBH

300MBH

400MBH

Gas Heat + Aux/ Supplemental Electric

2” MERV 10 OA Filters 0.01 0.02 0.03 0.03 0.04 0.05 0.06 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.15 0.16 0.17 0.18 0.20 0.21

Module

Energy Recovery

7 & 10 Ton 0.06 0.08 0.10 0.13 0.16 0.19 0.22 0.25 0.28 0.31 0.35 0.38 0.42 0.46 0.50 0.54 0.58 0.62 0.67 0.71 0.76

13, 15, & 20 Ton 0.05 0.05 0.07 0.09 0.11 0.13 0.15 0.18 0.20 0.22 0.25 0.27 0.30 0.33 0.36 0.39 0.42 0.45 0.48 0.51 0.55

7 & 10 Ton 0.01 0.01 0.01 0.02 0.02 0.02 0.03 0.03 0.03 0.04 0.04 0.04 0.05 0.05 0.06 0.06 0.06 0.07 0.07 0.08 0.08

13, 15, & 20 Ton 0.01 0.01 0.01 0.01 0.02 0.02 0.02 0.02 0.03 0.03 0.03 0.03 0.04 0.04 0.04 0.05 0.05 0.05 0.06 0.06 0.06

MERV 10 0.01 0.01 0.01 0.01 0.02 0.02 0.03 0.03 0.04 0.04 0.05 0.05 0.06 0.06 0.07 0.07 0.08 0.09 0.09 0.10 0.11

MERV 13 0.03 0.03 0.04 0.05 0.06 0.07 0.08 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.19 0.20 0.21 0.22

MERV 15 0.02 0.02 0.03 0.04 0.05 0.06 0.07 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.16 0.18 0.19 0.20 0.21

MERV 13 0.05 0.05 0.06 0.07 0.08 0.09 0.10 0.10 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18 0.19 0.21 0.22 0.23 0.24

MERV 16 0.02 0.03 0.03 0.03 0.04 0.04 0.05 0.05 0.06 0.06 0.07 0.07 0.08 0.08 0.09 0.09 0.10 0.10 0.11 0.12 0.12

Rainhood 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.02

Dampers 0.00 0.00 0.00 0.00 0.01 0.01 0.01 0.01 0.01 0.01 0.02 0.02 0.02 0.03 0.03 0.03 0.04 0.04 0.04 0.05 0.05

20kW 0.00 0.00 0.00 0.00 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.02

40kW - - 0.01 0.01 0.01 0.02 0.02 0.02 0.02 0.02 0.03 0.03 0.03 0.03 0.03 0.03 0.04 0.04 0.04 0.04 0.04

60kW - - - - 0.03 0.03 0.04 0.04 0.04 0.05 0.05 0.06 0.06 0.06 0.07 0.07 0.07 0.08 0.08 0.08 0.09

80kW - - - - - - - 0.04 0.04 0.05 0.05 0.06 0.06 0.06 0.07 0.07 0.07 0.08 0.08 0.08 0.09

High Temp Rise 0.03 0.03 0.04 - - - - - - - - - - - - - - - - - -

Low Temp Rise - - - 0.05 0.06 0.07 0.08 0.10 0.11

High Temp Rise - - 0.06 0.08 0.09 - - - - - - - - - - - - - - - -

Low Temp Rise - - - - - 0.10 0.11 0.13 0.16 0.18 0.21 0.24 0.27 0.31 0.34 0.38 - - - - -

High Temp Rise - - - - 0.09 0.11 0.14 - - - - - - - - - - - - - -

Low Temp Rise - - - - - - - 0.13 0.16 0.18 0.21 0.24 0.27 0.31 0.34 0.38 0.43 0.47 0.52 0.57 0.62

High Temp Rise - - - - - 0.07 0.08 0.09 0.11 - - - - - - - - - - - -

Low Temp Rise - - - - - - - - - 0.08 0.09 0.11 0.12 0.13 0.14 0.16 0.17 0.19 0.20 0.22 0.23

High Temp Rise - - - - - - - - 0.11 0.12 0.14 0.15 0.17 - - - - - - - -

Low Temp Rise - - - - - - - - - - - - - 0.13 0.14 0.16 0.17 0.19 0.20 0.22 0.23

175MBH - - - 0.10 0.13 0.16 0.19 0.22 0.26 0.30 0.34 0.39 0.44 0.49 0.54 0.59 0.65 - - - -

225MBH - - - - 0.13 0.16 0.19 0.22 0.26 0.30 0.34 0.39 0.44 0.49 0.54 0.59 0.65 0.71 0.78 0.84 0.91

310MBH - - - - - - - 0.17 0.20 0.23 0.25 0.28 0.32 0.35 0.38 0.42 0.46 0.49 0.53 0.58 0.62

High Temp Rise 0.03 0.04 0.04 - - - - - - - - - - - - - - - - - -

Low Temp Rise - - - 0.05 0.06 0.08 0.09 0.11 0.12 0.14 0.17 - - - - - - - - - -

High Temp Rise - - 0.07 0.08 0.10 - - - - - - - - - - - - - - - -

Low Temp Rise - - - - - 0.10 0.12 0.14 0.17 0.19 0.22 0.25 0.28 0.32 0.36 0.40 - - - - -

High Temp Rise - - - - 0.10 0.12 0.15 - - - - - - - - - - - - - -

Low Temp Rise - - - - - - - 0.14 0.17 0.19 0.22 0.25 0.28 0.32 0.36 0.40 0.44 0.49 0.54 0.59 0.64

High Temp Rise - - - -

Low Temp Rise - - - - - - - - - 0.09 0.11 0.12 0.13 0.14 0.16 0.17 0.19 0.20 0.22 0.23 0.25

High Temp Rise - - - - - - - - 0.12 0.13 0.15 0.16 0.18 - - - - - - - -

Low Temp Rise - - - - - - - - - - - - - 0.14 0.16 0.17 0.19 0.20 0.22 0.23 0.25

175MBH - - - 0.11 0.13 0.16 0.20 0.23 0.27 0.31 0.35 0.40 0.45 0.50 0.55 0.61 0.67 - - - -

225MBH - - - - 0.13 0.16 0.20 0.23 0.27 0.31 0.35 0.40 0.45 0.50 0.55 0.61 0.67 0.73 0.80 0.86 0.93

310MBH - - - - - - - 0.18 0.21 0.24 0.27 0.30 0.33 0.36 0.40 0.43 0.47 0.51 0.55 0.59 0.64

Electric Preheat 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01

28” Wheel 0.52 0.59 0.72 0.85 0.99 - - - - - - - - - - - - - - - -

36” Wheel - - 0.43 0.51 0.59 0.67 0.76 0.85 0.94 1.03 - - - - - - - - - - -

48” Wheel - - - - - 0.38 0.43 0.48 0.53 0.59 0.64 0.70 0.75 0.81 0.87 0.93 0.99 1.06 1.12 1.19 1.25

1111

1250

1500

1750

2000

2250

2500

2750

3000

3250

3500

3750

4000

4250

4500

4750

5000

5250

0.13 0.15 - - - - - - - - - -

- 0.07 0.09 0.10 0.12 - - - - - - - - - - - -

5500

5750

6000

Table 37.2 - Pressure Drop Data - Exhaust Fan j

Feature

2” MERV 10 RA Filters 0.01 0.02 0.03 0.03 0.04 0.05 0.06 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.15 0.16 0.17 0.18 0.20 0.21

28” Wheel 0.65 0.72 0.86 1.00 1.15 - - - - - - - - - - - - - - - -

ery Module

Energy Recov-

j Option and accessory static pressure drop data shown are approximate. Please consult the Breeze AccuSpec selection program for static pressure drop data at

conditions other than shown above.

36” Wheel - - 0.57 0.65 0.74 0.83 0.92 1.01 1.11 1.20 - - - - - - - - - - -

48” Wheel - - - - - 0.54 0.59 0.65 0.70 0.76 0.82 0.88 0.94 1.01 1.07 1.14 1.20 1.27 1.34 1.41 1.48

1111

1250

1500

1750

2000

2250

2500

2750

3000

3250

3500

3750

4000

4250

4500

4750

5000

5250

5500

5750

6000

45MCP15-500.7

OPTION AND ACCESSORY PRESSURE DROP TABLES

Table 46.1 - Pressure Drop Data - C-Cabinet Sized Unit Supply Fan jk

Unit

2” Primary

Filters

4” Secondary

Air

Control

Heat

Electric

Gas Heat

Gas Heat + Aux/ Supplemental Electric

Module

Energy Recovery

Feature

Evaporator Coil 0.11 0.13 0.15 0.16 0.18 0.20 0.21 0.23 0.25 0.27 0.29 0.32 0.36 0.40 0.44 0.49 0.53 0.58 0.62 0.67 0.87

Hot Gas Reheat Coil 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.06 0.06 0.07 0.08 0.08 0.09 0.10 0.11 0.13 0.18

MERV 10 0.02 0.02 0.02 0.03 0.03 0.03 0.04 0.04 0.04 0.05 0.05 0.06 0.07 0.07 0.08 0.09 0.10 0.11 0.11 0.12 0.16

MERV 13 0.06 0.06 0.07 0.08 0.08 0.09 0.09 0.10 0.11 0.11 0.12 0.13 0.15 0.16 0.17 0.19 0.20 0.22 0.23 0.25 0.31

MERV 15 0.05 0.05 0.06 0.07 0.07 0.08 0.08 0.09 0.10 0.10 0.11 0.12 0.14 0.15 0.16 0.18 0.19 0.21 0.22 0.24 0.30

MERV 13 0.08 0.08 0.09 0.10 0.10 0.11 0.11 0.12 0.13 0.13 0.14 0.15 0.17 0.18 0.19 0.21 0.22 0.24 0.25 0.27 0.33

MERV 16 0.03 0.04 0.04 0.05 0.05 0.06 0.06 0.06 0.07 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.15 0.16 0.17 0.19 0.25

Rainhood 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.02 0.02 0.02 0.02 0.02 0.04

Dampers 0.01 0.01 0.01 0.01 0.02 0.02 0.02 0.02 0.02 0.03 0.03 0.04 0.04 0.05 0.05 0.06 0.07 0.08 0.09 0.10 0.14

20kW 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.02 0.02 0.02 0.02 0.02

40kW 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.03 0.03 0.03 0.03 0.03 0.04 0.04 0.04 0.04 0.05 0.05 0.05 0.06

60kW 0.03 0.03 0.03 0.03 0.03 0.04 0.04 0.04 0.04 0.04 0.05 0.05 0.05 0.06 0.06 0.07 0.07 0.08 0.08 0.08 0.10

80kW 0.04 0.04 0.04 0.04 0.05 0.05 0.05 0.05 0.06 0.06 0.06 0.07 0.07 0.08 0.08 0.09 0.09 0.10 0.10 0.11 0.13

100kW - 0.04 0.04 0.04 0.05 0.05 0.05 0.05 0.06 0.06 0.06 0.07 0.07 0.08 0.08 0.09 0.09 0.10 0.10 0.11 0.13

300MBH 0.07 0.08 0.09 0.10 0.11 0.12 0.14 0.15 0.17 0.19 0.21 0.25 0.30 0.35 - - - - - - -

400MBH

500MBH

600MBH

350MBH

450MBH

400MBH

500MBH

600MBH

350MBH

450MBH

2” MERV 10 OA Filters 0.04 0.04 0.05 0.05 0.06 0.06 0.07 0.07 0.08 0.09 0.09 0.11 0.12 0.13 0.15 0.16 0.18 - - - -

High Temp Rise 0.09 0.10 0.11 0.13 0.14 - - - - - - - - - - - - - - - -

Low Temp Rise - - - - - 0.13 0.14 0.15 0.17 0.18 0.20 0.24 0.28 0.33

High Temp Rise - - - 0.13 0.14 0.16 0.18 0.19 0.21 0.23 - - - - - - - - - - -

Low Temp Rise - - - - - - - - - - 0.20 0.24 0.28 0.33 0.37 0.43 0.48 0.54 0.61 0.67 0.98

High Temp Rise - - - - - - 0.21 0.23 0.25 0.27 0.29 0.33 - - - - - - - - -

Low Temp Rise - - - - - - - - - - - - 0.37 0.42 0.46 0.51 0.56 0.61 0.66 0.71 0.94

High Temp Rise 0.14 0.16 0.18 0.21 0.23 - - - - - - - - - - - - - - - -

Low Temp Rise - - - - - 0.22 0.25 0.28 0.31 0.33 0.36 0.42 0.47 0.53 0.58 0.64 0.70 0.75 0.81 - -

High Temp Rise - - - 0.21 0.23 0.26 0.28 0.31 0.34 0.36 - - - - - - - - - - -

Low Temp Rise - - - - - - - - - - 0.36 0.42 0.47 0.53 0.58 0.64 0.70 0.75 0.81 0.87 1.09

300MBH 0.08 0.09 0.09 0.11 0.12 0.13 0.14 0.16 0.18 0.20 0.22 0.26 0.31 0.36 - - - - - - -

High Temp Rise 0.10 0.11 0.12 0.13 0.15 - - - - - - - - - - - - - - - -

Low Temp Rise - - - - - 0.13 0.15 0.16 0.18 0.19 0.21 0.25 0.29 0.34 0.39 0.44 0.50 0.56 0.62 - -

High Temp Rise - - - 0.13 0.15 0.17 0.18 0.20 0.22 0.24 - - - - - - - - - - -

Low Temp Rise - - - - - - - - - - 0.21 0.25 0.29 0.34 0.39 0.44 0.50 0.56 0.62 0.69 1.00

High Temp Rise - - - - - - 0.22 0.24 0.26 0.28 0.30 0.34 - - - - - - - - -

Low Temp Rise - - - - - - - - - - - - 0.39 0.43 0.48 0.52 0.57 0.62 0.68 0.73 0.96

High Temp Rise 0.14 0.17 0.19 0.21 0.24 - - - - - - - - - - - - - - - -

Low Temp Rise - - - - - 0.23 0.26 0.29 0.32 0.34 0.37 0.43 0.48 0.54 0.60 0.66 0.71 0.77 0.83 - -

High Temp Rise - - - 0.21 0.24 0.26 0.29 0.32

Low Temp Rise - - - - - - - - - - 0.37 0.43 0.48 0.54 0.60 0.66 0.71 0.77 0.83 0.88 1.12

Electric Preheat 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 - - - -

48” Wheel 0.50 0.55 0.60 0.65 0.70 0.76 0.81 0.86 0.92 0.98 1.03 1.15 - - - - - - - - -

58” Wheel 0.34 0.37 0.41 0.44 0.48 0.51 0.55 0.59 0.63 0.67 0.71 0.79 0.87 0.96 1.05 1.14 1.23 - - - -

3000

3250

3500

3750

4000

4250

4500

4750

5000

5250

5500

6000

6500

7000

7500

8000

8500

0.37 0.43 0.48 0.54 0.61 - -

0.35 0.37 - - - - - - - - - - -

9000

9500

10000

12000

Table 38.2 - Pressure Drop Data - Exhaust Fan j

Feature

2” MERV 10 RA Filters 0.04 0.04 0.05 0.05 0.06 0.06 0.07 0.07 0.08 0.09 0.09 0.11 0.12 0.13 0.15 0.16 0.18 - - - -

Module

Energy Recovery

j Option and accessory static pressure drop data shown are approximate. Please consult the Breeze AccuSpec selection program for static pressure drop data at

conditions other than shown above.

k If equipped with the hot water heat option, please consult the Breeze AccuSpec selection program for static pressure drop at design conditions.

48” Wheel 0.66 0.71 0.76 0.82 0.87 0.93 0.98 1.04 1.10 1.16 1.22 1.34 - - - - - - - - -

58” Wheel 0.50 0.53 0.57 0.61 0.65 0.68 0.72 0.77 0.81 0.85 0.89 0.98 1.07 1.16 1.26 1.36 1.46 - - - -

46 MCP15-500.7

3000

3250

3500

3750

4000

4250

4500

4750

5000

5250

5500

6000

6500

7000

7500

8000

8500

9000

9500

10000

12000

OPTION AND ACCESSORY PRESSURE DROP TABLES

Table 47.1 - Pressure Drop Data - D-Cabinet Sized Unit Supply Fan jk

Feature

Evaporator

Coil

Unit

Hot Gas

Reheat Coil

2” Primary

Filters

4” Secondary MERV 13 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.12 0.13 0.15 0.16 0.18 0.20 0.22 0.24

Air

Control

Electric Heat

400MBH Low Temp Rise 0.08 0.11 0.16 0.21 0.27 0.34 0.43 - - - - - - - -

500MBH

600MBH

800MBH

Gas Heat

900MBH High Temp Rise - - - 0.51 0.64 0.79 - - - - - - - -

1000MBH High Temp Rise - - - - 0.64 0.79 0.96 1.15 1.35 - - - - - -

1200MBH High Temp Rise - - - - - 0.53 0.63 0.73 0.84 0.96 1.09 1.22 - - -

1400MBH High Temp Rise - - - - - - - 0.73 0.84 0.96 1.09 1.22 - - -

1600MBH High Temp Rise - - - - - - - - 0.84 0.96 1.09 1.22 1.36 1.51 1.67

400MBH Low Temp Rise 0.11 0.15 0.20 0.26 0.33 0.41 0.50 - - - - - - - -

500MBH

600MBH

Gas Heat + Aux/

800MBH

Supplemental Electric

j Option and accessory static pressure drop data shown are approximate. Please consult the Breeze AccuSpec selection program for static

pressure drop data at conditions other than shown above.

30 & 40 Ton 0.17 0.24 0.32 0.41 0.51 0.62 0.73 0.86 0.99 - - - - - -

52 & 60 Ton - - - Future Future Future Future Future Future Future Future Future Future Future Future

30 & 40 Ton 0.05 0.06 0.09 0.11 0.13 0.16 0.19 0.22 0.26 - - - - - -

52 & 60 Ton - - - Future Future Future Future Future Future Future Future Future Future Future Future

MERV 10 0.01 0.02 0.03 0.04 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.14 0.15

MERV 13 0.05 0.07 0.08 0.10 0.12 0.13 0.15 0.17 0.19 0.21 0.23 0.25 0.27 0.30 0.32

MERV 15 0.02 0.03 0.04 0.06 0.07 0.08 0.10 0.11 0.13 0.15 0.17 0.19 0.21 0.23 0.25

Rainhood 0.00 0.00 0.00 0.00 0.01 0.01 0.01 0.01 0.01 0.01 0.02 0.02 0.02 0.02 0.03

Dampers 0.00 0.01 0.01 0.01 0.02 0.02 0.03 0.04 0.04 0.05 0.06 0.07 0.08 0.09 0.10

40kW 0.03 0.04 0.04 0.05 0.06 0.07 0.07 0.08 0.09 0.09 0.10 0.11 0.12 0.12 0.13

80kW 0.01 0.02 0.02 0.03 0.03 0.03 0.04 0.04 0.04 0.05 0.05 0.05 0.06 0.06 0.06

120kW 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.02 0.02 0.02 0.02 0.02 0.02 0.02

160kW - 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.02 0.02 0.02 0.02 0.02 0.02 0.02

200kW - - - 0.01 0.01 0.01 0.01 0.01 0.02 0.02 0.02 0.02 0.02 0.02 0.02

High Temp Rise 0.09 0.14 - - - - - - - - - - - - -

Low Temp Rise - - 0.16 0.21 0.27 0.34 0.43 0.52 0.62 - - - - - -

High Temp Rise - 0.13 0.17 - - - - - - - - - - - -

Low Temp Rise - - - 0.15 0.17 0.20 0.22 0.25 0.28 0.32 0.35 0.39 - - -

High Temp Rise - - 0.17 0.21 0.25 - - - - - - - - - -

Low Temp Rise - - - - - 0.20 0.22 0.25 0.28 0.32 0.35 0.39 0.42 0.46 0.51

High Temp Rise 0.12 0.18 - - - - - - - - - - - - -

Low Temp Rise - - 0.20 0.26 0.33 0.41 0.50 0.60 0.71 - - - - - -

High Temp Rise - 0.17 0.21 - - - - - - - - - - - -

Low Temp Rise - - - 0.20 0.23 0.26 0.30 0.33 0.37 0.41 0.45 0.50 - - -

High Temp Rise - - 0.21 0.26 0.31 - - - - - - - - - -

Low Temp Rise - - - - - 0.26 0.30 0.33 0.37 0.41 0.45 0.50 0.54 0.59 0.64

4000

5000

6000

7000

8000

9000

10000

11000

12000

13000

14000

15000

16000

17000

18000

47MCP15-500.7

MAINTENANCE

2. For units equipped for dual power supply sources, both sources of power must be disconnected to prevent electrical shock and equipment damage.

3. This unit contains R-410A high pressure refrigerant. Hazards exist that could result in personal injury or death. Installation, maintenance, and service must only be performed by an HVAC technician qualified in R-410A refrigerant and using proper tools and equipment. Due to much higher pressure of R-410A refrigerant, DO NOT USE service equipment or tools designed for refrigerants other than R410A.

WARNING

CAUtIoN

When servicing the unit, some components may be hot enough to cause pain or injury. Allow time for cooling of hot components before servicing.

that the unit has been wired according to the wiring diagram.

5. Check that fuses or circuit breakers are in place and sized correctly.

Fan Assembly

Direct drive fans include a direct coupled motor. Belt drive fan assemblies include the bearings, drive sheaves, belts, and auto belt tensioner.

For belt driven fans, most bearings are permanently lubricated, except for pillow block bearings or those identified with grease fittings. For blower bearings that are not permanently lubricated, lubricate according to the manufacturer’s instructions. Bearings should be checked for any unusual wear and replaced if needed.

For belt driven fans, drive sheaves should be checked at the same time the bearings are inspected. Check to make sure the sheaves are in alignment and are securely fastened to the blower and motor shafts.

Belt should be rechecked shortly after the unit has been installed to check that the belt tension is being maintained by the auto belt tensioner. After the initial start-up, monthly checks are recommended for belt wear.

Electrical Wiring

The electrical wiring should be checked annually for loose connections or deteriorated insulation.

IMPoRtANt

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

All cooling and heating equipment should be serviced before each season to assure proper operation. The following items may require a more frequent service schedule based on the environment in which the unit is installed, and the frequency of the equipment operation.

Before You Begin

1. Turn off power to the unit at the disconnect switch. If equipped with gas heating option, turn all hand gas valves to the “OFF” position.

2. For units equipped for dual power supply sources, both sources of power must be disconnected to prevent electrical shock and equipment damage.

3. Open the power compartment, controls compartment, and blower access doors. Refer to Figure 29.1 for location of doors and internal components.

4. Check that the supply voltage matches the unit supply voltage listed on the Unit Serial Plate. Verify that all wiring is secure and properly protected. Trace circuits to insure

Motors

Most motors require lubrication and are identified as such on the motor nameplate. For motors that are not permanently lubricated, lubrication intervals are recommended by the motor manufacturer based on a number of factors, including motor speed, operating hours, temperature, etc. Lubricate the motor according to the manufacturer’s instructions.

Filters

If the unit is supplied with a dirty filter switch, replace the filters any time the Modine Control System controller provides a dirty filter alarm notice.

Units without a dirty filter pressure switch should have the filters checked monthly. Replace if necessary. In dirty atmospheres, filter maintenance may be required more often. Pleat direction must be vertical to ensure optimum performance.

Outdoor Air Sensor, Supply Air Sensor,

and Return Air Sensor (if applicable)

1. Remove sensor from mounting bracket.

2. Remove any dust or dirt that may be clogging the screen material covering the air sample inlet openings on the end of the sensor probe. If required, remove the screened tip of the sensor and use a neutral detergent and water solution to clean the screen material. Do not use ethyl alcohol, hydrocarbons, ammonia, or derivatives.

48 MCP15-500.7

MAINTENANCE - CONTINUED

Cooling Coil Drain Pan and Drain System

The drain pan, trap, and drain pipe must be cleaned regularly to avoid blockage that can reduce or stop water flow as follows:

1. At the beginning of the cooling season, inspect and clean the entire cooling coil cabinet and condensate drain pan to remove contaminants.

2. Inspect and clean the condensate drain trap and piping. The use of a cleanout opening at the top of the trap (see Figure 8.2) can help facilitate this maintenance.

3. Fill the trap with water to ensure proper operation and replace the cap on the cleanout opening to close the system.

4. During the end of cooling season shutdown of the system, disconnect and remove all water from the trap and drain to prevent freeze damage. If local building codes permit, the trap may be filled with an antifreeze solution.

5. If the unit is used year round, regularly inspect and clean the cooling coil cabinet, condensate drain pan, and trap/ drain system to ensure proper function.

6. Depending on climate, freeze protection of the trap may be required during non-cooling days.

Refrigeration System Coil Maintenance

1. Periodically, inspect the coils (evaporator, condenser, and hot gas reheat if applicable) for signs of corrosion and leaks. Repair and replacement of the coil and the connecting piping, valves, etc., must be performed as needed by a qualified technician.

2. Should the coil surface need cleaning, caution should be exercised in selecting the cleaning solution as well as the cleaning equipment. Improper selection can result in damage to the coil and/or health hazards. Cleaning solutions must not be corrosive or cause damage to copper tube/aluminum fin, or all aluminum coils. Clean the coil from the leaving air-side so that foreign material will be washed out of the coil rather than pushed further in. Be sure to carefully read and follow the cleaning fluid manufacturer’s recommendations before using any cleaning fluid.

Note: The condenser coil is constructed of aluminum materials and contains refrigerant under high pressure. Do not use acidic solutions to clean the coil, as it could lead to corrosion.

Inlet Hood

If the unit is equipped with an outside air inlet hood, check to ensure the inlet screen behind the hood is clean and free of debris.

3. The heat exchanger should be checked annually for cracks. If a crack is detected, the heat exchanger should be replaced before the unit is put back into service.

4. The gas valves and piping should be checked annually for general cleanliness and tightness.

5. The gas controls should be checked to ensure that the unit

is operating properly.

6. If equipped with the standard efficiency (81%) gas heat

option:

a. Inspect and clean the condensate drain tray located under the heat exchanger tube openings.

b. Inspect and clean the condensate drain tubes located on the end of the drain tray that are routed to the outside of the cabinet. Ensure that the tubes are not kinked or blocked.

7. If equipped with the hybrid efficiency (D-Cabinet only) or

high efficiency (90% or 94%) gas heat option:

a. Inspect and clean the condensate drain trap and piping.

b. Fill the trap with water to ensure proper operation.

c. If a condensate neutralizer tube is installed, recharge per

the neutralizer tube manufacturer’s instructions.

d. Check the condensate overflow switch for cleanliness

and proper operation.

Manifold Assembly Removal

1. Shut off gas and electric supply.

2. Open the duct furnace control access compartment doors.

3. Disconnect gas manifold at ground union joint.

4. Remove the screws holding the manifold to the heat

exchanger support.

5. Slide the manifold through the manifold bracket.

6. Clean the orifices as necessary.

7. Slide the manifold back into the manifold bracket and

reinstall the screws that hold the manifold to the heat exchanger support.

8. Reconnect the gas line to the manifold at the ground joint

union.

9. Turn on the electric and gas supply.

10. Check the ground union joint for leaks with a soap solution.

Tighten if necessary.

11. Close the duct furnace control access compartment doors.

Duct Furnace

When providing annual maintenance for the duct furnace, keep the unit free from dust, dirt, grease and foreign matter. Pay particular attention to:

1. The power exhauster discharge opening and the combustion air inlet louvers.

2. The main burner orifices (avoid the use of hard, sharp instruments capable of damaging surfaces for cleaning these orifices). To check the main burner orifices, see Manifold Assembly Removal section on the next page.

49MCP15-500.7

MAINTENANCE - CONTINUED

Hot Water Heat Coil Maintenance

If the unit is supplied with a factory installed hot water heat coil, check the following:

1. Periodically, inspect the coils for signs of corrosion and leaks. Repair and replacement of the coil and the connecting piping, valves, etc., must be performed as needed by a qualified technician.

2. For cleaning the external surface of the coil and fins with compressed air and/or vacuum: The coil can

remain in the unit or be removed. Use compressed air blown into the leaving air side of the coil and/or vacuum from the entering air side of the coil to avoid pushing foreign material further into the coil.

3. For cleaning the external surface of the coil and fins with a cleaning solution: The coil must be removed from

the unit. Caution should be exercised in selecting the cleaning solution as well as the cleaning equipment. Improper selection can result in damage to the coil and/or health hazards. Cleaning solutions must not be corrosive or cause damage to copper tube/aluminum fin coils. Be sure to carefully read and follow the cleaning fluid manufacturer’s recommendations before using any cleaning fluid.

4. 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 is required.

Hot Water Freeze Stat

If the unit is supplied with a factory installed hot water coil freeze stat, check the following:

1. Disconnect the control wiring from the freeze stat terminals.

2. Remove the screws holding the freeze stat side access panel. Refer to Figure 50.1.

Figure 50.1 - Optional Factory Installed Hot Water

Coil Freeze Stat

Energy Recovery Exhaust Assembly

If the unit is equipped with a Modine supplied Energy Recovery Exhaust section, check the following:

1. The energy recovery wheel drive belt is subject to natural stretching which may affect wheel rotation and energy recovery performance. The belt should be checked periodically, especially within the first 400 hours of operation. If too loose, the belt must be shortened by removing the belt from the drive motor pulley, remove the belt linkage using a small Phillips head screwdriver, cut the belt to the required length, and reattach the belt linkage and tighten.

2. The bearings are permanently lubricated and under normal operating conditions maintenance is not required.

3. The wheel is to be checked for cleanliness. In most cases, the counterflow airflow will allow the rotary wheel to selfclean itself of contaminants that may adhere to the surface of the wheel. In situations where self-cleaning is not sufficient, the wheel can be cleaned with compressed air or high pressure water (room temperature water only). To clean the wheel, slide the wheel housing out of the unit casing. Apply the air or water jet evenly and a right angles to the wheel, being careful not to get any water on the inside of the unit casing. Use care not to damage the wheel physically and do not use chemicals.

4. Check wheel to housing seals and replace if worn.

Energy Recovery Wheel Electric Preheat

When providing annual maintenance for the electric preheat (if equipped), keep the unit free from dust, dirt, grease and foreign matter. Pay particular attention to:

1. The heating elements should be checked annually for cracks and discoloration. If a crack is detected, the heating elements should be replaced before the unit is put back into service. If the elements are dark gray, airflow across the heating elements should be checked to ensure that a blockage has not occurred or the blower is operating properly.

2. The electrical connections should be checked annually for general cleanliness and tightness.

3. The controls should be checked to ensure that the unit is operating properly.

Repeat Start-Up Procedure

Once complete, repeat applicable Start-Up Procedure steps as shown starting on page 16.

3. Slide the freeze stat assembly out.

4. Examine the freeze stat capilary for cleanliness and/or obstructions as necessary. Ensure the capillary has no kinks or breaks (replace if either of these conditions is present).

5. Replace the freeze stat assembly in reverse order. In replacing the assembly, be certain that the capillary support frame is properly located and supported. Do not force the side access panel. It will not fit if the frame is not properly aligned.

6. Reconnect the control wiring to the freeze stat terminals.

50 MCP15-500.7

SERVICE & TROUBLESHOOTING

WARNING

When servicing or repairing this equipment, use only factoryapproved service replacement parts which may be obtained by contacting Modine Manufacturing Company. Refer to the rating plate on the unit for complete unit model number, serial number, and company address. Any substitution of parts or controls not approved by the factory will be at the owner’s risk.

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

To check most of the Possible Remedies in the troubleshooting guide on the following pages, refer to the applicable sections of this manual. The troubleshooting tables are as follows:

• Tables 51.1 and 52.1 - Main Unit

• Tables 54.1 and 55.1 - Gas Heat Option with furnace

IMPoRtANt

model Digit 11=6 or 8.

CAUtIoN

Do not reuse any mechanical or electrical components which has been wet. Such component must be replaced.

Table 51.1 - Troubleshooting

Trouble Possible Cause Possible Remedy

A. Power Failure 1. Disconnect not turned on. 1. Turn on disconnect switch

2. Blown fuses or open circuit breaker 2. Check and replace or reset

3. Main power supply for unit turned off 3. Turn on power at main panel

B. Motor Failure 1. See Problem “A” 1. See Problem “A”

2. Failed motor 2. Check and replace

3. Loose wiring to motor 3. Check and tighten

4. Motor overloaded 4. Reset motor starter and check motor load

5. Improper supply voltage 5. Check and correct

C. Blower Not Turning or

Turns Slow

D.InsufcientAirow 1. Motor running backwards 1. Check and correct motor wiring to phase rotation of

E.ExcessiveAirow 1. Fan speed setting too high 1. Check and correct

1. See Problems “A” and “B” 1. See Problems “A” and “B”

2. Broken drive belt 2. Check and replace

3. Motor undersized for application 3. Contact Factory

4. Motor voltage too low 4. Check and correct

5. Supply power line sizing too small 5. Check and correct

6. Controls are in Unoccupied mode 6. Wait for Occupied mode or override

7. Controller alarm 7. Check and correct

8. Blower door open 8. Close the door

supply power, reverse any two lines to motor

2. Fan speed setting too low 2. Check and correct

3.Dirtyorcloggedltersorcoils 3. Check and clean or replace

4. Duct system has more static pressure drop than expected

5. Lack of straight duct at unit discharge outlet 5. Install straight duct at discharge outlet, as outlined in the

6. Dampers and/or discharge registers are closed 6. Check and correct

2. Filters not in place 2.Checkandreinstalllters

3. Ductwork grilles or registers not installed 3. Check and install

4. Duct system has less static pressure drop than expected

5. Access door is open 5. Close all unit side access doors

4. Check and correct

Duct Installation section of this Manual or contact Factory

4. Check and correct

51MCP15-500.7

SERVICE & TROUBLESHOOTING - CONTINUED

Table 52.1 - Troubleshooting (Continued)

Trouble Possible Cause Possible Remedy

F. Compressor(s)

Do Not Operate

G. Compressor(s)

Do Not Cycle Off

H. Dampers Do Not

Operate

I. Electric Heat Not

Functioning

J. Gas Heat Not

Functioning Properly

1. See Problems “A” and “B” 1. See Problems “A” and “B”

2. Controls are in Unoccupied mode 2. Wait for Occupied mode or override

3. Ambient lockout 3. Check and wait or override

4. Low pressure lockout 4. Check and wait or override

5. High pressure lockout 5. Check and wait or override

6. Inter-stage delay 6. Check and wait or override

7.Airowprovingswitchnotclosing 7. Check and correct

8. Thermostat not calling for cooling 8. Check and wait or override

9.Drainpanoatswitchopen 9. Check switch, check drain line (pan, trap, piping) for

1.Supplyairtemperaturenotsatised 1. Compressors will remain on until the supply air setpoint

1. See Problem “A” 1. See Problem “A”

2. Failed damper motor(s) 2. Check and replace

3. Loose wiring to damper motor(s) 3. Check and tighten

4. Controls are in Unoccupied mode 4. Wait for Occupied mode or override

5. Ambient lockout 5. Check and wait or override

1. See Problem “A” 1. See Problem “A”

2. See Problem “D” 2. See Problem “D”

3. Thermostat not calling for heat 3. Check and wait or override

4. Limit switches are open 4. Check and correct

5. Overload relay is tripped 5. Check and correct

6. Failed heat modules 6. Check and replace

1. See Problem “A” 1. See Problem “A”

2. See Problem “D” 2. See Problem “D”

3. Thermostat not calling for heat 3. Check and wait or override

4. Limit switches are open 4. Check and correct

5. Main gas supply not turned on 5. Check and correct

6. Air in gas line 6. Purge per instructions

7. Loose wiring to ignition controls or gas valves 7. Check and tighten

8. Failed ignition controller or gas valve 8. Check and replace

9.Failedamesensor 9. Check and replace

10. Improper supply air temperature sensor installation 10. Check and correct

11.Flamerolloutorashback

12. Not enough heat

13. Too much heat

14. Clogged condensate drain line (94% and 90% gas heat option only)

proper drainage, and verify trap is primed with water

issatised

11a. Main pressure too high (correct to 14” W.C. max)

11b.Oricetoolarge(verifytheymatchtheserialplate)

11c. Manifold pressure too low (reset)

12a.Unitcyclingonhighlimit(checkairow)

12b. Main pressure too low (must be 6” W.C. minimum)

12c. Unit undersized for conditions

12d. Improper supply air temperature sensor installation

13a. Manifold pressure too high (correct to 3.5” W.C.)

13b. Defective or improperly wired controls

14. Check condensate drain line, clear as required.

52 MCP15-500.7

PAGE INTENTIONALLY LEFT BLANK

53MCP15-500.7

SERVICE & TROUBLESHOOTING - CONTINUED

Table 54.1 - Furnace Master Control Board (VB1200) Error Codes

(Applies to B-, C-, and D-Cabinet Units with Gas Heat Option furnace model number Digit 11=6 or 8) j

Display

Code

888 Board Failure (Up to 10 sec @ power up)

Off UP Mode: Burner state = Off

Pur UP Mode: Burner state = Purge

Ign UP Mode: Burner state = Ignition

HEA UP Mode: Burner state = Warmup

Run UP Mode: Burner state = Run

rEt UP Mode: Burner state = Retry (with A01 or A02)

A01 Failed ignition attempt

A02 Lost Flame

A03 InsufcientCombustionAir

Limited Low Fire

A04

(due to Lost Flame Auto-Adaptation)

A05 Weak Flame Signal

No Low Fire Mode

A06

(due to Hi Gas Pressure at Low Fire)

A07 Loss of Inducer Motor Control

A08 Air Sensor Null Pressure Check out-of-tolerance

A99 COM Error – Slaves

E01 Failed Ignition

E02 Primary Limit Failure

E03 Modulation Valve Failure

E04 Air Sensor Failure - Pressure Reading Low

E05 Air Sensor Failure - Pressure Reading High

Gas Sensor Failure - Pressure Reading Low

E06

(Possible modulating valve actuator misalignment)

Gas Sensor Failure - Pressure Reading High

E07

(Possible modulating valve actuator misalignment)

E08 Improper Flame

E09 No Firing Rate Input

A20 Slave Furnace A COM Missing

A21 Slave Furnace A Lockout

A30 Slave Furnace B COM Missing

A31 Slave Furnace B Lockout

A40 Slave Furnace C COM Missing

A41 Slave Furnace C Lockout

Eid Invalid I.D. Plug Installed

j To clear furnace control board error codes, refer to the section “Clearing Furnace Control Board Error Codes” on page 23.

Description Additional comments and notes

Verify 24 VAC signal input at connector J6.

Normal Operation

Retrydelayfollowingeitherafailedignitionoraameloss.

Ignitionwassuccessfulbutthenamedisappeared.

Blocked vent with actuator position de-rated by >20% from FRI setting.

Flamelossatlowreresultsinanauto-adjustmentlimitoftheburnerturndown

by adjusting the minimum modulation voltage during the rest of the current cycle or until a CPU reset.

Flamepresencesignaloflessthan1.5μAindicatesanagedamerod.

TheGasPressureisnotmodulatingdowntolowre.

The Air Pressure is not modulating down at minimum inducer drive.

The Air Pressure sensor zero reading appears to be out-of-tolerance.

CRC errors, serial bus loaded down or possibly poor cable/routing.

Four failed ignition attempts have occurred.

Verify Primary Limit input at connector J8 and fuse at F1.

The Valve Actuator did not reach a Park or Full On position.

Includes air switch failure to open during pre-purge switch check, includes

insufcientairlockoutduetoblockedvent.

Includes air switch failure to close during pre-purge switch check.

Verify Gas Pressure Sensor signal input at connector J13.

SignicantGasPressure detected during the Off burner state.

The thermostat “W” input is calling for heat but the FRI is < 2.0 V.

Loss of a previously established serial communication link.

Refer to VB1201 slave board diagnostics table.

Loss of a previously established serial communication link.

Refer to VB1201 slave board diagnostics table.

Loss of a previously established serial communication link.

Refer to VB1201 slave board diagnostics table.

54 MCP15-500.7

SERVICE & TROUBLESHOOTING - CONTINUED

Table 55.1 - Furnace Slave Control Board (VB1201) Error Codes

(Applies only to C- and D-Cabinet Units with Gas Heat Option furnace model number Digit 11=8) j

Color Flashes Condition

Error Conditions

N/A

Red

Green

Yellow

Off No power to the control board

Steady On Hard lockout on control fault or no 24 VAC.

1 Insufcientinducerairpressurewheninducerison.

2 Inducer air pressure is too high when inducer is off.

3 Flamecircuitryfailure-ameisonwhenitshouldbeofforitisoffwhenitshouldbeon.

4 Gas valve failure.

5 Gas valve safety relay failure.

6 Reserved

7 Primary limit failure

8 Gas valve in test mode

9 Safety startup failed to validate inducer air path.

Normal and Warning Conditions

Slow Standby - no communication link established

Rapid Standby - in communication with Bus Master

1 Call for heat, no gas

2 Call for heat, gas 2 Callforheat,gas,amerodaged

Rapid Retry

55MCP15-500.7

MODEL IDENTIFICATION & SERIAL PLATES/NUMBERS

Model Identification

Depending on options included, the unit may have more than one Serial Plate. Figure 56.1 shows the Serial Plate for the main unit, while Figure 56.2 shows the Serial Plate for the gas heat option. When servicing, repairing or replacing parts on these units, locate the model Serial Plate of the unit and always give the complete Model Number and Serial Number of the unit. The Serial Plate is located on the door of the controls cabinet. For a complete description of the model number, see the Model Nomenclature on pages 57-59. Serial plates shown are examples and may vary slightly from what is on the actual unit(s). Refer to the unit(s) for the actual serial plates.

Figure 56.1 Serial Plate Example - B & C-Cabinet Units

Figure 56.2

Serial Plate Example - D-Cabinet Unit

Figure 56.3

Serial Plate Example - B-Cabinet Furnace

Figure 56.4 Serial Plate Example - C & D-Cabinet Furnaces

56 MCP15-500.7

MODEL NOMENCLATURE

Model Nomenclature

As noted in the previous section, units may have more than one Serial Plate. If the unit has the gas heat option, the furnace will have its own model number separate from the main unit.

• Table 57.1 shows the nomenclature for the gas heat section option.

• Tables 58.1 and 59.1 on the following pages show the nomenclature for the main unit.

Table 57.1 - Model Nomenclature - Gas Furnace Option for Model MPR

Digits Indicates Description Value

Single,StandardEfciency FSP

1,2,3 FurnaceModelPrex

4,5,6,7 Furnace Input Rating

8 Heat Exchanger 409 Stainless Steel Heat Exchanger S ● ● ●

9 Ignition System Direct Spark Ignition S ● ● ●

10 Gas Type Natural Gas N ● ● ●

11 Modulating Capacity Control

12 Air Temperature Rise

13 Not Used Not Currently Used 0 ● ● ●

14 Furnace Supply Voltage 115V/1ph (transformer from main supply voltage) A ● ● ●

Single,HighEfciencyCondensing FSC

Dual,StandardEfciency FMP

Dual,HighEfciencyCondensing FMC

Dual,StandardEfciency FDP

Quad,StandardEfciency FQP

Quad,HighEfciencyHybrid FQH

Dual,HighEfciencyCondensing FDC

0150 - 150,000 Btu/hr

thru

1600 - 1,600,000 Btu/hr

Gas Only, Multiple 4 ●

Gas & Power Exhaust, Single 6 ●

Gas and Power Exh Master, Staged Slave(s) 8 ● ●

High Air Temperature Rise H

Not Applicable N

See Next

Column

Cabinet

B C D

●

See Unit

Nomenclature

● ● ●Low Air Temperature Rise L

(Continued on next page)

57MCP15-500.7

MODEL NOMENCLATURE - MODEL MPR

Table 58.1 - Model Nomenclature - Main Unit

Digits Indicates Description Value

1, 2, 3 Unit Type Commercial Packaged Ventilation Unit MPR ● ● ●

4, 5 Unit Nominal Cooling

6 Cabinet Size Refer to Dimensions B, C, D ● ● ●

OA & RA Dampers

7 AirControlConguration

8 Evaporator Coil

9 Compressor Staging

10 Hot Gas Reheat

11 Condensor Arrangement

12 SupplyBlowerConguration

Supply Blower Motor HP

14 Blower Motor Type

15 Unit Supply Voltage

16 Power Options

OA Dampers (No RA) No Exhaust D ● ● ●

OA Dampers

(with Exhaust Opening)

High Capacity 4 Row, 14fpi

High Capacity 6 Row, 14fpi

VFD Head Pressure Control

Modulating EC Motor Head

Wheel Size

DX Coil

Tandem Digital Scroll (Digital Modulating + On/Off) (10-30 ton units) A ● ●

Single Digital Scroll (Modulating Digital) (7 ton units only) B ●

Dual Tandem Digital Scroll [(Digital Modulating - On/Off) & (On/Off - On/Off)] D ●

Modulating Hot Gas Reheat with E-Coat 2 ● ● ●

Pressure Control

(inches)

11 - 1 - K ● 12 - - 4 L ● 14 - - 7 M ● 16 2 - 8 N ● ● 20 3 - A Q ● ● 25 5 - C S ● ●

28 6 - - - ● 16 Dual - - E U ● 25 Dual - - J Y ●

ANPA

Supply Fan Motor Exhaust Fan Motor

ODP 1800 RPM 1800 RPM or N/A 1 ● ● ● ODP 3600 RPM 1800 RPM or N/A A ● ● ● ODP 1200 RPM 1800 RPM or N/A G ● ● ●

TE 1800 RPM 1800 RPM or N/A 2 ● ● ● TE 3600 RPM 1800 RPM or N/A B ● ● ● TE 1200 RPM 1800 RPM or N/A H ● ● ●

Deadfront Disconnect Convenience Outlet

575V/3ph (not available on 52/60 ton D-Cabinet) 7 ● ● ●

None

60A

100A

200A

400A

600A

7, 10, or 13 ton 07, 10, 13 ●

15 or 20 ton 15, 20 ● ●

26 ton 26 ● 30 ton 30 ● ●

40, 52, or 60 ton 40, 52, 60 ●

No Exhaust A ● ● ●

Energy Recovery Exhaust B ● ● ●

Power Exhaust C ● ● ●

Energy Recovery Exhaust E ● ● ●

Power Exhaust F ● ● ●

No E-Coat 1 ● ●

With E-Coat 2 ● ●

No E-Coat 3 ●

With E-Coat 4 ●

No Hot Gas Reheat 0 ● ● ●

Modulating Hot Gas Reheat 1 ● ● ●

Microchannel Coils A ● ●

Microchannel Coils with E-Coat (UV) B ● ●

Microchannel Coils E ●

Belt Drive

Microchannel Coils with E-Coat (UV) F ●

Direct Drive

k ANPL k ANPA k ANPL k

1 HP C or Q ● ● ●

1-1/2 HP D or R ● ● ●

2 HP E or S ● ● ● 3 HP F or T ● ● ● 5 HP G or U ● ● ●

7-1/2 HP H or V ● ● ●

10 HP J or W ● ● ● 15 HP K or X ● ● ● 20 HP L or Y ●

208V/3ph 4 ● ● ● 230V/3ph 5 ● ● ● 460V/3ph 6 ● ● ●

None N ● ●

Power by Others Z ● ●

None D ● ●

Unit Powered E ● ●

Power by Others F ● ●

None G ● ● ●

Unit Powered H ● ● ●

Power by Others J ● ● ●

None K ● ● ●

Unit Powered L ● ● ●

Power by Others M ● ● ●

None P ● ● ●

Unit Powered Q ● ● ●

Power by Others R ● ● ●

None S ●

Unit Powered T ●

Power by Others U ●

58 MCP15-500.7

Cabinet

B C D

(Continued on next page)

MODEL NOMENCLATURE - MODEL MPR - CONTINUED

Table 59.1 - Model Nomenclature - Main Unit (Continued from previous page)

Digits Indicates Description Value

None 0 ● ● ●

Electric 1 ● ● ●

17 Heating Section Type

18 Nominal Heat Capacity

19 Temperature Rise

20 Heat Control

Nominal Wheel Diameter

j Supply fans with belt drive are no longer offered and are shown for historical purposes. All units shipped after December, 2017 are direct drive supply fans. k ANPA are airfoil fans, ANPL are non-airfoil fans. l C through L include a Motor Starter, Q through Y include a Variable Frequency Drive (VFD). m MPR C-Cabinet units that interface to energy recovery exhaust will always be "N". The Wheel Diameter, Exhaust Blower Configuration, Exhaust Blower

Motor HP, and Energy Wheel Preheat is called out in the ERM model nomenclature, when applicable, on C-Cabinet sized units. All D-Cabinet units are “N”.

Exhaust Blower

Conguration

Exhaust Blower Motor HP

Energy Wheel Preheat

Natural Gas with 20kW (nominal) Aux/Supplemental Electric Heat 3 ● ● Natural Gas with 40kW (nominal) Aux/Supplemental Electric Heat 3 ●

20kW Electric - (derate for 208V/3ph) 40kW Electric - (derate for 208V/3ph) ● 40kW Electric - (derate for 208V/3ph) 80kW Electric - (derate for 208V/3ph) ● 60kW Electric - (derate for 208V/3ph)

120kW Electric - (derate for 208V/3ph) ●

80kW Electric - (derate for 208V/3ph) 160kW Electric - (derate for 208V/3ph) ● 100kW Electric - (derate for 208V/3ph) 200kW Electric - (derate for 208V/3ph) ●

150 MBH Gas - 80% 1 x 150 F ● 200 MBH Gas - 80% 1 x 200 G ● 250 MBH Gas - 80% 1 x 250 H ● 300 MBH Gas - 80% 1 x 300 (B), 2 x 150 (C) J ● ● 400 MBH Gas - 80% 1 x 400 (B), 2 x 200 (C, D) K ● ● ● 500 MBH Gas - 80% 2 x 250 L ● ● 600 MBH Gas - 80% 2 x 300 M ● ● 620 MBH Gas - 90% 2 x 310 P ● 800 MBH Gas - 80% 2 x 400 Q ● 175 MBH Gas - 94% 1 x 175 R ● 225 MBH Gas - 94% 1 x 225 S ● 310 MBH Gas - 94% 1 x 310 T ● 350 MBH Gas - 90% 2 x 175 U ● 450 MBH Gas - 90% 2 x 225 V ● ●

900 MBH Gas - 80% 2 x 200 + 2 x 250 (stacked) 1 ● 1000 MBH Gas - 80% 4 x 250 (stacked) 2 ● 1200 MBH Gas - 80% 4 x 300 (stacked) 3 ● 1400 MBH Gas - 80% 2 x 300 + 2 x 400 (stacked) 4 ● 1600 MBH Gas - 80% 4 x 400 (stacked) 5 ●

850 MBH Gas - 86% 2 x 200 + 2 x 225 (stacked) 6 ●

950 MBH Gas - 86% 2 x 250 + 2 x 225 (stacked) 7 ● 1220 MBH Gas - 86% 2 x 300 + 2 x 310 (stacked) 8 ● 1420 MBH Gas - 86% 2 x 400 + 2 x 310 (stacked) 9 ●

Hot Water Coil (only available on C-Cabinet) W ●

High Air Temp Rise (70°F to 100°F) H ● ● ●

Low Air Temp Rise (30°F to under 75°F) L ● ● ●

None (or Not Applicable for C- and D-Cabinet) N ● ● ●

11” Backward Inclined Plenum Fan 1 ● 16” Backward Inclined Airfoil Plenum Fan 2 ● 20” Backward Inclined Airfoil Plenum Fan 3 ●

None (or Not Applicable for C-Cabinet) N ● ● ●

None (or Not Applicable for C- and D-Cabinet) N ● ● ●

Natural Gas 2 ● ● ●

Hot Water (C-Cabinet Only) 4 ●

No Heating N ● ● ●

Not Applicable N ● ● ●

No Heating N ● ● ●

Modulating D ● ● ●

28” A ● 36” B ● 48” C ●

1 HP C or Q ●

1-1/2 HP D or R ●

2 HP E or S ● 3 HP F or T ● 5 HP G or U ●

7-1/2 HP H or V ●

10 HP J or W ●

20kW (nominal) Electric 2 ●

Cabinet

B C D

● ●

59MCP15-500.7

COMMERCIAL WARRANTY

Seller warrants its products to be free from defects in material and workmanship, EXCLUSIVE, HOWEVER, of failures attributable to the use of materials substituted under emergency conditions for materials normally employed. This warranty covers replacement of any parts furnished from the factory of Seller, but does not cover labor of any kind and materials not furnished by Seller, or any charges for any such labor or materials, whether such labor, materials or charges thereon are due to replacement of parts, adjustments, repairs, or any other work done. This warranty does not apply to any equipment which shall have been repaired or altered outside the factory of Seller in any way so as, in the judgment of Seller, to affect its stability, nor which has been subjected to misuse, negligence, or operating conditions in excess of those for which such equipment was designed. This warranty does not cover the effects of physical or chemical properties of water or steam or other liquids or gases used in the equipment.

BUYER AGREES THAT SELLER’S WARRANTY OF ITS PRODUCTS TO BE FREE FROM DEFECT IN MATERIAL AND WORKMANSHIP, AS LIMITED HEREIN, SHALL BE IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES, EITHER EXPRESS OR IMPLIED, WHETHER ARISING FROM LAW, COURSE OF DEALING, USAGE OF TRADE, OR OTHERWISE,

THERE ARE NO OTHER WARRANTIES, INCLUDING WARRANTY OF MERCHANTABILITY OR FITNESS FOR PURPOSE, WHICH EXTEND

BEYOND THE PRODUCT DESCRIPTION CONFIRMED BY BUYER AND

SELLER AS OF THE DATE OF FINAL AGREEMENT.

This warranty is void if the input to the product exceeds the rated input as indicated on the product serial plate by more than 5% on gas-fired and oil-fired units, or if the product in the judgment of SELLER has been installed in a corrosive atmosphere, or subjected to corrosive fluids or gases, been subjected to misuse, negligence, accident, excessive thermal shock, excessive humidity, physical damage, impact, abrasion, unauthorized alterations, or operation contrary to SELLER’S printed instructions, or if the serial number has been altered, defaced or removed.

BUYER AGREES THAT IN NO EVENT WILL SELLER BE LIABLE FOR COSTS OF PROCESSING, LOST PROFITS, INJURY TO GOODWILL, OR ANY OTHER CONSEQUENTIAL OR INCIDENTAL DAMAGES OF ANY KIND RESULTING FROM THE ORDER OR USE OF ITS PRODUCT, WHETHER ARISING FROM BREACH OF WARRANTY, NONCONFORMITY TO ORDERED SPECIFICATIONS, DELAY IN DELIVERY, OR ANY LOSS SUSTAINED BY THE BUYER.

BUYER’S REMEDY FOR BREACH OF WARRANTY, EXCLUSIVE OF ALL OTHER REMEDIES PROVIDED BY LAW, IS LIMITED TO REPAIR OR REPLACEMENT AT THE FACTORY OF SELLER, ANY COMPONENT WHICH SHALL, WITHIN THE APPLICABLE WARRANTY PERIOD DEFINED HEREIN AND UPON PRIOR WRITTEN APPROVAL, BE RETURNED TO SELLER WITH TRANSPORTATION CHARGES PREPAID AND WHICH THE EXAMINATION OF SELLER SHALL DISCLOSE TO HAVE BEEN DEFECTIVE; EXCEPT THAT WHEN THE PRODUCT IS TO BE USED BY BUYER AS A COMPONENT PART OF EQUIPMENT MANUFACTURED BY BUYER, BUYER’S REMEDY FOR BREACH, AS LIMITED HEREIN, SHALL BE LIMITED TO ONE YEAR FROM DATE OF SHIPMENT FROM SELLER. FOR GAS-FIRED PRODUCTS INSTALLED IN HIGH HUMIDITY APPLICATIONS AND UTILIZING STAINLESS STEEL HEAT EXCHANGERS, BUYER’S REMEDY FOR BREACH, AS LIMITED HEREIN, SHALL BE LIMITED TO TEN YEARS FROM DATE OF SHIPMENT FROM SELLER.

These warranties are issued only to the original owner-user and cannot be transferred or assigned. No provision is made in these warranties for any labor allowance or field labor participation. Seller will not honor any expenses incurred in its behalf with regard to repairs to any of Seller’s products. No credit shall be issued for any defective part returned without proper written authorization (including, but not limited to, model number, serial number, date of failure, etc.) and freight prepaid.

OPTIONAL SUPPLEMENTAL WARRANTY Provided a supplemental warranty has been purchased, Seller extends the

warranty herein for an additional four (4) years on certain compressors. Provided a supplemental warranty has been purchased, Seller extends the warranty herein for an additional four (4) years or nine (9) years on certain heat exchangers.

EXCLUSION OF CONSUMABLES & CONDITIONS BEYOND SELLER’S CONTROL

This warranty shall not be applicable to any of the following items: refrigerant gas, belts, filters, fuses and other items consumed or worn out by normal wear and tear or conditions beyond Seller’s control, including (without limitation as to generality) polluted or contaminated or foreign matter contained in the air or water utilized for heat exchanger (condenser) cooling or if the failure of the part is caused by improper air or water supply, or improper or incorrect sizing of power supply.

Component

Applicable Models

Heat Exchangers

Gas-Fired Units except MPR Models

Heat Exchangers

Low Intensity Infrared Units , Gas Heat option on MPR models

Compressors

Condensing Units for Cassettes

Burners

Low Intensity Infrared Units

Compressors

MPR Models

Other

Components excluding Heat Exchangers, Coils, Condensers, Burners, Sheet Metal

Heat Exchangers/Coils

Indoor and Outdoor Duct Furnaces and System Units, PSH/BSH, Steam/Hot Water Units, Oil-Fired Units, Electric Units, Cassettes,

Vertical Unit Ventilators

Compressors

Vertical Unit Ventilators

Burners

High Intensity Infrared Units

Sheet Metal Parts

All Products

TEN YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER, WITHIN TEN YEARS FROM DATE OF RESALE BY BUYER OR ANY OTHER USER, WITHIN TEN YEARS FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION, OR WITHIN ONE HUNDRED TWENTY-SIX MONTHS FROM DATE OF SHIPMENT FROM SELLER, WHICHEVER OCCURS FIRST

FIVE YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER, WITHIN FIVE YEARS FROM DATE OF RESALE BY BUYER OR ANY OTHER USER, WITHIN FIVE YEARS FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION, OR WITHIN SIXTY-SIX MONTHS FROM DATE OF SHIPMENT FROM SELLER, WHICHEVER OCCURS FIRST

TWO YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER, WITHIN TWO YEARS FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION, OR WITHIN THIRTY MONTHS FROM DATE OF SHIPMENT FROM SELLER, WHICHEVER OCCURS FIRST

ONE YEAR FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER, WITHIN ONE YEAR FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION, OR WITHIN EIGHTEEN MONTHS FROM DATE OF SHIPMENT FROM SELLER, WHICHEVER OCCURS FIRST

“APPLICABLE WARRANTY PERIOD”

As Modine Manufacturing Company has a continuous product improvement program, it reserves the right to change design and specifications without notice.

Modine Manufacturing Company

1500 DeKoven Avenue Racine, WI 53403 Phone: 1.800.828.4328 (HEAT) www.modinehvac.com

Modine Manufacturing MPR Installation And Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual