Sterling ME User Manual

Page 1

INSTALLATION AND SERVICE MANUAL

HVAC PRODUCTS

INDOOR MAKE-UP AIR UNIT ARRANGEMENTS

FOR HEATING, COOLING AND VENTILATING SYSTEMS

ATTENTION: READ THIS MANUAL, INDOOR DUCT FURNACE DISM MANUAL (STANDARD & POWER VENT TYPE) (EVAPORATIVE OR COOLING COIL MANUALS IF APPLICABLE), UNIT SUBMITTAL DATA SHEETS AND ALL LABELS ATTACHED TO THE UNIT CAREFULLY BEFORE ATTEMPTING TO INSTALL, OPERATE OR SERVICE THESE UNITS! CHECK UNIT DATA PLATES FOR TYPE OF GAS AND ELECTRICAL SPECIFICATIONS AND MAKE CERTAIN THAT THESE AGREE WITH THOSE AT THE POINT OF INSTALLATION. RECORD THE UNIT MODEL NUMBER AND SERIAL NO.(S) IN THE SPACE PROVIDED. RETAIN THIS DOCUMENT FOR FUTURE REFERENCE.

Model No.______________________________________________ Serial No. ________________________

(S) MAIM-6

J30-05383A

FOR Y OUR SAFETY

The use or storage of gasoline or other flammable vapors or liquids in open containers in the vicinity of this appliance is hazardous.

If you smell gas:

1. Open windows.

2. Don’t touch electrical switches.

3. Extinguish any open ﬂ ames.

4. Immediately call your gas supplier.

FOR Y OUR SAFETY

Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. This appliance must be installed by a licensed contractor or qualiﬁ ed service personnel. Read these installation, operating and maintenance instructions thoroughly before installing or servicing this equipment.

APPROVED FOR USE IN CALIFORNIA

WHEN UNITS ARE EQUIPPED WITH INTERMITTENT (SPARK) IGNITION.

Install, operate and maintain unit in accordance with manufacturer’s instructions to avoid exposure to fuel substances or substances from incomplete combustion which can cause death or serious illness. The state of California has determined that these substances may cause cancer , birth defects, or other reproductive harm. Install and Service this product to avoid exposure to airborne particles of glasswool ﬁ bers and/or ceramic ﬁ bers known to the State of Calif ornia to cause cancer through inhalation.

01/11

INSTALLER’S RESPONSIBILITY

Installer Please Note: This equipment has been test ﬁ red and inspected. It has been shipped

free from defects from our f actory. Ho w ever, during shipment and installation, problems such as loose wires, leaks or loose fasteners may occur. It is the installer’s responsibility to

inspect and correct any problems that may be found.

RECEIVING INSTRUCTIONS

Inspect shipment immediately when received to determine if any damage has occurred to the unit during shipment. After the unit has been uncrated, check for any visible damage to the unit. If any damage is found, the consignee should sign the bill of lading indicating such damage and immediately file claim for damage with the transportation company.

IMPORTANT: Look in direction of unit air ﬂ ow to determine whether unit is right hand or left hand accessible.

260 NORTH ELM ST., WESTFIELD, MA 01085

TEL: (413) 564-5540 FAX: (413) 562-5311

http://www.mestek.com

Please utilize this toll free number to contact your local representative 800-490-2290.

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TABLE OF CONTENTS

I. RECEIVING & PRE-INSTALLATION

INSTRUCTIONS ......................................................... 2

II. GENERAL INSTALLATION SAFETY

REQUIREMENTS (throughout IOM) ..................3, 4

Rigging .......................................................................4

III. INSTALLATION

Location ........................................................................5

Combustion Air Considerations ....................................5

Mounting / Locations ...................................................5

Suspension ...................................................................5

Mounting on Field Furnished Supports ........................6

Installation Clearances .............................................6, 7

Access Panel Removal ................................................7

Venting ..........................................................................7

Air for Combustion .......................................................7

Duct Connections .....................................................7, 8

Gas Piping ....................................................................8

Modulating Gas Control ............................................8, 9

Electrical Connections ............................................9, 10

DX Coil Equipped Units ..............................................10

Chilled Water Coil Equipped Units ..............................10

Evaporative Cooling Equipped Units ..........................10

IV. OPERATION

General Information ....................................................11

Gas Control System ...................................................11

Optional Gas Controls ..........................................11, 12

Air Handling Requirements and Adjustments ...... 12, 13

Lighting .......................................................................13

Gas Input Adjustment ...........................................13, 14

Pilot Adjustment .......................................................... 14

Primary Air Shutter Adjustment .................................. 14

Controls ......................................................................14

V. START UP ......................................................14, 15

VI. MAINTENANCE .......................................15 thru 18

VII. TROUBLESHOO TING ............................19 thru 24

VIII. REPLACEMENT PARTS ...................................24

IX. SERVICE NOTE ................................................... 24

X. W ARRANTY ..........................................................24

Canadian Installations ...............................................25

XI. DIMENSIONAL DATA ..............................26 thru 29

XII. MOTOR ELECTRICAL DATA .............................30

XIII. UNIT/SHIP WEIGHTS ........................................31

XIV. COOLING COIL DIMENSIONAL DATA ............32

XV. CENTER OF GRAVITY .................................32, 33

XVI. UNIT NUMBER DESCRIPTION ..................34, 35

XVII. START UP SHEET ...........................................36

Unless otherwise speciﬁ ed, the following conversions may be used for calculating SI unit measurements: 1 foot = 0.305 m 1 inch = 25.4 mm 1 psig = 6.894 kPa 1 pound = 0.435 kg 1 gallon = 3.785 L 1 cubic foot = 0.028 m

1 inch water column =0.249 kPa 1000 Btu per hour = 0.293 kW 1000 Btu/Cu. Ft. = 37.5 MJ/m

liter/second = CFM x 0.472 meter/second = FPM ÷ 196.8

The following terms are used throughout this manual to bring attention to the presence of potential hazards or to important information concerning the product:

Indicates an imminently hazardous situation which, if not av oided, will result in death, serious injury or substantial property damage.

Indicates an imminently hazardous situation which, if not avoided, could result in death, serious injury or substantial property damage.

Indicates an imminently hazardous situation which, if not avoided, may result in minor injury or property damage.

NOTICE: Used to notify of special instructions on installation, operation or maintenance which are important to equipment but not related to personal injury hazards.

I. RECEIVING INSTRUCTIONS

Inspect shipment immediately when received to determine if any damage has occurred to the crate during shipment.

After the unit has been uncrated, check for any visible damage to the unit. Check motor position and turn blower wheel to determine if damage has occurred to these critical parts.

If any damage is found, the consignee should sign the bill of lading indicating such damage and immediately ﬁ le claim for damage with transportation company.

PRE-INSTALLATION INSTRUCTIONS

When the unit is received and uncrated, check the external data plate and all labels on the unit for type of gas, electrical, and operational speciﬁ cations to conﬁ rm that these agree with those at point of installation. The unit is equipped with an Indoor Duct Furnace; also check the data plate and all labels located on each furnace.

Every Make-Up Air Unit will include an informational packet which will include the following: This make-up air manual, duct furnace, evaporative cooler/cooling coil manuals (if applicable to the unit order), wiring diagram(s), and special controls/data sheets.

Failure to comply with the general requirements may result in extensive property damage, severe personal injury or death.

NOTICE: It is the equipment owner’s responsibility to provide any scaffolding or other apparatus required to perform emergency service or annual/periodic maintenance to this equipment.

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Page 3

II. GENERAL SAFETY REQUIREMENTS

Open all disconnect switches before installing the unit. If the po wer disconnect is out of sight, lock it in the open position and ta g it to prevent unexpected application of power. Failure to do so may result in personal injury or death from electrical shock.

Failure to comply with the general requirements may result in extensive property damage, severe personal injury or death.

Never service any component without ﬁ rst disconnecting all electrical and gas supplies to the unit or severe personal injury or death may occur.

1. Installation must be made in accordance with local codes, or in absence of local codes, with ANSI Standard Z223.1-1996 (N.F.P.A. No 54) “National Fuel Gas Code”, or the latest edition of. All ANSI and NFPA Standards referred to in these installation instructions are the ones that were applicable at the time the design of this appliance was certiﬁ ed. The ANSI Standards are available from the American Gas Association, 1515 Wilson Boulevard, Arlington, Virginia 22209. The NFPA Standards are available from the National Fire Protection Association, Batterymarch Park, Quincy, Massachusetts 02269. The heaters are designed for use in airplane hangers when installed in accordance with ANSI/NFPA No. 409 and in public garages when installed in accordance with the NFPA No. 88A and NFPA No. 88B.

2. If installed in Canada, the installation must conform with local building codes, or in the absence of local building codes, with the current CGA-B149.1 or B149.2 “Installation Codes for Gas Burning Appliances and Equipment”. These indoor duct furnaces have been designed for and certified to comply with CGA 2.6.

3. No alterations are to be made on this equipment.

The duct furnace section of these make-up air units are certiﬁ ed by the American Gas Association for use with natural and LP (propane) gases!

Do not alter the duct furnace in any way or damage to the unit, se vere personal injury or death will occur.

4. Make certain that the power sources conform to the requirements of the heater.

5. Follow installation instructions CAREFULLY to avoid creating unsafe conditions. All wir ing should be done and checked by a qualiﬁ ed electrician, using copper wire only . All gas connections should be made and leak-tested by a suitably qualiﬁ ed individual, per instructions in this manual.

6. Use only the fuel for which the heater is designed (see nameplate). Using LP gas in a heater that requires natural gas, or vice versa, will create the risk of gas leaks, carbon monoxide poisoning and explosion.

Do not attempt to convert the heater for use with a fuel other than the one intended. Such conversion is danger ous, as it could create unsafe conditions that result in death, serious injury or substantial property damage.

7. Make certain that power source conforms to electrical requirements of heater. Disconnect power before installing or servicing heater. If power disconnect is out of sight, lock it in open position and tag it to prevent unexpected application of power. Failure to do so could result in fatal electric shock.

Do not depend upon a thermostat or other switch as the sole means of disconnecting power when installing or servicing heater. Always disconnect power at main circuit breaker as described above. Failure to do so could result in fatal electric shock.

8. Special attention must be given to any grounding information pertaining to this heater. To prevent the risk of electrocution, the heater must be securely and adequately grounded. This should be accomplished by connecting a grounded conductor from the service panel to the conduit box of the heater. T o ensure proper ground, the g rounding means must be tested by qualiﬁ ed ﬁ eld electrician.

9. Do not insert fingers or foreign objects into the heater or its air moving device. Do not block or tamper with the heater in any manner while in operation or just after it has been turned off, as some parts may be hot enough to cause injury.

10. This heater is intended for general heating applications ONLY. It must NOT be used in potentially dangerous locations such as ﬂ ammable explosive, chemical-laden or wet atmospheres.

In cases in which property damage may result from malfunction of the heater, a backup system or a temperature sensitive alarm should be used.

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Page 4

The open end of piping systems being purged shall not discharge into areas where there are sources of ignition or into conﬁ ned spaces UNLESS precautions are taken as follows: (1) By ventilation of the space, (2) control of purging rate, (3) elimination of all hazardous conditions. All precautions m ust be taken to perform this operation in a safe manner!

LOCA TIONS TO A V OID

Unit heaters should not be installed within corrosive or ﬂ ammable atmospheres. Do not locate any gas ﬁ red heater where air for combustion contains chlorinated vapors or acid fumes. Avoid locations where extreme drafts can affect burner operation.

Presence of these air impurities can cause premature failure of the heat exchanger and void the warranty (See limited warranty on page 24).

The venting system must be installed in accordance with heater manufacturer’s instr uctions. The venting system is an integral part of the unit and must not be altered

in the ﬁ eld!

RIGGING

Rig unit using either belt or cable slings. Use spreader bars to protect the top of the unit when it is lifted. See Figures 1 and 2. Mak e sure all hardware used in the lifting/mounting process is tightened and secured.

Figure 1 - Hoisting of Make-Up Air Unit Without Lifting Brackets

Figure 2 - Hoisting of Make-Up Air Unit With Lifting Brackets

On units with a total length of less than 104" (2642mm), excluding evaporative cooler, two holes are provided in the base rail on each side of the unit. Slide pipes beneath the unit through these holes and attach rigging to pipes for lifting the unit.

On units with a total length of a 104" (2642mm) or greater, excluding evaporative cooler, lifting lugs/brack ets attached to the base rail are provided. Once the unit is set in place these lifting brackets may be removed if required.

Attach rigging to lugs/brackets for lifting the unit. F or distance between lifting lugs/brackets and total unit lengths, refer to the Dimensional Data section of this manual. Also see Center of Gravity and W eights sections in this manual prior to lifting and apply accordingly to the lifting process.

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Page 5

III. INSTALLATION

LOCATION

Before placing the Make-Up Air unit in its permanent location, make certain that the structure is capable of carrying the additional load of this equipment. Check the unit weight given at the end of this manual.

Refer to Table for required clearances to combustible material, and Figure 5 for manufacturer’s recommendations.

3. In parking structures, Gas Fired Indoor Make-Up Air Handlers must be installed so that the burner ﬂ ames are located 18 in. (45mm) abo ve the ﬂ oor or protected by a partition not less than 18 in. (457mm) high as speciﬁ ed in NFPA 88A Parking Structures.

4. In public repair garages, Gas Fired Make-Up Air Handlers must be installed in a detached building or room separated from repair areas as speciﬁ ed in NFPA 88B Repair Garages.

Do not place unit in a location where service personnel can not safely service this equipment or personal injury could result.

NOTICE: When selecting a location for these MakeUp Air Units, both the size of the unit and the heating requirements of the building must be considered.

COMBUSTION AIR CONSIDERATIONS

The presence of chlorine vapors or other corrosive vapors in the combustion air supply for gas-ﬁ red heating equipment presents a potential corrosive hazard. Chlorine will, when exposed to ﬂ ame, precipitate from the compound (usually freon or degreaser vapors) and go into solution with any condensation that is present in the heat exchanger or associated parts. The result is hydrochloric acid which will readily attack all metals, including 300 grade stainless steel. Care should be taken to separate these vapors from the combustion process.

MOUNTING HEIGHT

1. When a Gas Fired Make-Up Air Handler is discharging directly into the heated space, a mounting height of eight feet (2.4m) above the ﬂ oor is recommended. Less efﬁ cient air distribution results at higher levels.

2. When Gas Fired Indoor Make-Up Air Handlers are installed in airplane hangars, NFP A speciﬁ es that the units must be at least ten feet (3.0m) abov e the upper surface of wings or engine enclosures of the highest aircraft to be stored in the hangar. This measurement should be made from the wing or engine enclosure (whichever is higher from the ﬂ oor) to the bottom of the heater. Heaters must be installed at least eight feet (2.4m) abov e the ﬂ oor in shops, ofﬁ ces, and other sections of the hangar where aircraft are not stored or housed. Refer to NFPA 409 Aircraft Hangars.

SUSPENSION

The unit should never be lifted by the fan housing, motor mounting, grille or ﬂ ue connection. These are not designed to support the total weight and may break, causing per sonal injury or unit damage.

Units can be set on supports or suspended by rod hangers from the sub-frame (and lifting brackets).

Any unit that has a side base rail longer than 104" (2.6m) requires additional field furnished supports by a qualiﬁ ed installer. Refer to all dimensional data and center of gravity information in this manual. If further information is required, contact the manufacturer’s technical service department.

The unit must be hung level from side to side and front to back, using the four (9/16" diameter) hanging holes (see Figure

3) in the skid rail, and 3/8" or 1/2" threaded rod or pipe.

Make certain that the structure to which the heater is to be mounted is capable of supporting its weight. Under no circumstances must the gas lines, the venting system or the electrical conduit be used to support the heater; or should any other objects (i.e. ladder, person) lean against the heater , gas lines, venting system or the electrical conduit for support.

Figure 3

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D8769

Page 6

MOUNTING ON FIELD FURNISHED SUPPORTS

Single, double, triple duct furnace models have base rails which are suitable for mounting either directly on solid planking or steel channels. (Refer to Figure 4).

Figure 4

Capacity

"C" Dim.

(CA)

30-5/8"

10/15

(778)

41-5/8"

20/25/50

"C"

Support Must Clear Return Air Opening And Fit Inside Base Rail Flange

30/35 60/70

40/80/12

(1057) 52-5/8"

(1337) 58-1/8" (1476)

INSTALLATION CLEARANCES

Minimum clearances to combustible material are shown on the unit data plate. It is important that clearances be maintained for servicing the unit, and that minimum clearances are provided from the unit to combustible material. Clearances around the ﬁ eld installed optional outside air hood (if unit is to be connected to one) must be unobstructed. See Figure 5.

Every gas appliance should be located with respect to building construction and other equipment so as to permit access to the unit. Clearances between ver tical walls and the vertical sides of the heater should be no less than 6 inches (152mm). Minimum clearance between the top of the heater and the ceiling is 6 inches (152mm). The minimum clearance from combustibles to the bottom of the furnace is 6 inches (the distance between the unit skid rail bottom and the furnace bottom is approximately 7 inches (178mm) which meets this 6 inch clearance requirement to combustible materials). The minimum clearance from combustibles to the ﬂ ue collector is 6 inches (152mm). Adequate clear ance must be maintained around all openings into the combustion chamber. Adequate clearance should be planned for the width of the unit to pull out the burner drawer. See Figure 5 and Table #T4088-B, D.

A pilot burner plate is provided in the Duct Furnace for easy access to the pilot burner and ignition system without opening burner drawer compartment. Accessibility is also provided for the safety switches included with your unit without removal of jacketry. Refer to the maintenance section and the Indoor Duct Furnace manual for more information.

The unit should never be lifted by furnace sections, blower housing/ﬁ lter/sections, motor mounts or ﬂ ue connections. These are not designed to support total weight of the unit, and may break, causing personal injury or property damage!

Figure 5 - Manufacturer’s Recommended Service Clearances

methods used to lift the Make-Up Air Unit are capable of supporting the weight of the heater during installation. Failure to heed this warning may result in property damage or personal injury.

Clearance For Drawer Pull-Out

D8773

AIR FLOW

Indoor

Make-Up

Unit

AIR FLOW

Make certain that the lifting

Note: Recommended ceiling clearance 36" (914mm) is to the top of the furnace venting collar assembly.

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Page 7

Make certain that the structure to which heater is to be mounted is capable of safely supporting its weight. Under no circumstances must the gas lines or the electrical conduit be used to support the heater. Failure to heed these warnings may result in property damage, personal injury or death.

Open all disconnect switches before installing the unit. Failure to do so may result in personal injury or death from electrical shock.

ACCESS PANEL REMOVAL

Unless your unit is equipped with optional hinged access doors, the air handler sections are equipped with access panels that are held in place with two “grip” latches.

To remove these access panels: use a slotted head screw driver to turn the latch screwhead counterclockwise. Using the handle provided, push the panel upwards. Pull the bottom of the panel out and lower the panel to disengage it from the top lip.

To replace access door panels: guide the panel door upwards on the tracks, and push up into the top lip, swing and lower the panel in place until it engages with the bottom panel. Turn the screwhead on each latch clockwise. The screw must turn freely one quarter turn before resistance is felt in order for the lock to engage. If latch does not hold, turn screw counter-clockwise sev er al turns and repeat the above procedure.

The furnace section service panel is easily accessible

- simply remove the mounting screws on the lower jacket panel to disengage and remove the panel; repeat procedure for installing back in place. See the

maintenance section and the duct furnace manual for more information regarding burner drawer removal/accessibility.

VENTING†

All venting installations shall be in accordance with the latest edition of Part 7, “Venting of Equipment”, of the National Fuel Gas Code, ANSI Z223.1-1996 (or the latest edition), or applicable provisions of local building codes.

CARBON MONOXIDE! Your venting system must not be blocked by any snow, snow drifts or any foreign matter. Inspect your venting system to ensure adequate ventilation exists at all times! Failure to heed these warnings could result in Carbon Monoxide Poisoning (symptoms include grogginess, lethargy, inappropriate tiredness, or flu-like symptoms).

The venting is an integral part of

the unit and must not be altered in the ﬁ eld.

The units are available in two types of venting processes

- Natural or Power Vented. Natural Vent units are equipped with a draft diverter; air for combustion enters in through an opening in the draft diverter, and products of combustion are discharged through a ﬂ ue vent (ﬁ nal connections ﬁ eld installed). The High Efﬁ ciency Power Vented units feature a factory installed power venter and sealed ﬂ ue collector that controls combustion and excess air during the on-cycle.

VENT SYSTEMS - TERMINATION CLEARANCE REQUIREMENTS Minimum Clearances for Structure Termination Locations

Door, window or 4 feet below any gravity air inlet 4 feet horizontally 1 foot above Forced air inlet within 10 feet 3 feet above Adjoining building or parapet 6 feet Adjacent public walkways 7 feet above grade

*If the vent terminal is to be installed near ground level, the vent terminal must be positioned at least six inches (152mm) above the

maximum anticipated snow depth.

†Refer to the Indoor Duct Furnace Manual for more venting requirements.

AIR FOR COMBUSTION

Appliances shall be installed in a location in which the facilities for ventilation per mit satisfactory combustion of gas, proper venting, and the maintenance of ambient temperature at safe limits under normal conditions for use.

Appliances shall be located in such a manner as not to interfere with proper circulation of air within the conﬁ ned space. When buildings are so tight that normal inﬁ ltration does not meet air requirements, outside air shall be introduced per Sections 1.3.4.2 and 1.3.4.3 of ANSI Z223.1 for combustion air requirements. A permanent opening or openings having a total free area of not less than one square inch per 5,000 Btu/Hr of total input rating of all appliance within the space shall be provided. Refer to the Indoor Duct Furnace Manual supplied with your unit for more requirements.

DUCT CONNECTIONS

All ductwork must be properly supported so that no strain is put on the unit. Do not alter or bend the discharge duct ﬂ anges supplied on your make-up air unit.

Duct connections must have a removable access panel in the duct which is connected to a duct furnace. The duct openings shall be accessible when the unit is installed in service, and shall be of such size that smoke or reﬂ ected light may be observed inside the casing to indicate the presence of leaks in the heating element. The covers for the panels shall be attached in such a manner as to prevent leaks . Ducts (or optional outside air hoods) exposed to the outdoors must be insulated and sealed to prevent water from entering either the unit or building through the duct.

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Page 8

If a single, double or triple duct furnace only unit is

connected to a return air duct, or any other inlet air restriction, the appliance shall be installed on the positive pressure side of the air circulating blower.

The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psig (3.5 kPa).

When connecting return air duct to Standard or High CFM cabinets, attach duct to return air opening ﬂ ange when no dampers are used. Otherwise, if dampers are used, attach return air duct around collar at bottom of damper assembly. Also refer to the Dimensional Data section of this manual, Submittal Data Sheets and Indoor Duct Furnace Manual speciﬁ ed for your unit.

GAS PIPING††

All gas piping must be installed in accordance with local codes. It is required that a ground union be installed adjacent to the gas valve of each duct furnace, and a ground union be installed just external of each duct furnace for unit servicing. On vertical runs, a drip leg should be provided upstream of any control manifold. A gas shutoff valve should be, or may be required by local codes, installed upstream of the external ground union for each duct furnace. A 1/8 inch N.P.T. plugged tapping, accessible for test gauge connection, must be installed immediately upstream of the unit gas supply connection.

†† For complete Gas Piping installation, see the Indoor Gas-Fired Duct Furnace Installation and Service Manual.

Gas piping must be installed to allow for removal of burner drawer for unit maintenance. Refer to Figure 5, and the maintenance section.

To avoid equipment damage or possible personal injury, do not connect gas piping to this unit until a supply line pressure/ leak test has been completed. Connecting the unit before completing the pressure/leak test may damage the unit gas valve and result in a ﬁ re hazard.

The appliance must be isolated from the gas supply piping system by closing the individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig (3.5 kPa).

For additional gas piping information, including pipe sizing and drip leg installation, refer to Indoor Gas-Fired Duct Furnace Installation and Service Manual.

For additional piping information, refer to the National Fuel Gas Code Z233.1 (latest edition).

NOTICE: If the gas duct furnace is to be ﬁ red with LP gas, consult local LP gas dealer for piping size information.

NOTICE: Unit installation for use with propane (bottled) gas must be made by a qualified LP gas dealer or installer. He will insure proper joint compounds are used for making pipe connections; that air is purged from lines; that a thorough test is made for leaks before operating the unit; and that it is properly connected to propane gas supply system.

Before any connection is made to an e xisting line supplying other gas appliances, contact the local gas company to make certain that the existing line is of adequate size to handle the combined load.

Check all connections for leaks with soap solution.

MODULATING GAS CONTROL (OPTIONAL)* Mechanical: On units equipped with mechanical modulating

gas control, the temperature sensing bulb for the gas v alv e must be ﬁ eld installed in the supply plenum. Carefully uncoil the capillary tubing to prevent kinking or sharp bends.

Do not rely on a gas shutoff valve to isolate the unit while conducting gas pressure/leak tests. These valves may not be completely shutoff, exposing the unit gas valve to excessive pressure, resulting in damage.

Do not over-tighten the inlet gas piping at unit gas valve or stresses that could crack the valve may result.

Never use an open ﬂ ame to detect gas leaks. Explosive conditions may e xist which would result in personal injury or death.

The gas line should be supported so that no strain is placed on the unit. Pipe compounds which are not soluble to liquid petroleum gases must be used on threaded joints.

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/2" (12.7mm) of the connection to the bulb or the valve.

Do not bend the capillary tubing within

Repeated bending may cause the tubing to leak or break.

Center and fasten the temperature sensing bulb in the supply duct at least 6 inches beyond the last duct furnace section. See Figure 7.

Figure 7

(152)

Min.

Supply Duc

Temperature Sensing Bulb Mounted To "L" Bracket Centered In Supply Duct.

D8772

Duct Furnace

AIR FLOW

Page 9

Electronic: On units equipped with electronic modulating control, follow control manufacturer’s installation instructions for sensing of outlet air temperature.

*Also refer to the Indoor Duct Furnace Installation Manual supplied with your unit.

ELECTRICAL CONNECTIONS

All electrical connections, line voltage and thermostat, are made in the Electrical Cabinet (See Figure 8). Line voltage connections are made at the High Voltage Terminal Block. Thermostat connections are made at the Main Connection Board (See Figure 9).

Do not use any tools (i.e. screwdriver, pliers, etc.) across terminals to check for po wer. Use of a voltmeter is recommended.

HAZARDOUS VOL TAGE!

DISCONNECT ALL ELECTRIC POWER INCLUDING REMOTE DISCONNECTS BEFORE SERVICING. Failure to

Locate the thermostat in accordance with the instructions supplied with the thermostat. All ﬁ eld wir ing must have a minimum temperature rating of 85°C (185°F). Control wiring shall be a minimum of 18 gauge wire size. Control wiring must be sized for length of run.

disconnect power before servicing can cause severe personal injury or death.

All electrical connections must conform to: ANSI/NFPA No. 70-1996 (or latest edition) National Electrical Code and applicable local codes. In Canada, to the Canadian

Locate line voltage disconnect box per local codes. If mounting the disconnect box to the unit, never mount it to a unit access panel. Possible locations include the front of the blower or ﬁ lter section (See Figure 10). Electrical conduit must be routed so as not to interfere with removal of any access panel.

Electrical Code, Part I CSA Standard C22.1.

NOTICE: Should any original wire supplied with the

The Make-Up Air packaged unit is wired at the factory and ready to be connected. Actual unit wiring will differ according to the options chosen. Each unit is shipped

unit have to be replaced, it must be replaced with wiring having a temperature rating of at least 105°C (221°F).

with its own wiring diagram; refer to this wiring diagram for all electrical connections to the unit.

Figure 8 - Make-Up Air Unit-Standard Blower Cabinet, Single Duct Furnace with Various Options Shown

[Power Vented ME Unit Shown]

1. Mixed Air Controller

2. Return Firestat

3. Economizer

4. Filters

5. Blower Motor

6. Reverse Air Flow Switch

7. Clogged Filter Switch

8. High Voltage Barrier, Lamp and Circuit Breaker Mount

9. Main Connection Board with Fan Time Delay and Function Relays

10. Power Venter Motor Assembly (includes Relay and Air Pressure Switch)

11. Junction Box/Ignitor

12. Time Delay Freezestat

13. Supply Firestat

14. Duct Thermostat

15. Primary Safety Limit

16. Gas Valve

17. High Limit Safety Switch

18. Transformer

19. Electrical Wiring Inlet

20. High Voltage Terminal Block

21. Door Safety Switch

22. Contactor

23. Centrifugal Blower

24. Damper Motor

25. Outside and Return Dampers

26. Ambient Lockout

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Page 10

Figure 9 - Electrical Cabinet

Figure 10 - Disconnect Box Locations

Disconnect Box Located On Outside Air Application

Return Air Inlet

DX COIL EQUIPPED UNITS (OPTIONAL)

See Coil Installation/Maintenance Manual for Refrigerant Piping, Liquid and Suction Line Components, Refrigerant Charging and Thermal Expansion Valve Adjustment. Remove coil cabinet access door located next to blower section. Cut holes in ﬁ xed door to allow suction and liquid line passage. Provide weatherproof seal around suction and liquid lines at piping plate when installed.

The DX Coil has a 300 ft/min. (1.524 m/s) minimum and a 600 ft/min. (3.048 m/s) maximum velocity through the coil requirement. This is due to prevention of coil icing or condensate blow-off. To calculate the velocity through the coil, apply the following formula:

Velocity =

Cooling Air Flow in CFM (m3/s)

through the coil Coil Surface Area in ft2 (m2) Condensate Drain piping must have a P-trap in line

immediately downstream of drain pan connection, external to the unit, to prevent possible outside air leakage into unit. The P-trap shall be of sufficient differential to overcome negative pressure of the indoor air blower. A minimum height difference of 2" (51mm) is required (See Figure 11). Before unit operation begins, the P-trap must be primed with either water (summer) or glycol (winter).

CHILLED WATER COIL EQUIPPED UNITS (OPTIONAL)

See Coil Installation/Maintenance Manual for General Coil Piping Recommendations. Remove coil cabinet access door, cut holes in door to allow chilled w ater piping passage. Provide weatherproof seal around chilled water pipes at piping plate when installed.

The Chilled Water Coil has a 600 ft/min (3.048 m/s) maximum velocity through the coil requirement. This is due to prevention of condensate blow-off. To calculate the velocity through the coil apply the following formula:

Velocity =

Cooling Air Flow in CFM (m3/s)

through the coil Coil Surface Area in ft2 (m2) Condensate Drain piping must have a P-trap in line

immediately downstream of drain pan connection, external to the unit, to prevent possib le outside air leakage into unit. The P-trap shall be of sufﬁ cient differential to overcome negative pressure of the indoor air blower. A minimum height difference of 2" is required (See Figure

11). Bef ore unit operation begins, prime P-trap with either water (summer) or glycol (winter).

EVAPORATIVE COOLER EQUIPPED UNITS (OPTIONAL)

Refer to Evaporative Cooler Installation and Service Manual for water and electrical connections.

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Page 11

Drain Pan Connection

Total

Height

of Trap

X = 1/2 “H” H = At Least 1 Inch Plus Casing Static Pressure

D3887

Total Height Of Trap = X+ H + (1-1/2 X Pipe Diameter)

Unit

Housekeeping

Pad

IV. OPERATION

GENERAL INFORMATION

Refer to Indoor Gas-Fired Duct Furnace Installation and Service Manual for speciﬁ c information regarding the heating operation of this unit.

All units are equipped with an intermittent ignition pilot system. The pilot is lit and e xtinguished each cycle of unit heating operation.

The gas valve consists of two operators which provide gas to the pilot and main burners. Both operators are energized and de-energized by the ignition control module each heating cycle.

The pilot burner includes an ignitor and ﬂ ame sense probe. The ignitor provides the spark, originating at the ignition control module, to light the pilot. The ignition control module proves and monitors the pilot ﬂ ame through the ﬂ ame sensing probe.

On natural gas units, the ignitor will continue to spark and pilot gas will continue to ﬂ ow until the pilot ﬂ ame is proven.

LP (propane) units are equipped with 100% lockout. The lockout function shuts off the main and pilot gas valves if the pilot gas fails to ignite within 90 seconds of the onset of trial for ignition.

The gas control system operates at 24 VAC and is supplied by a stepdown transf ormer found in the electrical cabinet that will match the unit line voltage speciﬁ ed. See Figure 8 for unit controls location.

Figure 11 - Drain Pan Connection

SEQUENCE OF OPERATION

All units follow the same basic sequence of operation and is as follows (additional power vented sequences are also described):

1. Thermostat calls for heat. (Po wer vented units only:

Draftor relay energizes draftor with call for heat).

2. Ignition control module energizes pilot operator of gas

valve and initiates spark at ignitor of the pilot burner.

3. Pilot burner ignition is proven to the ignition control

by the ﬂ ame sense probe and sparking of the ignitor is discontinued.

4. Once pilot burner operation is proven, the ignition

control module energizes the main burner operator of the gas valve, allowing gas flow to the main burners. (Pow er vented units only: In addition, draftor operation must be proven b y dr aftor pressure s witch before ignition control module energizes main burner operator of gas valve).

5. Approximately 60 seconds after the main burners

light, the fan time delay initiates fan operation.

Do not use a thermostatic fan control switch when either two-stage ﬁ ring or modulated gas controls are used.

GAS CONTROL SYSTEM

The standard unit comes equipped for single stage operation. Unit heating operation is accomplished at full input.

Each duct furnace is equipped with an individual ignition control system which consists of the following components: ignition control module, gas valve and pilot burner.

The ignition control module is the heart of the ignition control system. This control initiates all gas ﬂ ow, provides means to light the pilot burner, proves and monitors the pilot burner operation.

6. Ther mostat is satisfied and call for heat is

removed. (Power vented units only: Draftor relay de-energizes draftor with removal of call f or heat).

7. Ignition control module de-energizes pilot and main

burner operators of the gas valve , ceasing all gas ﬂ ow.

8. Approximately two minutes after satisfying the

thermostat, fan operation ceases.

OPTIONAL GAS CONTROLS

These units are available with optional gas controls which will give either multi-stage or modulating operation. The sequence of operation of those units equipped with these optional gas controls differs only at what rate each duct furnace’s main burners ignite and operate at, or the order of duct furnace ﬁ ring for those units equipped with two or three duct furnaces.

Two Stage Units: Two stages of heating; ﬁ rst stage is 50% of full rate, second stage is 100% of full rate. Main burner ignition is at ﬁ rst stage only.

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Page 12

Three Stage Units: Dual duct furnace models: First furnace is equipped with two stage heating; second furnace is equipped with single stage heating but ﬁ red independently, giving three stages of heating. Triple duct furnace models: Each duct furnace is equipped with single stage heating but fired independently, giving three stages. Each stage is 33% of the unit’s full input rate . Duct furnace one will always light ﬁ rst and disengage last.

Four Stage Units: Dual duct furnace models only. Each duct furnace is equipped with two stage heating but ﬁ red independently, giving four stages. Each stage is 25% of the units full input rate. Duct furnace one will always light ﬁ rst and disengage last.

Six Stage Units: Triple duct furnace models only. Each duct furnace is equipped with two stage heating but ﬁ red independently giving six stages. Each stage is 16.5% of the units full input rate. Duct furnace one will always light ﬁ rst and disengage last.

Electronic Modulation Units: These units are equipped with an electronic modulating control which provides unit ﬁ ring capabilities of 50 to 100% of the units full input rate. This control is found in the gas train downstream of the gas valve and allows main bur ner ignition only at the maximum rate. A thermostat with remote setpoint adjustment modulates the gas input.

AIR HANDLING REQUIREMENTS AND ADJUSTMENTS

Remove wooden shipping support from beneath blower housing of Blower Section (if applicable) to prevent possible unit damage or improper unit operation.

Static Pressure through the unit should never exceed

2.0” W.C. (0.50 kPa). Units operate at a temperature rise range of 30 to 80°F (17 to 44°C).

NOTICE: It is impor tant that the ﬁ nal temperature leaving the unit does not exceed 160° F (71°C). When ﬁ nal air throughput adjustments are being made, a check of the discharge air temperature should be made after unit has operated for 15 to 20 minutes.

A unit should never be allowed to cycle on the primary limit for a prolonged period of time. It is a safety control to prevent a ﬁ re. If cycling on the primary limit is noted, corrective measures should be taken immediately. Failure to do so could result in unit damage or a ﬁ re.

NOTICE: At initial unit installation, unit should be started momentarily to conﬁ rm proper blower wheel rotation as the unit will deliver some air with the blower wheel running backwards.

Multi-Stage w/Electronic Modulation Units:These dual

and triple duct furnace models are equipped with an electronic modulating control on duct furnace one and single or two stage heating on each successive duct furnace. Furnace one (modulated) will ﬁ re ﬁ rst and disengage last. Additional stages of heat will engage after furnace one has ﬁ red at maximum modulation capability for the duration of the delay setting. The amount of modulation and each stage size depends

upon

unit size and the number of stages. See following chart.

Modulation Stage

Number Capabilities Size of Stages (% of full input) (% of full input)

2 25 - 50 50 3 16.5 - 33 33 4 25 -50 25 6 16.5 - 33 16.5

Two basic air control systems can be used to deliver conditioned air to the occupied space: intermittent or constant fan operation.

Intermittent Fan Operation: The unit employs an air control system which utilizes a fan time delay relay to operate the fan while heating and the thermostat while cooling. Refer to unit wiring diagram.

Constant Fan Operation: The unit can be wired to give an air control system which constantly circulates air through the unit and occupied space with constant fan operation. Refer to unit wiring diagram.

NOTICE: Check blower belt tension. Proper belt tension is important to the long life of the belt and motor. Proper belt tension will allow the belt to be depressed 1/2" to 3/4".

It is important that the blower motor and the blower wheel pulleys be in good alignment, with the motor and blower shafts parallel.

Belt tension must be adjusted to give approximately

/4" deﬂ ection of the belt when ﬁ nger pressure is applied to the middle of the belt (See ﬁ gure 12). Small changes in this tension may be necessary for optimum operation. Belts will stretch over a period of time, requiring an adjustment to this tension. See MAINTENANCE section for belt and pulley adjustments.

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Page 13

These units are set at the factory for the RPM required to

1/2" TO 3/4"

meet the air volume (CFM) and external static pressure ordered. If the estimated exter nal static is incorrect, or changes were made to the duct system, the blower RPM may need to be changed.

Both the Standard and High CFM Blowers use motors which are equipped with adjustable pitch pulleys. After removing belt(s), loosen the pulley set screw and remo ve the key, turn adjustable half of a pulley clockwise to increase RPM, or counter-clockwise to decrease RPM. Insert key, tighten set screw and replace belt(s). Adjust belt tension to give

/2" to 3/4" belt play when depressed.

Blower motor full load amps should never be exceeded. Improper unit operation or motor failure could result.

After changing blower RPM, conﬁ rm blower motor full load amps have not been exceeded. See motor data plate for maximum full load amps.

3. Set thermostat to highest level. This will initiate the sequence of operation detailed in the Gas Control System section. Check main burners for operation.

4. Set thermostat to lowest level. This will interrupt power to the ignition control and shut off gas. Conﬁ rm pilot and main burners have been extinguished.

5. Set the thermostat to the desired setting.

For complete unit shutdown, proceed as follows:

1. Turn off the gas valve(s) main manual valve.

2. Set thermostat to lowest setting.

3. Shut off all electric power.

GAS INPUT ADJUSTMENT

When shipped from the factory, all units are equipped for the average heat content of the gas which is stamped on the unit rating plate.

Figure 12

LIGHTING

(Refer to Indoor Duct Furnace Manual for all heating functions - general comments are as follows.) Purge the gas line to the unit of air before attempting to light the pilot. Check for gas leaks.

Never use an open ﬂ ame to detect gas leaks. Explosive conditions may exist which could result in personal injury or death.

This unit is equipped with an intermittent ignition system. A lighting instruction label is attached to the unit. To set the intermittent ignition system into operation, proceed as follows:

Since the heat content of gas varies by locality, the input must be checked after installation of the unit. If the unit is overﬁ red it will shorten the life of the heat exchanger. Never exceed the input on the rating plate.

For an accurate input rate measurement, the following meter method should be used to determine unit input rate. If the meter method is not possible, a manifold pressure check should be made.

Meter Method of Checking Input Rate

1. Obtain the heating value of the gas from the local

utility or gas dealer. This should be in units of Btu/ft3 (MJ/m3).

2. Determine the gas ﬂ ow rate as shown in the f ollowing

example. EXAMPLE: Assume this unit has a input rate of 250,000 Btu/hr (73.2 kW) and the heating value of the gas is 1000 Btu/ft3 (37.3 MJ/m3).

Gas 250,000 Btu/hr Flow = Rate

1000 Btu/ft3 x 60 min/hr

= 4.17 ft3/min

3. Before determining the gas ﬂ ow rate to the unit, all

other gas appliances connected to the same meter must be turned off.

4. Fire unit according to instructions.

1. Turn on the gas valve(s) main manual valve.

2. Turn on electrical power. The unit is now under thermostat control.

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Page 14

5. After approximately 15 minutes of unit operation, determine volume of gas used in ﬁ ve minutes of unit operation. For the Example above the unit should use

4.17 ft3/min x 5 minor 20.8 ft3 (1.97 L/s x 5 min x 60 s/ min = 591L) of gas. Minor input adjustments can be made by removing pressure regulator cap and turning regulator clockwise to increase input or counter clockwise to decrease input. Any appreciable adjustment in input rate should be made by reoriﬁ cing.

Method to Check Manifold Pressure

1. Close the manual valve of unit gas valve.

2. Install a

/8" pipe connection in the tapped hole

provided in the gas valve body near outlet of the valve.

CONTROLS (also see the Indoor Duct Furnace Manual): Primary Limit Control: The primary limit control is a

factory installed component surface mounted in the inlet airstream at the end of the heat exchanger. When the temperature reaches the limit setpoint, normally caused by insufﬁ cient air throughput, all gas is shutoff. The limit control has an automatic reset and once the unit has cooled, it will reset itself. This is a safety control and if cycling on the primary limit is noted, corrective action must be taken. See unit wir ing diagram for electrical location. This control must never be bypassed. Upon completion of unit installation, the primary limit must be checked for proper operation. This can be accomplished by removing power to the indoor air blower and a call for heat.

3. Attach manometer to 1/8" pipe connection by means

of a rubber hose.

4. Fire unit according to instructions and obser ve the

pressure and conﬁ rm it matches the unit manifold pressure from the unit rating plate.

5. Small variations in the manifold pressure can be

made by means of the gas valve pressure regulator. Remove pressure regulator cap and turn regulator clockwise to increase pressure or counter-clockwise to decrease pressure.

PILOT ADJUSTMENT

Disconnect wire from terminal marked MV at gas valve.

2. Provide call for heat.

3. Pilot adjustment is found on the gas valve. Remove pilot adjustment cap.

4. Adjust the pilot screw to provide properly sized ﬂ ame.

5. A proper pilot burner ﬂ ame is a soft steady ﬂ ame that envelopes 3/8 to 1/2 inch (9.5 to 12.7mm) of the ﬂ ame sense probe tip.

6. Replace the pilot adjustment cap.

7. Reconnect wire to terminal MV.

PRIMARY AIR SHUTTER ADJUSTMENT

After the unit has been in operation for at least 15 minutes, adjust the primary air ﬂ ow to the burners. Tur n the friction-locked manually rotated air shutters clockwise to close, counter clockwise to open. For correct air adjustment, close the air shutter until yellow tips in the ﬂ ame appear. Then open the air shutter to the point just beyond the position where yellow tipping disappears.

Clogged Filter Switch: (Optional) The clogged ﬁ lter s witch monitors the pressure differential across the air ﬁ lters. If this pressure differential becomes too great, the s witch will alert of this condition. At this point the air ﬁ lters must either be cleaned or replaced. The switch will reset itself.

Firestat: (Optional) Located in either the return airstream, the supply airstream, or both, this control monitors temperatures with setpoints which are ﬁ eld adjustable. If the temperature exceeds the setpoint, the control will cease unit operation. To resume unit operation, a manual reset of this control is required.

Freezestat: (Optional) Located in either the return airstream, the supply airstream, or both, this control monitors temperatures with setpoints which are ﬁ eld adjustable. If the temperature does not exceed the setpoint, the control will cease unit operation.

V. START UP

Before starting the unit, use the “Installation Check Sheet” (located at the end of this manual) and read the Indoor Duct Furnace Manual entirely in conjunction with the procedures outlined below to ensure that the unit is completely and properly installed and ready for start up.

It is the installer’s responsibility to check all safety controls! Check and test the operational functions of all safety devices supplied with this unit. Failure to do so could result in unsafe conditions and may result in death, serious injury or property damage.

1. Inspect all wiring connections; connections should be clean and tight. Trace circuits to insure that actual

wiring agrees with the “as wired” diagrams provided with the unit. Information in the wiring

diagram title block should match the data appearing on the unit nameplate.

2. Lubricate all electrical motors according to the manufacturer’s recommendations.

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Page 15

3. Verify that the system switch is in the OFF position.

4. Check unit supply voltage to ensure that it is within the utilization range.

5. Inspect the interior of the unit; remove any debris or tools which may be present.

Starting Unit in Heating Mode

1. Close the unit disconnect switch which provides power to the unit.

High voltage is present in some areas of the unit (primarily the main electrical cabinet) with the unit disconnect switch closed. Failure to exercise caution when working in the presence of energized electrical components may result in injury or death from electrical shock.

2. Set the thermostat/switching subbase as indicated below: a. position the heating system switch at either HEAT or AUTO; b. set the fan switch to AUTO.

3. Place the system switch in the ON position. With the thermostat calling for heat, unit operation is automatic.

Starting Unit in Cooling Mode

1. Close the unit disconnect switch which provides power to the unit.

2. Set the thermostat/switching subbase as indicated below: a. position the cooling system switch at either COOL or AUTO; b. set the fan switch to AUTO.

3. Place the system switch in the ON position.

With the thermostat calling for cooling, unit operation is automatic.

Final Checkout

Run the unit sequentially through its stages of heating and cooling. Once proper unit operation is verified, perform these ﬁ nal steps:

1. Inspect unit for debris and/or misplaced tools and hardware.

3. Cycle unit on all safety controls to verify proper unit operation.

4. Confirm proper operating control (thermostat or ductstat) operation by cycling unit.

5. Secure all exterior panels in place.

VI. MAINTENANCE

HAZARDOUS VOL TAGE!

DISCONNECT ALL ELECTRIC POWER INCLUDING REMOTE DISCONNECTS BEFORE SERVICING. Failure to disconnect power before servicing can cause severe personal injury or death.

It is the service technician’s responsibility to check all safety controls! Chec k and test the operational functions of all safety devices supplied with this unit. Failure to do so could result in unsafe conditions and may result in death, serious injury or property damage.

These units have been developed for indoor installation. Maintenance is required and it is suggested that the following unit servicing and inspections be performed routinely. Also read in entirety and refer to the Indoor Duct Furnace Manual for maintenance requirements.

Inspect area near unit to be sure that there is no combustible material located within the minimum clearance requirements (See Figure 5). Service panels provide easy access to the gas controls (located in duct furnace section), the blower compartment, the electrical cabinet and the supply plenum. To remove the service door from any of these compartments, refer to access panel removal section in beginning of this manual.

The pilot burner can be serviced by removing the pilot plate from the main burner drawer assembly.

The (rear) high limit safety switch is accessible by removing the exterior upper jacket, then remove the mounting plate from the side panel of the heat exchanger. This limit must have proper surface contact when reinstalled. The (front) primary safety limit is accessible by removing the mounting cover from the furnace jacket.

2. Be sure all gas valves and controls are in the operating position if the unit will be operating immediately.

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Page 16

To remove the main burner drawer assembly (also refer to Indoor Duct Furnace Installation and Service Manual) for servicing the burners, proceed as follows:

1. Shut off the gas supply at the gas shutoff valve and electrical power to the unit.

14. Inspect and service the blower section of the system.

15. Inspect and check the operational functions of all safety devices equipped with y our unit to ensure that all devices are performing adequately.

2. Break the union upstream of duct furnace gas valve and loosen the union external to the furnace; swing downward the piping to clear drawer.

3. Disconnect duct furnace gas valv e wiring taking note of all wire locations. Disconnect ignitor and ﬂ ame sensing probe wires at ignition control module and any other wires.

4. Remove the loc king screws holding the burner drawer assembly in position.

5. Slide the burner drawer out of the duct furnace.

6. Removal of b urners is accomplished by sliding burner towards manifold, compressing locating spring, until the rear of the burner clears slot in back of burner drawer.

7. With burner drawer removed from duct furnace, inspect the inside surfaces of the heat exchanger. Wire brush if necessary.

8. Remove any dirt, dust or other foreign matter from the burners using a wire brush and/or compressed air. Insure all par ts of the burner are unobstructed. Inspect and clean pilot burner if necessary.

9. Reassemble the duct furnace by replacing all parts in order.

10. Light unit per the unit lighting instructions.

HIGH LIMIT AND/OR SAFETY LIMIT MAINTENANCE

To service or replace high limit and/or safety limit:

1. T urnoff the manual gas v alv e and electrical power to the MS unit.

2. To service the High Limit:

a. Remove the Mounting Cover located on the

access side of the unit toward the rear (Air Inlet) of the furnace section. Remove the mounting plate from the side panel of the heat exchanger. The mounting plate is part of the High Limit; making note of wire locations for reconnecting.

b. c. Reassemble the High Limit by replacing all parts

3. To service the Safety Limit:

a. Remove Mounting Cover located on the access

b. Remove all electrical connections from the Safety

c. Reassemble the Safety Limit by replacing all parts

4. Complete appropriate start-up procedure as given in

Remove all electrical connections from the High Limit; making note of wire locations f or reconnecting.

in order; making sure the High Limit is making proper surface contact when installed.

side of the unit toward the front (Air Outlet) of the furnace section.

Limit; making note of wire locations for reconnecting.

in order; making sure the Safety Limit is making proper surface contact with the side of the heat exchanger.

the “Start-Up” section of the MAIM manual.

11. Check the burner adjustment. See the “Primary Air Adjustment” section of this manual.

12. Check all gas control valv es and pipe connections for leaks.

Under no circumstance should combustible material be located within the speciﬁ ed clearances. Failure to provide proper clearance could result in personal injury or property damage from ﬁ re.

13. Check the operation of the duct furnace gas valve by lowering the setting of the thermostat, stopping the operation of the duct furnace. The duct furnace gas valve should close, extinguishing the pilot and main burner ﬂ ames.

— 16 —

5. Check Burner Adjustment.

Check gas control valv es and pipe connection f or leaks .

Under no circumstance should combustible material be located within the speciﬁ ed clearances. Failure to provide proper clearance could result in personal injury or property damage from ﬁ re.

7. Check operation of auto gas valve.

8. Check operation of safety devices.

9. Inspect and service blower section of system.

Page 17

SEASONAL MAINTENANCE

The unit should be thoroughly checked before the start and at the end of each heating and cooling season.

A. Motors and belts should be inspected. B. Tighten belts if loose. C. Check and clean DX or Chilled W ater coil twice yearly ,

if unit is so equipped per manufacturer’s service manual. Chilled Water coil must be winterized at beginning of heating season (i.e. drain water from coil per manufacturer’s instructions).

D . Check air throughput at beginning of heating season

to confirm unit operation is within the specified temperature rise range.

Standard CFM Blower Air Filter Size Requirements

Number of Filters Required Unit Input 16 x 20 (in) 20 x 20 (in)

100 MBH (29.3 kW) 4 150 MBH (44.0 kW) 4 200 MBH (58.6 kW) 4 250 MBH (73.2 kW) 4 300 MBH (87.9 kW) 4 2 350 MBH (102.6 kW) 4 2 400 MBH (117.2 kW) 6 500 MBH (146.5 kW) 4 600 MBM (175.8 kW) 4 2

E. At beginning of heating season clear Condensate

Drain Pan and P-trap of w ater if unit is equipped with DX or Chilled water coil. Clean out drain pan and ﬁ ll P-trap with a non-toxic glycol solution.

F. Evaporative cooler must be cleaned and maintained

per manufacturer’s instr uction frequently during the operating season.

G. Inspect Control Dampers during periodic maintenance.

Damper pivot points should be cleaned to ensure free damper operation.

H. Blower wheels should be checked periodically for dirt

build-up on blades. Clean as required.

FILTERS

The ﬁ lter section has been designed to incor porate (as standard) one-inch washable ﬁ lters. Other optional ﬁ lter types are also available: two-inch washable throwaw a ys; or one or two inch hi-efﬁ ciency 30% pleated ﬁ lters.

It is recommended that air ﬁ lters be changed or cleaned at least four times a year . More frequent attention to ﬁ lters is required if the air being handled by the unit is unusually dirty. Air ﬂ ow reduction, caused by the dirty air ﬁ lters, will increase the discharge air temperature and may cause unit cycling on the primary limit.

700 MBM (205.1 kW) 4 2 800 MBH (234.4 kW) 6

High CFM Blower Air Filter Size Requirements

Number of Filters Required Unit Input 16 x 20 (in) 20 x 20 (in)

100 MBH (29.3 kW) 8 150 MBH (44.0 kW) 8 200 MBH (58.6 kW) 8 250 MBH (73.2 kW) 8 300 MBH (87.9 kW) 8 4 350 MBH (102.6 kW) 8 4 400 MBH (117.2 kW) 12 500 MBH (146.5 kW) 8 600 MBH (175.8 kW) 8 4 700 MBH (205.1 kW) 8 4 800 MBH (234.4 kW) 12 1,200 MBH (351.6kW) 12

Filters (by others) should be serviced regularly and changed or washed when necessary to maintain the required air throughput. In a dusty environment, ﬁ lters may clog up in less than one month.

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Page 18

KEY B PROJECTS TO PROVIDE A GRIP FOR REMOVING. DO NOT OPERATE SHEAVE WITH FLANGE PROJECTING

BEYOND THE HUB END.

D3881

Figure 13 AIR BLOWER

STANDARD CFM BLOWER

Belt Tension Adjustment Standard CFM Blower belt tension can be adjusted by loosening motor mounting bolts marked A (See Figure 13). To tighten belt, slide motor down motor mounting bracket and re-fasten motor to mounting bracket.

High CFM Blower belt(s) tension can be adjusted by ﬁ rst loosening motor mounting plate bolts marked A (See Figure 13). To tighten belt tension, turn belt tension adjustment screws marked B (See Figure 13) counterclockwise. To loosen belt tension, turn clockwise. Once belt tension has been adjusted, re-fasten motor mounting plate bolts.

Blower RPM Adjustment

HIGH CFM BLOWER

To adjust blower RPM:

1. Loosen and remove belt(s).

2. Match driver pulley to one found in Figure 14.

3. Loosen set screw(s) marked A.

4. If driver pulley is equipped with external key, marked B, remove.

Figure 14

5. Adjust driver pulley pitch diameter for desired speed by opening (slower) or closing (faster) moving parts by half or full turns. Do not open sheave past point where ﬂ ange projects past the hub end.

6. If driver pulley is equipped with external key, marked B, replace.

7. Tighten set screw(s) marked A.

8. Replace and retension belt(s).

9. Realign drive if necessary.

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Page 19

VII. TR OUBLESHOOTING

For troubleshooting of the duct furnace, refer to the Indoor Gas-Fired Duct Furnace Installation and Service Manual. For Evaporative Cooler/Cooling Coil equipped units , refer to these speciﬁ c manuals f or additional troubleshooting guides.

For additional troubleshooting, see following Troubleshooting Guide.

TROUBLESHOOTING GUIDE

AIR BLOWER

PROBLEM PROBABLE CAUSE SOLUTION

1. Noise Blower Wheel Hitting Scroll Side a. Blower Wheel not centered in blower housing. b. Damaged blower housing. c. Damaged blower wheel. d. Shaft loose in blower bearing. e. Blower Wheel loose on shaft. f. Blower bearing loose in bearing support. Blower Wheel Hitting Cutoff a. Cutoff not secure in blower housing. b. Cutoff damaged. c. Cutoff improperly positioned.

Drive a. Pulley not tight on shaft (motor and/or blower wheel). b. Belts too loose. Adjust for belt stretching after 48 hours of operation. c. Belts too tight. d. Belts wrong cross section. e. Belts not matched in length on multi-belt drive. f. Variable pitch pulleys not adjusted so each pulley has same pitch diameter (multi-belt drives). g. Misaligned pulleys. h. Belts worn. i. Motor or motor base loose. j. Belts oily or dirty. k. Improper drive selection. Bearing a. Defective bearing. b. Needs lubrication. c. Loose on bearing support. d. Loose on shaft. e. Seals misaligned. f. Foreign material in bearing. g. Worn bearing. h. Fretting corrosion between inner race and shaft. Shaft Seal Squeal a. Needs lubrication. b. Misaligned.

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Page 20

PROBLEM PROBABLE CAUSE SOLUTION

1. Noise Blower Wheel a. Loose on shaft. b. Defective blower wheel. Do not run blower. Contact manufacturer. c. Unbalanced. d. Worn as a result of contact with

Housing a. Foreign material in housing. b. Cutoff of other part loose (rattling during operation). Electrical a. Lead-in cable not secure. b. AC hum in motor or relay. c. Starting relay chatter. d. Noisy motor bearings. e. Single phasing a 3 phase motor. Shaft a. Bent. b. Undersized. May cause noise at blower wheel, bearings or pulley. c. If more than two bearings are on a shaft, they must be properly aligned. High Air Velocity a. Duct work too small for application. b. Blower selection too small for application. c. Registers or grilles too small for application. d. Cooling coil with insufﬁ cient face area for application. Obstruction in High Velocity Air Stream a. Dampers.

c. Grilles. d. Sharp elbows. e. Sudden expansion in duct work. f. Sudden contraction in duct work. g. Turning vanes. Pulsation or Surge a. Blower too large for application. b. Ducts vibrate at same frequency as blower pulsations. Rattles and/or Rumbles a. Vibrating duct work. b. Vibrating cabinet parts. c. Vibrating parts not isolated from building.

2. CFM Low - Blower a. Forward curved blower wheel installed backwards.

Insufﬁ cient Air Flow

c. Cutoff missing or improperly installed. d. Blower wheel RPM too low. Duct System a. Actual system is more restrictive than expected. b. Dampers closed. c. Registers closed. d. Leaks in supply duct.

may cause Rattle or Pure Tone Whistle

b. Blower operating backwards.

abrasive or corrosive material.

b. Registers.

— 20 —

Page 21

PROBLEM PROBABLE CAUSE SOLUTION

2. CFM Low Filters Dirty or clogged.

Insufﬁ cient Air Flow

Obstructions in High Velocity Air Stream a. Obstruction near unit outlet. b. Sharp elbows near unit outlet. c. Improperly designed turning vanes. d. Projections, dampers or other obstructions in part

3. CFM High - System a. Oversized duct work.

Too Much Air Flow

c. Registers or grilles not installed. d. Filters not in place. e. System resistance lower than anticipated. Blower Blower RPM is too great.

4. Blower Does Not Operate Installation a. Incorrect electrical connection. b. Wrong voltage. c. Blown fuse. Unit a. Broken belt(s). b. Loose pulleys. c. Power to unit is disconnected. d. Motor overload protector has broken circuit. e. Optional thermostats, ﬁ restats, freezestats may

Coil - DX or Chilled Water Dirty or clogged.

of duct system where air velocity is high.

b. Access door open.

lockout blower operation if set incorrect.

TROUBLESHOOTING GUIDE

ELECTRIC MOTORS

PROBLEM PROBABLE CAUSE SOLUTION

1. Motor Blown fuse or open circuit breaker. Replace fuse or reset circuit breaker. Overload trip. Check and reset, if manual. Improper line connections. Check connections to unit wiring diagram. Improper current supply. Check to determine that power supply agrees with

Mechanical failure. Determine that motor and drive turn freely.

Motor overloaded. Reduce load or replace motor. With a 3 phase power source, one Check line for open phase.

Defective capacitor. Replace capacitor.

2. Motor Stalls Wrong application. Consult manufacturer. Overloaded motor. Reduce load or replace motor. Low line voltage. Check across AC line and correct

phase may be open.

motor nameplate speciﬁ cations.

Check bearings.

if possible.

— 21 —

Page 22

PROBLEM PROBABLE CAUSE SOLUTION

3. Motor runs and then Partial loss of line voltage. Check for loose connections.

dies down.

4. Motor does not Motor undersized for application. Replace with larger motor.

come up to speed.

Line wiring to motor is too small. Install larger line wiring.

5. Motor takes too long Excessive load. Replace with larger motor.

to accelerate.

6. Wrong Rotation (3 Phase) Improperly wired to AC line (wrong Check unit wiring diagram. Reverse any two line

7. Motor Overheats Motor overloaded. Replace with larger motor. Motor ventilation clogged. Clean motor. Motor (3 phase) may have open phase. Check to insure that all connections are tight. Line voltage too high or too low. Check across AC line and correct if possible. Worn blower bearings. Replace blower bearings.

8. Motor Vibrates Motor mounting bolts loose. Tighten mounting bolts. Driven equipment unbalanced. Balance driven equipment. Worn motor bearings. Replace motor. 3 phase Motor running on single phase. Check for open circuit and correct. Bent motor shaft. Replace motor.

9. Rapid Motor Bearing Excessive overhung load due to over Reduce belt tension.

Wear

Voltage too low at motor terminals. Check across AC line and correct if possible.

Loose connection. Check connections and tighten where necessary.

sequence of phases).

tensioned belt.

Determine adequacy of main power supply.

voltage connections.

TROUBLESHOOTING GUIDE

FAN ASSEMBLY

PROBLEM PROBABLE CAUSE SOLUTION

1. Short Belt Life Spin burns from belt slippage. Tension belt. High ambient temperature. Use Gripnotch belts. Grease or oil on belts. Clean belts and pulleys. Worn pulleys. Replace pulleys. Belt Misalignment. Realign drive.

2. Belts turn over in grooves Damaged belt. Replace belt. Excessive vibration. Tension belts. Replace belts if damaged. Worn pulleys. Replace pulleys. Pulley Misalignment. Realign drive.

3. Belt Squeal Excessive load. High starting load.Retension drive.

4. Belt Breakage Foreign material in drive. Provide drive guard. Belts damaged during installation. Replace belts. Extreme Overload. Eliminate overload.

5. Excessive Vibration Damaged belt cord section. Replace belts. Loose belts. Tension drive. Belts improperly tensioned. Tension drive with slack of each belt on the

same side of drive.

— 22 —

Page 23

PROBLEM PROBABLE CAUSE SOLUTION

6. Belts mismatched Belts improperly tensioned, causing Replace belts and tension drive with slack of each

after service

Old belts and new belts used Replace with new belts.

Different brand name belts used Replace with a set of Machine Matched Belts.

Driver and driven shafts shifted Realign drive.

Belt cord section damaged during Replace belts and install properly.

7. Drive fails to adjust Fretting corrosion (drive allowed to Driver pulley must be disassembled,

more stretch of some belts than others. belt on the same side of the drive.

on same drive.

from parallel.

installation.

operate at one speed over a period cleaned and lubricated, then of time). reassembled.

TROUBLESHOOTING GUIDE

DX COOLING COIL

PROBLEM PROBABLE CAUSE SOLUTION

1. No or Insufﬁ cient Coil icing. a. Low liquid line pressure.*

Cooling

c. Low air ﬂ ow across coil. Air binding. Purge and charge system. Thermal expansion valve.** a. Bulb mounted at incorrect location. b. Bulb not secured properly. Insufﬁ cient air ﬂ ow. a. See air blower troubleshooting. b. Clogged coil Air bypassing coil. Caulk safe off. Undersized system, demand Replace system.*

Too much outside air. Check outside air dampers. Refrigerant leak. Determine leak location and correct. Low liquid pressure. Determine cause and correct.*

2. Water in Conditioned Air Exceeding coil face velocity - 600 fpm. Reduce unit air ﬂ ow. Drain pan p-trap clogged. Clean pan and p-trap.

* Refer to condensing unit installation and service manual. **Refer to thermal expansion valve installation instruction.

b. Thermal expansion valve.**

exceeding cooling system capacity.

— 23 —

Page 24

TROUBLESHOOTING GUIDE

CHILLED WATER COOLING COIL

PROBLEM PROBABLE CAUSE SOLUTION

1. No or Insufﬁ cient Cooling Circulating pump failure. Repair or replace pump.* Chilled water temperature Check chiller.*

Air binding (air in coil). Bleed coil. Insufﬁ cient chilled water ﬂ ow. a. Circulating pump capacity is inadequate.* b. System piping losses too great. Insufﬁ cient air ﬂ ow. a. See air blower troubleshooting. b. Clogged coil Air bypassing coil. Caulk safe off. Undersized system, demand Replace system.*

Too much outside air. Check outside air dampers.

2. Water in Conditioned Air Exceeding coil face velocity - 600 fpm. Reduce unit air ﬂ ow. Drain pan P-trap clogged. Clean pan and p-trap.

*Refer to Manufacturer’s Installation and Service Manual.

not cool enough.

exceeding cooling system capacity.

VIII. REPLACEMENT PARTS

To order Replacement Parts, please provide the following information to your local representative:

• Model Number

• Serial Number

• Part description and Number as shown in

Replacement Parts Literature

Due to the many conﬁ gurations, options and voltage characteristics available on Make-Up Air Packaged Units, the information provided in this manual is somewhat general in context. Should user or service organization incur a problem, the nature of which is not herein, we urge you to contact the manufacturer.

IX. SERVICE NOTE

It would be of great assistance to us if you can provide If further assistance is required, please contact the manufacturer’s customer service department

the model and serial numbers and the wiring diagram

number, as well as the access type.

X. LIMITED WARRANTY

All components are warranted by the manufacturer to be free from defects in material and workmanship for period of one (1) year from the date of shipment from the manufacturing plant.

The manufacturer will repair or replace, at its option, any component which, upon inspection, it ﬁ nds to be defective, provided that the Make-Up Air Packaged Unit has been operated within its listed capacity, has been installed in accordance with all furnished instruction, has not been misused or subjected to neglect and has received reasonable and necessary maintenance. This warranty does not cover labor costs or other costs incurred in repairing, removing, installing, servicing or handling of parts or completed products.

This W arr anty does not cover loss due to corrosion by chemicals precipitated in the air such as halogenated hydrocarbons. The manufacturer will in no event be liable for incidental or consequential damages of any kind whatsoever. Written permission is required prior to the retur n of defective components. All returns must be sent with all transportation charges prepaid to the plant designated in the written permission. This warranty is extended only to the original owner of the Make-Up Air Package Unit.

— 24 —

Page 25

“FOR CANADIAN INSTALLATIONS ONLY”

The following instructions apply to Canadian installations in addition to installation and operating instruction:

1. Installation must conform with local building codes, or in absense of local codes, with current CGA B149.1, Installation Codes for Natural Gas Burning Appliances and Equipment, or CGA B149.2, Installation Codes for Propane Gas Burning Appliances and Equipment.

2. Any reference to U.S. standards or codes in these instructions are to be ignored and the applicab le Canadian standards or codes applied.

3. Any references to deration at altitudes in excess of 2000 feet are to be ignored. When installed in Canada at altitudes of 2000 to 4500 feet, the unit heaters must be oriﬁ ced to 90% of the normal altitude r ating, and be so marked in accordance with the C.G.A. certiﬁ cation.

4. Duct furnaces are designed certiﬁ ed to comply with CGA 2.6.

5. In Canada, installation is suitable in airplane hangars when acceptable to the enforcing authorities, and in public garages when installed in accordance with current CGA B149 Installation Codes for Gas Burning Appliances and Equipment.

6. All electrical connections must be in accordance with Canadian Electrical Code, Part 1, CSA Standard C22.1.

7. Canadian units include vent cap and a reducer/increaser (if required) furnished by the man ufacturer.

8. In Canada, the vent system must be adequately supported to pre vent sagging; but in no case shall the supports be less than every 3 feet.

9. If using a metal vent system under positive gauge pressure in Canada, a slip ﬁ t vent connection must be secured by a least two corrosive resistant screws, or other mechanical locking means.

10. Canadian units require the following vent equivalent lengths; 5 feet minimum; 50 feet maximum.

11. The vent shall not terminate — a. Less than 6 feet from a combustion air inlet of another appliance. b. Less than 3 feet from any other building opening or any gas service regulator. c. Directly above a gas utility meter or service regulator.

12. Vent terminal shall be located not less than one foot above grade.

13. It is recommended that the heater and vent system be checked once a year by a qualiﬁ ed serviceman.

— 25 —

Page 26

XI. DIMENSIONAL DATA — ARRANGEMENTS

Table #T4088-B, D

CAPACITY A B F† G J L U V Dia.** 10 32-7/8 15-9/16 16-3/8 31-1/16 24 77-3/8 73-5/8 4 (835) (395) (416) (789) (610) (1965) (1870) (102) 15 32-7/8 18-5/16 20-1/2 31-1/16 24 77-3/8 73-5/8 4 (835) (465) (521) (789) (610) (1965) (1870) (102) 20 43-7/8 23-13/16 23-1/2 42-1/16 35 77-3/8 73-5/8 5 (1114) (605) (597) (1068) (889) (1965) (1870) (127) 25 43-7/8 29-5/16 31-1/2 42-1/16 35 77-3/8 73-5/8 5 (1114) (745) (800) (1068) (889) (1965) (1870) (127) 30 54-7/8 34-13/16 34-1/4 53-1/16 46 77-3/8 73-5/8 6 (1394) (884) (870) (1348) (1168) (1965) (1870) (152) 35 54-7/8 40-5/16 42-1/4 53-1/16 46 77-3/8 73-5/8 6 (1394) (1024) (1073) (1348) (1168) (1965) (1870) (152) 40 60-3/8 45-13/16 48 58-9/16 51-1/2 77-3/8 73-5/8 6 (1534) (1164) (1219) (1487) (1308) (1965) (1870) (152) 50 43-7/8 29-5/16 31-1/2 42-1/16 35 103 3/8 99-5/8 5 (1114) (745) (800) (1068) (889) (2626) (2530) (127) 60 54-7/8 34-13/16 34-1/4 53-1/16 46 103 3/8 99-5/8 6 (1394) (884) (870) (1348) (1168) (2626) (2530) (152) 70 54-7/8 40-5/16 42-1/4 53-1/16 46 103-3/8 99-5/8 6 (1394) (1024) (1073) (1348) (1168) (2626) (2530) (152) 80 60-3/8 45-13/16 48 58-9/16 51-1/2 103-3/8 99-5/8 6 (1534) (1164) (1219) (1487) (1308) (2626) (2530) (152)

NOTES: Dimensions are in inches (Dimensions in parenthesis are in millimeters) * These dimensions are outside damper measurements. † “F” Dimension is the recommended clearance to service the burner drawer. “J” is an outside dimension for return air dampers. **“V” Dia. = Flue Opening (ME - Power Vent Units Only); the 4” to 5” reducer adaptor is to be ﬁ eld supplied/installed for unit capacities 10 & 15. The 5” to 6” increaser adaptor is supplied by the manufacturer for unit capacities 30, 35, 40, 60, 70, & 80 (required for each furnace’s ﬂ ue). Gas Inlet sizes: Natural Gas: Capacities 10 thru 20 = 1/2”; Capacities 25 thru 80 = 3/4”. LP Gas: Capacities 10 thru 20 = 1/2”; Capacities 25 thru 80 = 1/2” or 3/4”. All dimensional drawings for the “B” and “D” Indoor Arrangement are shown as Dual Furnace Unit Capacities (50/80). The dimensional data for Single Furnace Capacities (10/40) are tabulated in table 6 accordingly for all capacities.

— 26 —

Page 27

DIMENSIONAL DATA — ARRANGEMENTS

19" (483)

Discharge

Opening

1" (25) Cap

B Discharge

Opening

J Return

Air Opening

Outside

1-5/16" x 5/8" (33 x 16) Typ. Anchor Hole Location

10-5/8"

(270)

†

10-1/8"

(257)

44-1/4"

(1124)

12"

(305)

Gas Connection

18-7/8" (479)

x J Typ.

O.S. Damper

Opening

6-1/2"

(165)

Electrical Connections

18-7/8" (479)

X J Typ.

O.S. Damper

Opening

19-1/2"

(495)

D4084 T4088B,D

19"

(483)

44"

(1118)

26"

(660)

(127)

4-3/4" (121)

46"

(1168)

2-5/8"

(67)

U (Capacities 50/80)

U (Capacities 10/40)

18-7/8" (479)

x J Typ.

O.S. Damper

Opening

19" (483)

Discharge

Opening

1" (25) Cap

B Discharge

Opening

J Return Opening

Outside

1-5/16" x 5/8" (33 x 16) Typ. Anchor Hole Location

10-5/8"

(270)

†

44-1/4" (1124)

10-1/8"

(257)

12"

(305)

Gas Connections

6-1/2" (165)

Electrical Connections

43"

(1092)

D4085A T4088B,D

Evaporative Cooler

19"

(483)

26"

(660)

(121)

(127)

36"

(914)

46"

(1118)

U (Capacities 10/40)

U (Capacities 50/80)

1" Cap(Overhang)

Unit Type [UT] “ME”, Capacities [CA] 10 - 80, Indoor Arrangement [IA] “B”

Unit Type [UT] “ME”, Capacities [CA] 10 - 80, Indoor Arrangement [IA] “D”

* These Dimensions are Outside Damper Measurements. ** These Units Are Supplied With A (5’’ To 6’’) Increaser (Required For Each Furnace’s Flue). † Recommended Service Drawer Clearance. For tabulated dimensions, see table T4088-B, D.

— 27 —

Page 28

DIMENSIONAL DATA — ARRANGEMENTS

Arrg G Arrg K CAPACITY A B F G J L M Q R U U V Dia.**

Table #T4088K/T4089G

10 32-7/8 15-9/16 16-3/8 31-1/16 24 113-1/2 21-1/4 60-5/16 26-5/8 108-1/2 134-1/2 4

(835) (395) (416) (789) (610) (2883) (540) (1532) (676) (2756) (3416) (102) 15 32-7/8 18-5/16 20-1/2 31-1/16 24 113-1/2 20-1/4 60-5/16 26-5/8 108-1/2 134-1/2 4 (835) (465) (521) (789) (610) (2883) (514) (1532) (676) (2756) (3416) (102) 20 43-7/8 23-13/16 23-1/2 42-1/16 35 113-1/2 20-1/4 60- /16 26-5/8 108-1/2 134-1/2 5 (1114) (605) (597) (1068) (889) (2883) (514) (1532) (676) (2756) (3416) (127) 25 43-7/8 29-5/16 31-1/2 42-1/16 35 113-1/2 20-1/4 60-5/16 26-5/8 108-1/2 134-1/2 5 (1114) (745) (800) (1068) (889) (2883) (514) (1532) (676) (2756) (3416) (127) 30 54-7/8 34-13/16 34-1/4 53-1/16 46 113-1/2 20-1/4 60-5/16 26-5/8 108-1/2 134-1/2 6 (1394) (884) (870) (1348) (1168) (2883) (514) (1532) (676) (2756) (3416) (152) 35 54-7/8 40-5/16 42-1/4 53-1/16 46 113-1/2 20-1/4 60-5/16 26-5/8 108-1/2 134-1/2 6 (1394) (1024) (1073) (1348) (1168) (2883) (514) (1532) (676) (2756) (3416) (152) 40 60-3/8 45-13/16 48 58-9/16 51-1/2 113-1/2 21-1/4 60-5/16 26-5/8 108-1/2 134-1/2 6 (1534) (1164) (1219) (1487) (1308) (2883) (540) (1532) (676) (2756) (3416) (152) 50 43-7/8 29-5/16 31-1/2 42-1/16 35 139-1/2 20-1/4 60-13/16 35-1/8 134-1/2 160-1/2 5 (1114) (745) (800) (1068) (889) (3543) (514) (1545) (892) (3416) (4077) (127) 60 54-7/8 34-13/16 34-1/4 53-1/16 46 139-1/2 20-1/4 60-13/16 35-1/8 134-1/2 160-1/2 6 (1394) (884) (870) (1348) (1168) (3543) (514) (1545) (892) (3416) (4077) (152) 70 54-7/8 40-5/16 42-1/4 53-1/16 46 139-1/2 20-1/4 60-13/16 35-1/8 134-1/2 160-1/2 6 (1394) (1024) (1073) (1348) (1168) (3543) (514) (1545) (892) (3416) (4077) (152) 80 60-3/8 45-13/16 48 58-9/16 51-1/2 139-1/2 21-1/4 60-13/16 35-1/8 134-1/2 160-1/2 6 (1534) (1164) (1219) (1487) (1308) (3543) (540) (1545) (892) (3416) (4077) (152) 12 60-3/8 45-13/16 48 58-9/16 51-1/2 165-1/2 21-1/4 86-1/8 35-1/8 160-1/2 186-1/2 6 (1534) (1164) (1219) (1487) (1308) (4204) (540) (2188) (892) (4077) (4737) (152)

NOTES: The dimensional data is tabulated for single and dual furnace capacities accordingly. Using table 7 (#T4088K/T4089G), Capacities 10 & 15 apply only to Arrangement “K”; Capacity 12 applies only to Arrangement “G”. Dimensions are in inches (Dimensions in parenthesis are in millimeters). * These dimensions are outside damper measurements. † “F” Dimension is the recommended clearance to service the burner drawer. “J” is an outside dimension for return air dampers. ** “V” Dia. = Flue Opening (ME - Power Vent Units Only); the 4” to 5” reducer adaptor is to ﬁ eld installed for unit capacities 10 & 15. The 5” to 6” increaser adaptor is supplied by the manufacturer for unit capacities 30, 35, 40, 60, 70, 80 & 12 (required for each furnace’s ﬂ ue). Gas Inlet sizes: Natural Gas: Capacities 10 thru 20 = 1/2”; Capacities 25 thru 12 = 3/4”.

LP Gas: Capacities 10 thru 20 = 1/2”; Capacities 25 thru 12 = 1/2” or 3/4”.

— 28 —

Page 29

DIMENSIONAL DATA — ARRANGEMENTS

18-7/8" (479)

x J Typ.

O.S. Opening

18-7/8" (479)

x J Typ.

O.S. Damper

Opening

†

G Outside

1-1/16" x 5/8" (33 x 16) Typ. Anchor Hole Location

Discharge

Opening

19" (483)

Discharge

Opening

1" (25) Cap

J Return Air

Opening

Gas Connections

45-5/8"

(1159)

10-1/8"

(257)

6-1/2"

(165)

Electrical Connections

Lifting Brackets

19-1/2"

(495)

82"

(2083)

D4086 T4089G

44"

(1118)

26"

(660)

26"

(660)

10-1/8"

(270)

(127)

U (Capacities 20/40)

U (Capacities 50/80)

U (Capacity 12)

2-5/8"

(67)

4-3/4" (121)

12"

(305)

18-7/8" (479)

x J Typ.

O.S. Opening

45-5/8" (1159)

10-1/8"

(257)

(127)

4-3/4" (121)

Gas Connections

Electrical Connections

26"

(660)

12"

(305)

18-7/8" (479)

x J Typ.

O.S. Damper

Opening

6-1/2" (165)

Lifting Brackets

19-1/2"

(495)

108"

(2743)

D4087 T4088K

44"

(1118)

2-5/8"

(67)

†

Outside

1-1/16" x 5/8" (33 x 16) Typ. Anchor Hole Location

Discharge

Opening

19" (483)

Discharge

Opening

1" (25) Cap

J Return Air

Opening

10-1/8"

(270)

U (Capacities 20/40)

U (Capacities 50/80)

Unit Type [UT] “ME”, Capacities [CA] 20 - 12, Indoor Arrangement [IA] “G”

Unit Type [UT] “ME”, Capacities [CA] 10 - 80, Indoor Arrangement [IA] “K”

— 29 —

Page 30

XII. MOTOR ELECTRICAL DATA

Full Load Current In Amperes

1 - (115/1/60) 2 - (208/1/60) 3 - (230/1/60)

ODP

1/2 HP 7.2 8.0 5.2 4.6 3.7 4.0 2.8 3.8 4.0 2.6 2.3 3/4 HP 11.6 11.0 8.0 6.3 5.2 5.4 4.2 5.3 5.5 4.0 3.2

1 HP 13.0 13.4 8.6 8.5 6.6 6.8 6.5 6.7 4.3 4.3

1-1/2 HP 18.0 15.2 12.5 12.6 9.3 8.2 9.0 7.6 6.3 6.3

2 HP 21.0 23.0 17.6 17.6 11.3 11.7 10.5 8.1 8.8 8.8 3 HP 33.0 34.0 17.7 17.5 16.5 17.0 11.8 5 HP 23.5 21.0 23.0 19.1

7-1/2 HP 33.0 31.0 31.0 29.0

10 HP 49.0 39.0 38.0 15 HP

ODP

1/2 HP 2.1 2.2 1.8 2.0 2.2 2.2 1.8 1.7 1.1 1.1 0.9 1.0 3/4 HP 3.0 3.2 2.5 3.4 2.8 2.4 2.8 1.7 1.4 1.2 1.4

1 HP 3.4 3.7 3.0 3.3 3.4 3.6 2.8 3.0 1.7 1.8 1.4 1.5

1-1/2 HP 4.8 5.0 4.3 4.5 4.8 4.8 4.2 4.1 2.4 2.4 2.1 2.1

2 HP 6.2 6.0 5.7 6.3 5.6 5.5 5.4 3.1 2.8 2.8 2.7 3 HP 9.2 8.5 8.6 8.6 8.0 8.2 4.3 4.0 4.1 5 HP 12.2 12.0 11.2 11.2 5.6 5.6

7-1/2 HP 21.0 21.0 19.2 18.8 9.6 9.4

10 HP 26.0 27.0 25.0 25.0 12.5 12.5 15 HP 37.4 38.9 35.4 37.0 17.7 18.5

ODP

1/2 HP 0.8 0.9 3/4 HP 1.1 1.1

1 HP 1.3 1.5 1.1 1.1

1-1/2 HP 1.7 1.6

2 HP 2.1 2.2 3 HP 3.1 3.1 5 HP 5.2 5.2

7-1/2 HP 7.6 7.6

10 HP 10.0 10.0 15 HP 14.1 15.1

PEODP4PETE

4 - (208/3/60) 5 - (230/3/60) 6 - (460/3/60) 2

7 - (575/3/60) 2

PEODP4PETE

ODP

PEODP4PETE

Motor Type (MT) Legend:

ODP - Open Drip Proof

ODP

TE - Totally Enclosed PEODP - Premium Efﬁ ciency Open Drip Proof PETE - Premium Efﬁ ciency Totally Enclosed

PEODP4PETE

— 30 —

Page 31

XIII. UNIT/SHIP WEIGHTS

Motor Shipping Weight (lbs) - Approximate

1 - (115/1/60) 2 - (208/1/60) 3 - (230/1/60)

ODP

1/2 HP 20.0 24.0 32.0 30.0 21.0 24.0 32.0 21.0 24.0 32.0 30.0 3/4 HP 23.0 30.0 30.0 41.0 23.0 30.0 30.0 25.0 30.0 30.0 41.0

1 HP 32.0 32.0 40.0 44.0 32.0 32.0 32.0 32.0 40.0 44.0

1-1/2 HP 40.0 41.0 47.0 57.0 40.0 41.0 40.0 41.0 47.0 57.0

2 HP 42.0 67.0 65.0 64.0 50.0 67.0 42.0 48.0 65.0 64.0 3 HP 78.0 86.0 78.0 86.0 78.0 86.0 90.0 5 HP 87.0 87.0 99.0 95.0

7-1/2 HP 134.0 138.0 134.0 138.0

10 HP 165.0 140.0 161.0 15 HP

ODP

1/2 HP 19.0 18.0 22.0 22.0 19.0 18.0 22.0 22.0 19.0 18.0 22.0 22.0 3/4 HP 27.0 26.0 27.0 27.0 22.0 27.0 31.0 27.0 22.0 27.0 31.0

1 HP 24.0 26.0 36.0 37.0 24.0 26.0 36.0 37.0 24.0 26.0 36.0 37.0

1-1/2 HP 28.0 34.0 40.0 42.0 28.0 34.0 40.0 42.0 28.0 34.0 40.0 42.0

2 HP 35.0 46.0 49.0 35.0 42.0 46.0 49.0 35.0 42.0 46.0 49.0 3 HP 48.0 69.0 69.0 48.0 69.0 69.0 48.0 69.0 69.0 5 HP 76.0 77.0 76.0 77.0 76.0 77.0

7-1/2 HP 117.0 136.0 117.0 136.0 117.0 136.0

10 HP 128.0 158.0 128.0 158.0 128.0 158.0 15 HP 217.0 255.0 217.0 255.0 217.0 255.0

ODP

1/2 HP 22.0 18.0 3/4 HP 20.0 22.0

1 HP 28.0 26.0 33.0 38.0

1-1/2 HP 40.0 42.0

2 HP 46.0 48.0 3 HP 66.0 69.0 5 HP 74.0 91.0

7-1/2 HP 114.0 143.0

10 HP 145.0 153.0 15 HP 234.0 302.0

PEODP4PETE

4 - (208/3/60) 5 - (230/3/60) 6 - (460/3/60) 2

7 - (575/3/60) 2

PEODP4PETE

ODP

PEODP4PETE

Motor Type (MT) Legend:

ODP - Open Drip Proof

ODP

TE - Totally Enclosed PEODP - Premium Efﬁ ciency Open Drip Proof PETE - Premium Efﬁ ciency Totally Enclosed

PEODP4PETE

Cooling Coil Weight Adder (Approximate)

DX COIL

(CA) Capacity 4 Row 6 Row 10, 15 70 lbs. 95 lbs. 20, 25, 50 95 lbs. 130 lbs. 30, 35, 60, 70 119 lbs. 166 lbs. 40, 80 130 lbs. 182 lbs.

CHILLED W ATER COIL

(CA) Capacity 4 Row 6 Row 10, 15 170 lbs. 222 lbs. 20, 25, 50 215 lbs. 287 lbs. 30, 35, 60, 70 264 lbs. 359 lbs. 40, 80 284 lbs. 389 lbs.

— 31 —

Indoor Arrangement [IA] "B, D, G, K"

Shipping Weights (lbs.)

Arrangement [IA]

Capacity [CA]

BDGK

10 637 803 929 15 662 828 954 20 785 982 972 1103 25 812 1009 1021 1149 30 937 1163 1186 1321 30 983 1209 1238 1374 40 1048 1287 1314 1460 50 1144 1340 1349 1476 60 1318 1543 1565 1701 70 1389 1613 1634 1770 80 1490 1729 1748 1893 12 2181

Page 32

FIGURE 15

INSIDE UNIT WALL

“ L” MAX.

31-3/4"

(806)

26" (660)

OUTSIDE BOTTOM PANEL

(25)

24"

(700)

33"

(838)

39"

(991)

(76)

13"(330)

MAX. COIL

DEPTH

7/8" (22)

TOP

53-1/4" (1353)

“ L” INSIDE MAX.

CABINET OPENING

42-1/4" (1073)

58-3/4" (1492)

31-1/4" (794)

30/35/60/70

UNIT SIZE

20/25/50

40/80

10/15

XIV. COIL CABINET DIMENSIONAL DATA

Maximum Coil Dimensions

FIGURE 16

Side Opening

of Coil Module

MU = NATURAL VENT ME = POWER VENT

XV. CENTER OF GRAVITY

— 32 —

Page 33

CENTER OF GRAVITY– refer to Figure 16

Values Based on Average Motor Weight and Average Coil Size (Arrangement K)

(Actual Center of Gravity and Corner Weights For Speciﬁ c Motor Size and Speciﬁ c Coil are Available Upon Request)

Unit Without Outside Air Hood Without Outside Air Hood Type,

Capacity Width Length X-Coor Y-Coor Corner #1 Corner #2 Corner #3 Corner #4 X-Coor Y-Coor Corner #1 Corner #2 Corner #3 Corner #4

ME10 32.75 72 35.8 15.4 161 159 141 142 N/A N/A N/A N/A N/A N/A

ME15 32.75 72 36.7 15.4 163 169 150 145 N/A N/A N/A N/A N/A N/A

ME20 43.75 72 36.2 20.6 195 196 174 173 59.6 20.7 223 274 246 200

ME25 43.75 72 37.0 20.6 197 207 185 175 60.5 20.8 229 292 264 207

ME30 54.75 72 37.2 25.2 230 246 209 196 61.5 25.4 266 351 304 230

ME35 54.75 72 37.2 25.1 243 260 219 205 60.9 25.1 283 365 308 239

ME40 60.25 72 37.8 27.9 253 278 239 217 61.1 27.9 295 385 332 255

ME50 43.75 98 50.7 20.8 275 294 267 250 75.0 20.9 301 382 350 275

ME60 54.75 98 50.7 25.6 318 340 299 280 75.4 25.7 348 448 396 308

ME70 54.75 98 50.9 25.6 336 362 317 294 75.2 25.5 368 471 410 320

ME80 60.25 98 51.6 28.3 353 391 347 313 75.4 28.3 389 500 443 344

Center of Gravity

ARRANGEMENTS “B” & “D” ARRANGEMENT “G”

Corner Weights (lbs)

Center of Gravity

Corner Weights (lbs)

ME12 60.25 124 65.0 28.6 456 503 454 412 89.5 28.5 485 615 553 435

ARRANGEMENT “K” with CHILLED WATER COIL ARRANGEMENT “K” with DX COOLING COIL Unit Without Outside Air Hood Without Outside Air Hood Type,

Capacity Width Length X-Coor Y-Coor Corner #1 Corner #2 Corner #3 Corner #4 X-Coor Y-Coor Corner #1 Corner #2 Corner #3 Corner #4

ME10 32.75 134 70.0 15.8 254 278 259 237 73.0 15.7 217 259 239 200

ME15 32.75 134 71.2 15.9 254 288 271 239 74.3 15.8 217 269 252 203

ME20 43.75 134 71.7 21.1 287 330 306 266 74.4 21.0 249 311 287 229

ME25 43.75 134 72.8 21.1 293 348 324 273 75.5 21.0 255 329 305 236

ME30 54.75 134 73.9 26.1 330 407 370 301 73.9 26.1 330 407 370 301

ME35 54.75 134 73.9 25.9 343 422 379 308 76.3 25.8 305 403 359 272

ME40 60.25 134 74.3 28.7 357 444 403 324 76.6 28.6 319 426 383 288

ME50 43.75 160 87.2 21.1 377 452 420 351 90.4 21.0 336 436 403 311

ME60 54.75 160 87.5 26.0 430 518 468 388 90.3 25.9 388 503 451 348

Center of Gravity

Corner Weights (lbs)

Center of Gravity

Corner Weights (lbs)

ME70 54.75 160 88.5 25.8 443 548 488 394 91.2 25.7 402 532 470 355

ME80 60.25 160 89.2 28.6 462 582 525 416 91.9 28.5 421 567 508 377

— 33 —

Page 34

XVI. UNIT NUMBER DESCRIPTION INDOOR MAKE-UP AIR UNITS

Digit M X X — 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 + Item Preﬁ x UT CA FT FM IA CO GT GC SV MT MS AI AC AS

(Internal use Only)

1, 2 - Unit Type [UT]

ME - Power Vented Indoor Make-up Air Unit

3, 4 - Capacity [CA]

Single Furnace Double Furnace 10 - 100,000 BTU/HR 50 - 500,000 BTU/HR 15 - 150,000 BTU/HR 60 - 600,000 BTU/HR 20 - 200,000 BTU/HR 70 - 700,000 BTU/HR 25 - 250,000 BTU/HR 80 - 800,000 BTU/HR 30 - 300,000 BTU/HR 35 - 350,000 BTU/HR Triple Furnace 40 - 400,000 BTU/HR 12 - 1,200,000 BTU/HR

5 - Furnace Type [FT]

A - Standard Temperature Rise (30-80° F) Right Side Access B - Standard Temperature Rise (30-80° F) Left Side Access 0 - None Z - Other

6 - Furnace Construction Material [FM]

1 - Aluminized Steel 2 - 409 Stainless Steel (First Furnace Only) 3 - 409 Stainless Steel (All Furnace Sections) 4 - 321 Stainless Steel (First Furnace Only) 5 - 321 Stainless Steel (All Furnace Sections) 6 - 409 Stainless Steel Package (First Furnace Only) 7 - 409 Stainless Steel Package (All Furnace Sections) 8 - 321 Stainless Steel Package (First Furnace Only) 9 - 321 Stainless Steel Package (All Furnace Sections) 0 - None Z - Other

7 - Indoor Arrangement (includes furnace section(s) [IA]

A - Duct Furance (50/12 [CA] only) K - Blower (High CFM) / Cooling B - Blower (Standard) 0 - None D - Blower (Standard) / Evap. Z - Other G - Blower (High CFM)

8 - Coil Options [CO]

A - DX Coil, 4 Row Single Circuit E - Chilled Water Coil, 4 Row B - DX Coil, 4 Row Dual Circuit G - Chilled Water Coil, 6 Row C - DX Coil, 6 Row Single Circuit 0 - None D - DX Coil, 6 Row Dual Circuit Z - Other

9 - Gas Type [GT]

1 - Natural Gas 2 - LP Gas (Propane) 3 - Natural Gas w/100% Lockout 0 - None

10 - Gas Control [GC]

A - Single Stage Gas (Standard) B - Two Stage Gas H - Electronic Modulation w/Room Sensing J - Electronic Modulation w/Duct Sensing K - Electronic Modulation w/Duct Sensing & Ovrd. Stat L - Electronic Modulation w/External 4-20 mA Input (Furnace One) M - Electronic Modulation w/External 4-20 mA Input (All Furnaces) N - Electronic Modulation w/External 0-10 VDC Input (Furnace One) P - Electronic Modulation w/External 0-10 VDC Input (All Furnaces) R - Two Stage Remote Temperature Control w/Duct Sensor S - Three Stage Remote Temperature Control w/Duct Sensor T - Four Stage Remote Temperature Control w/Duct Sensor U - S-350 2 Stage Modular Electronic Control System W - S-350 3 Stage Modular Electronic Control System X - S-350 4 Stage Modular Electronic Control System Y - S-350 6 Stage Modular Electronic Control System 0 - None Z - Other

11 - Supply Voltage [SV]

1 - 115/1/60 5 - 230/3/60 2 - 208/1/60 6 - 460/3/60 3 - 230/1/60 7 - 575/3/60 4 - 208/3/60 0 - None Z - Other

12 - Motor Type [MT]

1 - Open Drip Proof (Standard) 2 - Totally Enclosed 3 - Premium Efﬁ ciency, Open Drip Proof 4 - Premium Efﬁ ciency, Totally Enclosed 5 - Two Speed One Winding, Open Drip Proof 6 - Two Speed Two Winding, Open Drip Proof 0 - None Z - Other

13 - Motor Sizes [MS]

A - 1/2 HP. w/Contactor M - 1-1/2 HP. w/Mag. Starter 1 - 1 HP. VFD B - 3/4 HP. w/Contactor N - 2 HP. w/Mag. Starter 2 - 1-1/2 HP. VFD C - 1 HP. w/Contactor P - 3 HP. w/Mag. Starter 3 - 2 HP. VFD D - 1-1/2 HP. w/Contactor R - 5 HP. w/Mag.Starter 4 - 3 HP. VFD E - 2 HP. w/Contactor S - 7-1/2 HP. w/Mag. Starter 5 - 5 HP. VFD G - 3 HP. w/Contactor T - 10 HP. w/Mag. Starter 6 - 7-1/2 HP. VFD H - 5 HP. w/Contactor U - 15 HP. w/Mag. Starter 7 - 10 HP. VFD J - 1/2 HP. w/Mag. Starter 0 - None 8 - 15 HP. VFD K - 3/4 HP. w/Mag. Starter Z - Other L - 1 HP. w/Mag. Starter

14 - Air Inlet Conﬁ guration [AI]

1 - Outside Air (OA) 4 - Outside Air and Return Air (OA/RA) 2 - Outside Air w/Air Hood* 5 - Outside and Return Air w/Air Hood* 3 - Return Air (RA) 0 - None Z - Other

*Hood shipped separately

15 - Air Control & Damper Arrangement [AC]

A - Outside Air 2 Pos. Motor / Spring Return B - Return Air 2 Pos. Motor / Spring Return C - OA/RA 2 Pos. / Spring Return D - OA/RA Mod. Mtr. w/Mixed Air Control / Min. Pot. E - OA/RA Mod. Mtr. w/Mixed Air Control / Min. Pot. / SR G - OA/RA Mod. Mtr. w/Mixed Air Control H - OA/RA Mod. Mtr. w/Mixed Air Control / SR J - OA/RA Mod. Mtr. w/Min. Pot. K - OA/RA Mod. Mtr. w/Min. Pot. / SR L - OA/RA Mod. Mtr. w/Dry Bulb / Mixed Air Control / Min. Pot. M - OA/RA Mod. Mtr. w/Dry Bulb / Mixed Air Control / Min. Pot. /SR N - OA/RA Mod. Mtr. w/Enthalpy Controlled Economizer / SR P - OA/RA Mod. Mtr. w/Pressure Control (Space Pressure) Q - OA/RA Mod. Mtr. w/Carbon Dioxide (CO R - OA/RA Mod. Mtr. w/S-350-P Proportional Mixed Air Control / SR S - OA/RA Mod. Mtr. w/0-10 VDC & 4-20 mA Analog Input (External Input) T - OA/RA Mod. Mtr. w/0-10 VDC & 4-20 mA Analog Input / SR (External Input) U - ASHRAE Cycle I (OA/RA 2 Pos. Mtr. w/Warm-up Stat / SR)

ASHRAE Cycle II (OA/RA Mod. Mtr. w/Warm-up Stat / Mixed Air / Min. Pot. / SR)

W X - ASHRAE Cycle III (OA/RA Mod. Mtr. w/Warm-up Stat / Mixed Air / SR) Y - Manual Dampers 0 - None MOD = Modulating Damper Motor Z - Other OA = Outside Air RA = Return Air SR = Spring Return

16 - Accessories [AS]

A1 - Moisture Eliminator H1 - Return Firestat A2 - Horizontal Return H2 - Supply Firestat A3 - Low Leak Damper H3 - Freezestat w/ Time Dela y A5 - Furnace Drip Pan, 409 Stainless H4 - Ambient Lockout - Single Furnace (ME only) H6 - Ambient Lockout - Dual Furnace A6 - High Altitude Unit H7 - Ambient Lockout - T riple Furnace A7 - High Pressure Regulator A8 - Unit Derate J1 - Interlock Rela y - 24V Coil DPDT 10A, Plug-in J2 - Interlock Relay - 24/115V Coi l SPDT 10A B1 - Filters - 1" WA (Standard) J3 - Interlock Relay - 24/115/230V Coil DPDT 10A B2 - Filters - 2" WA J4 - Interlock Relay - 24V Coi l 4PDT 10A B3 - Filters - 2" T A B4 - Filters - 1" 30% K1 - Manual Reset High Limit Switch † B5 - Filters - 2" 30% K2 - High / Low Gas Pressure Limit Switches K3 - Status Lamp (Elec. Cabinet) C1 - Evap. Cooler - Fill & Drain Kit K4 - F an Time Delay (Arrangement “A” Only) C2 - Evap. Cooler - 12" Celdek C3 - Evap. Cooler - Freezestat w/o Time Delay L1 - 30 Amp, Fused Disconnect Switch† C4 - Evap. Cooler - 8" Glasdek C5 - Evap. Cooler - 12" Glasdek L4 - 60 Amp, Non Fused Disconnect Switch† D1 - Time Clock - 7 Day† D2 - Time Clock - 24 Hour† M2 - Vent Caps† M3 - Flue Adapter(s) (4-5 inches)† E1 - Clogged Filter Switch M4 - V ertical Concentric V ent Kit (MS only)† E2 - G.F .I. Conv enience Outlet 115V AC† M5 - Horizontal Concentric V ent Kit (MS only)† E3 - Remote Control Panel† E4 - Manual Blower Switch N5 - Service Convenience Package N6 - Double Wall Construction F1 - Ductstat - One Stage† F2 - Ductstat - T wo Stage† R1 - Field Installed VFD R2 - Factory Installed VFD G1 - Thermostat - T87K w/Subbase† R3 - VFD Remote Keypad f or use w/R1†

Thermostat - T87K w/Subbase & Guard

G2 -

Thermostat - T834N w/Subbase (Sterling Stat)

G3 -

Thermostat - TB8220U - 7 Day Programmable

G4 G5 - Thermostat - TH5220D (T wo Stage)† R7 - 2-Speed VFD Relays G6 - Locking Thermostat Cover† R8 - 3-Speed VFD Relays

Note: All thermostats are Mercury free 0 - None Z1 - Other (Specify)

† = Field Installed

Media K5 - Air Flow Prove Switch (Dwyer 1910-0)†

Media L2 - 30 Amp, Non Fused Disconnect Switch†

Media L3 - 60 Amp, Fused Disconnect Switch†

) R/A Monitor

† R4 - CO2 Sensor - 100% OA†

† R5 - CO2 Sensor - Mixed Air†

† R6 - Pressure Sensor†

— 34 —

Page 35

INDOOR MAKE-UP AIR PRODUCTS

EV B/F/D

F/D B

CCF/D B

B/F/D

EV B/F/D

F/D B

CCF/D B

F/D B

Submittal Index

(Single Furnace Units)

IA “B”

CA (10/40)

IA “D”

CA (10/40)

IA “G”

CA (10/40)

IA “K”

CA (10/40)

IA “A”

CA (50/80)

IA “B”

CA (50/80)

Unit Type (UT)

Power V enting (ME)

B/F/D

Submittal

Number

ME-40-B

ME-40-D

ME-40-G

ME-40-K

ME-80-A

ME-80-B

IA “D”

CA (50/80)

IA “G”

CA (50/50)

IA “K”

CA (50/80

IA “A”

CA 12

IA “G”

CA 12

IA = Indoor Arangement (Digit #7) CA = Capacity (Digits #3 and 4) Air Inlet Conﬁ gurations may vary (Digit #14) Refer to complete Model Number Designation for more details.

ME-80-D

ME-80-G

ME-80-K

ME-12-A

ME-12-G

Legend: B/F/D = Standard Blower/Filter/Damper Module

B = Hi CFM Blower Module

F/D = Hi CFM Filter/Damper Module

CC = Cooling Coil Module

EV = Evap. Cooler Module

— 35 —

Page 36

XVII. GAS EQUIPMENT START-UP

Customer ____________________________________ Job Name & Number _________________________

PRE-INSPECTION INFORMATION

With power and gas off.

Type of Equip:

Serial Number _________________________ Model Number __________________________ Name Plate Voltage: _____________ Name Plate Amperage: _____________ Type of Gas: Natural LP Tank Capacity ______ lbs. Rating: ______ BTU @ ____ °F

______ kg ______ kw @ ____ °C

Unit Heater Duct Furnace Indoor Rooftop

❐ Are all panels, doors, vent caps in place? ❐ Has the unit suffered any external damage? Damage ______________________________ ❐ Does the gas piping and electric wiring appear to be installed in a professional manner? ❐ Has the gas and electric been inspected by the local authority having jurisdiction? ❐ Is the gas supply properly sized for the equipment? ❐ Were the installation instructions followed when the equipment was installed? ❐ Have all ﬁ eld installed controls been installed? ❐ Do you understand all the controls on this equipment? If not, contact your wholesaler or rep.

(DO NOT START this equipment unless you fully understand the controls.)

GENERAL

With power and gas off.

❐ Make certain all packing has been removed. ❐ Tighten all electrical terminals and connections. ❐ Check damper linkages for tightness. ❐ Check all fans & blowers for free movement. ❐ Check all controls for proper settings. ❐ Check all set screws on blowers and bearings. ❐ Check belt tightness.

BLOWER

With power on and gas off.

❐ Check voltage L1 _____ L2 _____ L3 _____ ❐ Check rotation of main blower. ❐ Check motor amps L1 _____ L2 _____ L3 _____ ❐ Blower RPM _____________ ❐ Check air ﬁ lters. (Record quantity & size.)

GAS HEATING

With power and gas on.

❐ Inlet gas pressure. ____ in. W.C. or ____ kPa ❐ Pilot & main burner ignition. ❐ Manifold gas pressure. ____ in. W.C. or ____ kPa ❐ Cycle on HIGH LIMIT. ❐ Cycle ﬁ restat and/or freezestat. ❐ Check electronic modulation. Set at: __________ ❐ Check mechanical modulation. Set at: ________ ❐ Cycle and check all other controls not listed. ❐ Check operation of remote panel. ❐ Entering air temp. _____ °F or ____ °C ❐ Discharge air temp. (high ﬁ re) ____ °F. or ____ °C ❐ External static pressure ____ in. W.C. or ____ kPa ❐ Cycle by thermostat or operating control.

— 36 —

Sterling ME User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual