Sterling MS User Manual

INSTALLATION AND SERVICE MANUAL

SEPARATED COMBUSTION

INDOOR MAKE-UP AIR UNIT ARRANGEMENTS

FOR HEATING, COOLING AND VENTILATING SYSTEMS

ATTENTION: READ THIS MANUAL, SEPARATED COMBUSTION INDOOR DUCT FURNACE SCDFM MANUAL (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. ________________________

MSIOM-3

J30-06624

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 qualified service personnel. Read these installation, operating and maintenance instructions thoroughly before installing or servicing this equipment.

APPROVED FOR USE IN CALIFORNIA

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.

12/12

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) 568-9571 FAX: (413) 562-8437

www.mestek.com

TABLE OF CONTENTS

I. RECEIVING & PRE-INSTALLATION

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

II. GENERAL INSTALLATION SAFETY

REQUIREMENTS ..............................................3, 4

Location ........................................................................4

Combustion Air Considerations ....................................4

Suspension/Rigging ..................................................5

III. INSTALLATION

Installation Clearances ...............................................11

Venting ........................................................................12

Duct Connections .......................................................13

Gas Piping ..................................................................13

Modulating Gas Control ..............................................14

Electrical Connections ..........................................14, 15

DX Coil Equipped Units ..............................................16

Chilled Water Coil Equipped Units ..............................16

Evaporative Cooling Equipped Units ..........................16

IV. OPERATION

General Information ....................................................16

Gas Control System ...................................................16

Sequence of Operation ..............................................17

Optional Gas Controls ................................................17

Air Handling Requirements and Adjustments ............18

Lighting .......................................................................19

Gas Input Adjustment ................................................. 19

Pilot Adjustment .......................................................... 20

Primary Air Shutter Adjustment .................................. 20

Controls ......................................................................20

V. START UP ......................................................20, 21

VI. MAINTENANCE .......................................21 thru 24

VII. TROUBLESHOO TING ............................25 thru 30

VIII. REPLACEMENT PARTS ...................................30

IX. SERVICE NOTE ...................................................30

X. W ARRANTY ..........................................................30

Canadian Installations ...............................................31

XI. DIMENSIONAL DATA ..............................32 thru 37

XII. MOTOR ELECTRICAL DATA .............................38

XIII. UNIT/SHIP WEIGHTS ........................................39

XIV. COOLING COIL DIMENSIONAL DATA ............40

XV. SUBMITTAL INDEX ............................................41

XVI. MODEL NUMBER DESCRIPTION ....................42

XVII. START UP SHEET ...........................................44

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

Make-up Air Units with multiple furnaces are shipped in sections. Each section has a label with Order no.,

Model No., Unit No., and Part No. marked on it. Make certian that the order, model, and part numbers agree on each section to be connected together.

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

— 2 —

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 the latest edition of ANSI Standard Z223.1 (N.F.P.A. No 54) National Fuel Gas Code. All ANSI and NFP A 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 National Standards Institute, Inc., 11 West 42nd Street, New York, NY 10036 or www. ansi.org. 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/NFP A No . 409 and in public garages when installed in accordance with the NFP A 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 CSA-B149.1 or B149.2 “Installation Codes for Gas Burning Appliances and Equipment”. These indoor duct furnaces have been designed for and certiﬁ ed to comply with CSA 2.6.

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.

3. No alterations are to be made on this equipment. The duct furnace section (capacities 100 thru 400 MBH)

of these make-up air units are certiﬁ ed by ETL 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.

— 3 —

9. Do not insert fingers or foreign objects into the heater or its air moving device. Do not bloc k 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.

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.

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.

Refer to unit data plate for required clear ances to combustible material, and Figure 11 for manufacturer’ s recommendations .

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.

NOTICE: The furnace section(s) of this unit is equipped for bottom access serviceability only! Provide adequate clearance (base rail to ﬂ oor is 18 inches minimum).

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.

Presence of these air impurities can cause premature failure of the heat exchanger and void the warranty (See limited warranty on page 30).

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

the ﬁ eld!

MOUNTING HEIGHT

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.

3. In parking structures, Gas Fired Indoor Make-Up Air

Handlers must be installed so that the burner ﬂ ames are located 18" (457mm) above the ﬂ oor or protected by a partition not less than 18" (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.

— 4 —

SUSPENSION/RIGGING

Make certain that the structure to which the single, dual, triple furnace and air handler sections 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.

The unit should never be lifted by any unit component other than the base rail assembly. Unit components other than base rail assembly are not designed to support the total weight and may break, causing personal injury or unit damage.

Units can be set on field furnished supports/cradle with access available to furnace bottom section, 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 ﬁ eld furnished supports by a qualiﬁ ed installer. Refer to all dimensional data in this manual. If further information is required, contact the manufacturer’s technical service department.

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

Refer to Figures 1 and 2 for Single Furnace Make-Up Air Unit rigging requirements. Refer to Figures 3, 4 and 5 for Dual/Tr iple Furnace Make-Up Air Unit rigging requirements, which ships to the site in two sections (Figure 3 is the air handler section and 4 and 5 are the furnace sections.).

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/brackets 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. For distance between lifting lugs/brackets and total unit lengths, refer to the Dimensional Data section of this manual.

The unit must be hung level from side to side and front to back. It is recommended to use the (9/16" diameter) hanging holes in the skid rail, and 1/2" threaded rod or pipe, and/or whatever other supports may be required to adequately support the unit. A ﬁ eld supplied cradle or other means of support may also be required. The installer is responsible for determining adequate and safe suspension methods.

— 5 —

Figure 1 -

(4) Lifting Point Locations (2) At Each End Of Air Handler Unit

Use Spreader Bars To Prevent Damage To Units

D6559

(8) Lifting Point Locations (4) On Each Side Of Duct Furnace Unit

Use Spreader Bars To Prevent Damage To Units

(6) Lifting Point Locations (3) On Each Side Of Duct Furnace Unit

Use Spreader Bars To Prevent Damage To Units

Hoisting of Make-Up Air Unit (Single Furnace)

Without Lifting Brackets

Figure 2 -

Hoisting of Make-Up Air Unit

With Lifting Brackets

Figure 4 - Hoisting Double Furnace Unit

D6558

Figure 5 - Hoisting Triple Furnace Unit

(Single Furnace)

Figure 3 - Hoisting Make-Up Air Handler Unit

D6558

Refer to Figures 3, 4 and 5 for dual/triple furnace Make Up Air rigging requirements. Dual/triple furnace units ship to the site in two sections (Figure 3 is the air handler section; Figures 4 and 5 are the furnace sections).

— 6 —

III. INSTALLATION

Refer to all dimensional data within the manuals equipped with your unit.

SINGLE FURNACE UNITS

Single furnace units (capacities 10-40) consist of a furnace section and an air handler section mounted on a common base rail.

MULTIPLE FURNACE UNITS

Multiple furnace units consist of two sections: a furnace section with two duct furnaces (capacities 50-80) or three duct furnaces (capacity 12) mounted on a common base rail; and a separate air handler section mounted on its own base rail. A ﬂ exible connector kit is also equipped with your unit. Each section has a label with Order

No., Model No., Unit No., and Part No. marked on it. Make certain that the order, model, and part numbers agree on each section to be connected together . The

two sections should be moved individually and mounted in their permanent location (see “Suspension/Rigging” sections). Ensure that both ﬂ ange assemblies are in alignment with a 5" (127mm) space between the ﬂ ange assemblies. See the f ollo wing instructions for installation of the ﬂ exible connector kit between the two sections.

INSTALLING FLEXIBLE CONNECTOR - Refer to Figure 6

1. Make sure that the furnace section and the air

handler section are in alignment and installed with a 5" (127mm) space between the ﬂ ange assemblies.

2. Remove the top e xtension panel of the duct furnace

for access to the inside bottom ﬂ ange assemblies.

4. Measure the distance from the top of the ﬂ ange assembly to the slot at the bottom of the ﬂ ange assembly. Make a second 90 degree bend at the measured distance from the ﬁ rst bend in the ﬂ exible duct connector.

5. Slide the flexible connector through the slots in the ﬂ ange assemblies until the vertical par t is tight against the sides of the ﬂ ange assemblies.

Bend second vertical section up around the ﬂ anges. Make sure all bends are straight and ev en for proper ﬁ t.

7. Bend down top section of ﬂ exible connector. Cut metal parts of ﬂ exible connector to o verlap the 4 inch section by at least 1-1/2 inches (38mm), but cut the fabric portion 1-1/2 inches longer than the metal.

8. Screw metal portions of ﬂ exible connector to the flange assemblies using drill screws. Space the screws approximately 4 to 6" (102 to 152mm) on center. Fasten the bottom section in place by screwing down from the inside. Fasten the overlapped area with two screws in the metal on each side of the fabric. Seal the fabric joint with RTV sealer and allow to cure . Replace and reseal top extension panel on furnace section.

9. Apply sealing tape to seams between ﬂ anges and ﬂ exible connector and to vertical ﬂ ange connections. Test for air leaks during initial start-up. Reseal as required.

Table 1 - Flexible Connector Kit

3. Measure ﬂ exible connector in the ﬂ at to conﬁ rm that it is correct for the unit being installed. Refer to Table

1. Make a 90 degree bend 4" (102mm) from one end of the ﬂ exible duct connector.

Unit (Approx.) Straight Length Capacity Flexible Connector (CA) Required

50 102 Inch (2.59m) 60 114 Inch (2.90m) 70 124 Inch (3.15m) 80/12 135 Inch (3.43m)

— 7 —

Furnace Assembly

Flange Assembly

with Flange

Mounts to

Air Handler

Approx.

for Flexible

2" Slots

Connector

AIR FLOWAIR FLOW

Panel

Top Extension

STEP 1

14.500

Approx.

5.000

Approx.

9.000

***

* * *

***

D6453-1

side of unit

Bend at approx.

4" on access

Assembly on both Furnace and Air Handler

to bottom of the inside of Flange

Remove Top Extension Panel of Duct Furnace to fasten Flexible Connector

Connector into

Slide Flexible

place tightly

before fastening

sheet metal for

1-1/2" Overlap

proper installation

1-1/2" Overlap

fabric for

Furnace

Duct

(4) Slots

STEP 2 STEP 3

Bend at 90∞

STEP 4

STEP 5

D6453-2

Figure 6A

Figure 6B

— 8 —

Flexible Connector

Continue bending

tightly around Flange

Assembly making sure

bends are neat and even

Keep uniform distance

around Flange Assembly

on all sides, (approx. 2")

D6453-3

STEP 6

STEP 7

Figure 6C

Figure 6D

using Drill Screws provided

fasten Flexible Connector to

Flange Assembly securely

space Screws between 4" - 6"

keep uniform distance

around Flange Assembly

on all sides (approx. 2")

for sheet metal overlap use (2)

screws on each side of fabric

Flexible Connector Assembly ready for

application of Sealing

Tape provided for testing

for air leaks (see sht. 5)

Use Sealant between

layers of fabric for

proper installation (by others in field)

STEP 8

D6453-4

— 9 —

AIR FLOW

D6453-5

14.500

stips of Sealing Tape to be

continuous or overlapping

used when sealing Flexible

Connector to Flange Assembly

Approx.

5.000

Approx.

AIR FLOW

9.000

Approx.

***

* *

***

use Sealing Tape on

inside of Bottom Flange

Flexible

Connector

Flange

Assembly

Sealing Tape covers

Screw heads and seams

Figure 6E

STEP 9

on Flange

connections

use Sealing Tape

— 10 —

Figure 7 - Arrangement B & D Capacities10/40

D6554

(8) Suspension Point Locations (4) On Each Side Of Unit

D6555

(4) Suspension Point Locations (2) At Each End Of Air Handler Unit

(6) Suspension Point Locations (3) On Each Side Of Duct Furnace Unit

Both Units Must Be Suspended At Same Height For Proper Fit Of Flex Connector

D6556

Both Units Must Be Suspended At Same Height For Proper Fit Of Flex Connector

(4) Suspension Point Locations (2) At Each End Of Air Handler Unit

(8) Suspension Point Locations (4) On Each Side Of Duct Furnace Unit

Figure 8 - Arrangement G Capacities 10/40

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 11.

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.

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 18" (457mm). Minimum clearance between the top of the heater and the ceiling is 6" (152mm). The minimum clearance to the bottom of the furnace is 25" (635mm). The minimum clearance from combustibles to the ﬂ ue collector is 6" (152mm). The minimum clearance from combustibles to the vent pipe is 6" (152mm). See Figure 11.

Figure 9 - Arrangement G Capacities 50/80

Figure 10 - Arrangement G Capacity 12

— 11 —

*It is recommended that adequate clearance be kept to the bottom of the furnace(s) to make sure a service technician can safely service the unit(s),

The unit should never be lifted by furnace sections, blower housing/filter/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!

Make certain that the lifting 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.

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.

Inspect the suspension and/or support system for the make-up air unit to ensure that all fasteners are tight and the unit is secure before working underneath the unit. Failure to do so could result in property damage, personal injury, or death.

Figure 11 - Manufacturer’s Recommended Service Clearances

5/16

(8mm)

5/16

(8mm)

5/16

(8mm)

5/16

(8mm)

D6573

Field

Ductwork

18(457mm)

Air

Inlet

18 (457mm)

AIR FLOW

17.5 (444mm)

Ductwork

18(457mm)

(635mm)

Field

AIR FLOW

Supply

Ductwork

5/16

(8mm)

5/16

(8mm)

5/16

(8mm)

5/16

(8mm)

36 (914mm)

Ductwork

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

18 (457mm)

Supply

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 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 ﬂ ulike symptoms).

The venting is an integral part of

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

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

Vent Systems

Termination Clearance Requirements

Minimum Clearance

Structure/Object

for Termination Locations

USA CANADA

Door, window, or gravity vent inlet; combustion air inlet for other appliances

9 inch for 10,000 to 50,000 BTU/Hr input; 12 inch for input exceeding 50,000 BTU/Hr.

9 inch (230mm) for 10,000 to 50,000 BTU/Hr input; 12 inch (305mm) for input exceeding

50,000 BTU/Hr. Forced air inlet within 10 feet 3 feet above 6 feet (1.8m) Adjoining Building or parapet 6 feet 6 feet (1.8m)

Adjacent public walkways

7 feet above grade

7 feet (2.1m) above

grade

3 feet (0.9m)

horizontally from

meter/regulator Electric, gas meters & regulators

4 feet horizontal

asembly. 6 feet

(1.8m), any

direction, from

a gas service

regulator vent outlet Above grade level* 1 foot* 1 foot (0.3m)*

*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.

— 12 —

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.

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.

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.

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.

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" N.P.T. plugged tapping, accessible for test gauge connection, must be installed immediately upstream of the unit gas supply connection.

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 solub le to liquid petroleum gases must be used on threaded joints.

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).

The appliance must be isolated from the gas supply piping system by closing the individual manual shutoff valv e 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 Separated Combustion Indoor Gas-Fired Duct Furnace Installation and Service Manual.

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

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!

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

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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 qualiﬁ ed 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 thor ough test is made for leaks before operating the unit; and that it is properl y 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)*

AIR FLOW AIR FLOW

Electrical Cabinet

Air Handler

Junction Box

Duct Furnace

Conduit

Low Voltage

Conduit

Line Voltage

D03304

*** *

***

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

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

ELECTRICAL CONNECTIONS

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

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

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.

All electrical connections must conform to: the latest edition of ANSI/NFPA No. 70, National Electrical Code, and applicable local codes. In Canada, to the Canadian Electrical Code, Part I CSA Standard C22.1.

Single furnace make-up air packaged units are wired at the factory and are ready to be connected. Multiple furnace make-up air units are shipped in two parts, the air handler section and the furnace section. After mounting the two sections and installing the ﬂ exible duct connector, connect the free end of the ﬂ exible conduits from the air handler section to the junction box on the duct furnace. Each wire has a distinctive marking. Connect each wire to its respectively marked terminal in the duct furnace junction box. See Figure 13A. Actual unit wiring will differ according to the options chosen. Each unit is shipped with its own wiring diagram; refer to this wiring diagram for all electrical connections to the unit.

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 15). Electrical conduit must be routed so as not to interfere with removal of any access panel.

NOTICE: Should any original wire supplied with the unit have to be replaced, it must be replaced with wiring having a temperature rating of at least 221°F (105°C).

Figure 13A

All line voltage and thermostat connections are made in the Electrical Cabinet (See Figure 13B). Line voltage connections are made at the High Voltage Terminal Block. Thermostat connections are made at the Main Connection Board (See Figure 14).

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