Trane GGAA, GZAA, GGBA, GZBA Installation, Operation And Maintenance Manual

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Page 1

Installation, Operation, and Maintenance

Indoor Make-Up Air Unit Arrangements

For Heating, Cooling, and Ventilating Systems

MMooddeellss::

GGAA GGBA

GZAA GZBA

Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training. Improperly installed, adjusted or altered equipment by an unqualified person could result in death or serious injury. When working on the equipment, observe all precautions in the literature and on the tags, stickers, and labels that are attached to the equipment.

May 2017

SSAAFFEETTYY WWAARRNNIINNGG

MMUUAA--SSVVXX000055BB--EENN

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Introduction

Read this manual thoroughly before operating or servicing this unit.

Warnings, Cautions, and Notices

Safety advisories appear throughout this manual as required. Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions.

The three types of advisories are defined as follows:

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It could also be used to alert against unsafe practices.

Indicates a situation that could result in equipment or property-damage only accidents.

Important Environmental Concerns

Scientific research has shown that certain man-made chemicals can affect the earth’s naturally occurring stratospheric ozone layer when released to the atmosphere. In particular, several of the identified chemicals that may affect the ozone layer are refrigerants that contain Chlorine, Fluorine and Carbon (CFCs) and those containing Hydrogen, Chlorine, Fluorine and Carbon (HCFCs). Not all refrigerants containing these compounds have the same potential impact to the environment. Trane advocates the responsible handling of all refrigerants-including industry replacements for CFCs and HCFCs such as saturated or unsaturated HFCs and HCFCs.

Important Responsible Refrigerant Practices

Trane believes that responsible refrigerant practices are important to the environment, our customers, and the air conditioning industry. All technicians who handle refrigerants must be certified. The Federal Clean Air Act (Section 608) sets forth the requirements for handling, reclaiming, recovering and recycling of certain refrigerants and the equipment that is used in these service procedures. In addition, some states or municipalities may have additional requirements that must also be adhered to for responsible management of refrigerants. Know the applicable laws and follow them.

PPrrooppeerr FFiieelldd WWiirriinngg aanndd GGrroouunnddiinngg RReeqquuiirreedd!!

FFaaiilluurree ttoo ffoollllooww ccooddee ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy.. AAllll ffiieelldd wwiirriinngg MMUUSSTT bbee ppeerrffoorrmmeedd bbyy qquuaalliiffiieedd ppeerrssoonnnneell.. IImmpprrooppeerrllyy iinnssttaalllleedd aanndd

ggrroouunnddeedd ffiieelldd wwiirriinngg ppoosseess FFIIRREE aanndd EELLEECCTTRROOCCUUTTIIOONN hhaazzaarrddss.. TToo aavvooiidd tthheessee hhaazzaarrddss,, yyoouu MMUUSSTT ffoollllooww rreeqquuiirreemmeennttss ffoorr ffiieelldd wwiirriinngg iinnssttaallllaattiioonn aanndd ggrroouunnddiinngg aass ddeessccrriibbeedd iinn NNEECC aanndd yyoouurr llooccaall//ssttaattee//nnaattiioonnaall eelleeccttrriiccaall ccooddeess..

WWAARRNNIINNGG

MUA-SVX005B-EN

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IInnttrroodduuccttiioonn

WWAARRNNIINNGG

PPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirreedd!!

FFaaiilluurree ttoo wweeaarr pprrooppeerr PPPPEE ffoorr tthhee jjoobb bbeeiinngg uunnddeerrttaakkeenn ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy.. TTeecchhnniicciiaannss,, iinn oorrddeerr ttoo pprrootteecctt tthheemmsseellvveess ffrroomm ppootteennttiiaall eelleeccttrriiccaall,, mmeecchhaanniiccaall,, aanndd cchheemmiiccaall hhaazzaarrddss,, MMUUSSTT ffoollllooww pprreeccaauuttiioonnss iinn tthhiiss mmaannuuaall aanndd oonn tthhee ttaaggss,, ssttiicckkeerrss,, aanndd llaabbeellss,, aass wweellll aass tthhee iinnssttrruuccttiioonnss bbeellooww::

•• BBeeffoorree iinnssttaalllliinngg//sseerrvviicciinngg tthhiiss uunniitt,, tteecchhnniicciiaannss MMUUSSTT ppuutt oonn aallll PPPPEE rreeqquuiirreedd ffoorr tthhee wwoorrkk bbeeiinngg uunnddeerrttaakkeenn ((EExxaammpplleess;; ccuutt rreessiissttaanntt gglloovveess//sslleeeevveess,, bbuuttyyll gglloovveess,, ssaaffeettyy ggllaasssseess,, hhaarrdd hhaatt//bbuummpp ccaapp,, ffaallll pprrootteeccttiioonn,, eelleeccttrriiccaall PPPPEE aanndd aarrcc ffllaasshh ccllootthhiinngg)).. AALLWWAAYYSS rreeffeerr ttoo aapppprroopprriiaattee MMaatteerriiaall SSaaffeettyy DDaattaa SShheeeettss ((MMSSDDSS))//SSaaffeettyy DDaattaa SShheeeettss ((SSDDSS)) aanndd OOSSHHAA gguuiiddeelliinneess ffoorr pprrooppeerr PPPPEE..

•• WWhheenn wwoorrkkiinngg wwiitthh oorr aarroouunndd hhaazzaarrddoouuss cchheemmiiccaallss,, AALLWWAAYYSS rreeffeerr ttoo tthhee aapppprroopprriiaattee MMSSDDSS//SSDDSS aanndd OOSSHHAA//GGHHSS ((GGlloobbaall HHaarrmmoonniizzeedd SSyysstteemm ooff CCllaassssiiffiiccaattiioonn aanndd LLaabbeelllliinngg ooff CChheemmiiccaallss)) gguuiiddeelliinneess ffoorr iinnffoorrmmaattiioonn oonn aalllloowwaabbllee ppeerrssoonnaall eexxppoossuurree lleevveellss,, pprrooppeerr rreessppiirraattoorryy pprrootteeccttiioonn aanndd hhaannddlliinngg iinnssttrruuccttiioonnss..

•• IIff tthheerree iiss aa rriisskk ooff eenneerrggiizzeedd eelleeccttrriiccaall ccoonnttaacctt,, aarrcc,, oorr ffllaasshh,, tteecchhnniicciiaannss MMUUSSTT ppuutt oonn aallll PPPPEE iinn aaccccoorrddaannccee wwiitthh OOSSHHAA,, NNFFPPAA 7700EE,, oorr ootthheerr ccoouunnttrryy--ssppeecciiffiicc rreeqquuiirreemmeennttss ffoorr aarrcc ffllaasshh pprrootteeccttiioonn,, PPRRIIOORR ttoo sseerrvviicciinngg tthhee uunniitt.. NNEEVVEERR PPEERRFFOORRMM AANNYY SSWWIITTCCHHIINNGG,, DDIISSCCOONNNNEECCTTIINNGG,, OORR VVOOLLTTAAGGEE TTEESSTTIINNGG WWIITTHHOOUUTT PPRROOPPEERR EELLEECCTTRRIICCAALL PPPPEE AANNDD AARRCC FFLLAASSHH CCLLOOTTHHIINNGG.. EENNSSUURREE EELLEECCTTRRIICCAALL MMEETTEERRSS AANNDD EEQQUUIIPPMMEENNTT AARREE PPRROOPPEERRLLYY RRAATTEEDD FFOORR IINNTTEENNDDEEDD VVOOLLTTAAGGEE..

Trademarks

WWAARRNNIINNGG

TTooxxiicc FFuummeess aanndd FFiibbeerrss!!

IInnssttaallll,, ooppeerraattee aanndd mmaaiinnttaaiinn uunniitt iinn aaccccoorrddaannccee wwiitthh mmaannuuffaaccttuurreerr''ss iinnssttrruuccttiioonnss ttoo aavvooiidd eexxppoossuurree ttoo ffuueell ssuubbssttaanncceess oorr ssuubbssttaanncceess ffrroomm iinnccoommpplleettee ccoommbbuussttiioonn wwhhiicchh ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iillllnneessss.. TThhee SSttaattee ooff CCaalliiffoorrnniiaa hhaass ddeetteerrmmiinneedd tthhaatt tthheessee ssuubbssttaanncceess mmaayy ccaauussee ccaanncceerr,, bbiirrtthh ddeeffeeccttss,, oorr ootthheerr rreepprroodduuccttiivvee hhaarrmm.. IInnssttaallll aanndd SSeerrvviiccee tthhiiss pprroodduucctt ttoo aavvooiidd eexxppoossuurree ttoo aaiirrbboorrnnee ppaarrttiicclleess ooff ggllaasssswwooooll ffiibbeerrss aanndd//oorr cceerraammiicc ffiibbeerrss kknnoowwnn ttoo tthhee SSttaattee ooff CCaalliiffoorrnniiaa ttoo ccaauussee ccaanncceerr tthhrroouugghh iinnhhaallaattiioonn..

This document and the information in it are the property of Trane, and may not be used or reproduced in whole or in part without written permission. Trane reserves the right to revise this publication at any time, and to make changes to its content without obligation to notify any person of such revision or change.

All trademarks referenced in this document are the trademarks of their respective owners.

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Table of Contents

Receiving Instructions . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . 6

Pre-Installation Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

General Safety Requirements. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . 7

Locations to Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Installation. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . 11

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Combustion Air Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Mounting Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Mounting On Field-Furnished Supports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Installation Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Access Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Venting† . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Air For Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Duct Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Gas Piping†† . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Modulating Gas Control (Optional)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

DX Coil Equipped Units (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Chilled Water Coil Equipped Units (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Evaporative Cooler Equipped Units (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Operation. . . . . . . . . . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . . . . 22

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Gas Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Sequence of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Optional Gas Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Air Handling Requirements and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Gas Input Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Pilot Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Primary Air Shutter Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Start-Up . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . . . . . .. . . . . . . . . . . 28

Maintenance. . . . . . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . 30

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TTaabbllee ooff CCoonntteennttss

Main Burner Drawer Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

High Limit and/or Safety Limit Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Seasonal Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Air Blower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Troubleshooting . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . 36

Troubleshooting Guide — Air Blower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Troubleshooting Guide — Electric Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Troubleshooting Guide — Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Troubleshooting Guide — DX Cooling Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Troubleshooting Guide — Chilled Water Cooling Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Dimensional Data — Arrangements . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . 43

Unit Type GG, Indoor Arrangements B, Capacities 10–80 . . . . . . . . . . . . . . . . . . . . . . . 44

Unit Type GG, Indoor Arrangements D, Capacities 10–80 . . . . . . . . . . . . . . . . . . . . . . . 44

Unit Type GG, Indoor Arrangements G, Capacities 20–12. . . . . . . . . . . . . . . . . . . . . . . 45

Unit Type GG, Indoor Arrangements K, Capacities 10–80 . . . . . . . . . . . . . . . . . . . . . . . 46

Motor Electric Data . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . . . . . .. . . . . . . . . . . . 47

Unit Shipping Weights. . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . 48

Coil Cabinet Dimensional Data. . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. 50

Center of Gravity . . .. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . .. . . . . . . . . . 51

Center of Gravity Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Indoor Make-Up Air Unit Number Description . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. 53

Indoor Make-Up Air Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Gas Equipment Start-Up. . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . 57

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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 cosignee should sign the bill of lading indicating such damage and immediately file claim for damage with transportation company.

Pre-Installation Instructions

This equipment has been test fired and inspected. It has been shipped free from defects from our factory. However, 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.

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 specifications to confirm that these agree with those at point of installation. The unit is equipped with an Indoor Duct Furnace. Check the data plate and all labels located inside each furnace.

Every unit will include an informational packet which will include the following:

• Blower manual

• Indoor duct furnace and evaporative cooler/cooling coil manuals (if applicable)

• Wiring diagram(s)

• Factory installed service convenience options manual (if applicable)

• Special controls/data sheets

NNoottee:: It is the 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 7

General Safety Requirements

HHaazzaarrddoouuss SSeerrvviiccee PPrroocceedduurreess!!

FFaaiilluurree ttoo ffoollllooww aallll pprreeccaauuttiioonnss iinn tthhiiss mmaannuuaall aanndd oonn tthhee ttaaggss,, ssttiicckkeerrss,, aanndd llaabbeellss ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy.. TTeecchhnniicciiaannss,, iinn oorrddeerr ttoo pprrootteecctt tthheemmsseellvveess ffrroomm ppootteennttiiaall eelleeccttrriiccaall,, mmeecchhaanniiccaall,, aanndd cchheemmiiccaall hhaazzaarrddss,, MMUUSSTT ffoollllooww pprreeccaauuttiioonnss iinn tthhiiss mmaannuuaall aanndd oonn tthhee ttaaggss,, ssttiicckkeerrss,, aanndd llaabbeellss,, aass wweellll aass tthhee ffoolllloowwiinngg iinnssttrruuccttiioonnss:: UUnnlleessss ssppeecciiffiieedd ootthheerrwwiissee,, ddiissccoonnnneecctt aallll eelleeccttrriiccaall ppoowweerr iinncclluuddiinngg rreemmoottee ddiissccoonnnneecctt aanndd ddiisscchhaarrggee aallll eenneerrggyy ssttoorriinngg ddeevviicceess ssuucchh aass ccaappaacciittoorrss bbeeffoorree sseerrvviicciinngg.. FFoollllooww pprrooppeerr lloocckkoouutt//ttaaggoouutt pprroocceedduurreess ttoo eennssuurree tthhee ppoowweerr ccaann nnoott bbee iinnaaddvveerrtteennttllyy eenneerrggiizzeedd.. WWhheenn nneecceessssaarryy ttoo wwoorrkk wwiitthh lliivvee eelleeccttrriiccaall ccoommppoonneennttss,, hhaavvee aa qquuaalliiffiieedd lliicceennsseedd eelleeccttrriicciiaann oorr ootthheerr iinnddiivviidduuaall wwhhoo hhaass bbeeeenn ttrraaiinneedd iinn hhaannddlliinngg lliivvee eelleeccttrriiccaall ccoommppoonneennttss ppeerrffoorrmm tthheessee ttaasskkss..

• 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:

– Do not touch electrical switches.

– Extinguish any open flames.

– Immediately call your gas supplier.

• Open all disconnect switches before installing the unit. If the power disconnect is out of sight, lock it in the open position and tag 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 ﬁrst disconnecting all electrical and gas supplies to the unit or severe personal injury or death may occur.

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

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

• 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.

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 certiﬁed. 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 certiﬁed by the American Gas Association for use with natural and LP (propane) gases!

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

WWAARRNNIINNGG

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GGeenneerraall SSaaffeettyy RReeqquuiirreemmeennttss

5. Follow installation instructions CAREFULLY to avoid creating unsafe conditions. All wiring should be done and checked by a qualiﬁed electrician, using copper wire only. All gas connections should be made and leak-tested by a suitably qualiﬁed 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.

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.

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. To ensure proper ground, the grounding means must be tested by qualiﬁed ﬁeld 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 ﬂammable 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.

WWAARRNNIINNGG

FFiirree HHaazzaarrdd aanndd TTooxxiicc FFuummeess!!

FFaaiilluurree ttoo ffoollllooww iinnssttrruuccttiioonnss bbeellooww ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy.. TThhee ooppeenn eenndd ooff ppiippiinngg ssyysstteemmss bbeeiinngg ppuurrggeedd mmuusstt NNOOTT ddiisscchhaarrggee iinnttoo aarreeaass wwhheerree tthheerree aarree ssoouurrcceess ooff iiggnniittiioonn oorr iinnttoo ccoonnffiinneedd ssppaacceess UUNNLLEESSSS pprreeccaauuttiioonnss aarree ttaakkeenn aass ffoolllloowwss::

•• BByy vveennttiillaattiioonn ooff tthhee ssppaaccee..

•• BByy ccoonnttrroolllliinngg tthhee ppuurrggiinngg rraattee..

•• BByy eelliimmiinnaattiinngg aallll hhaazzaarrddoouuss ccoonnddiittiioonnss

Unless otherwise speciﬁed, the following conversions may be used for calculating SI unit measurements:

• 1 inch = 25.4 mm

• 1 foot = 0.305 m

• 1 gallon = 3.785 L

• 1 pound = 0.454 kg

• 1 psig = 6.894 kPa

• 1 cubic foot = 0.028 m

• 1000 Btu/Cu. Ft. = 37.5 MJ/m

• 1000 Btu per hour = 0.293 kW

• 1 inch water column = 0.249 kPa

• liter/second = CFM x 0.472

• meter/second = FPM ÷ 196.8

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Locations to Avoid

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

HHeeaatt EExxcchhaannggeerr DDaammaaggee!!

FFaaiilluurree ttoo ffoollllooww iinnssttrruuccttiioonnss ccoouulldd rreessuulltt iinn ddaammaaggee ttoo tthhee hheeaatt eexxcchhaannggeerr aanndd vvooiidd tthhee wwaarrrraannttyy.. DDoo nnoott llooccaattee aannyy ggaass ffiirreedd hheeaatteerr wwhheerree aaiirr ffoorr ccoommbbuussttiioonn ccoonnttaaiinnss iimmppuurriittiieess ssuucchh aass cchhlloorriinnaatteedd vvaappoorrss oorr aacciidd ffuummeess.. AAvvooiidd llooccaattiioonnss wwhheerree eexxttrreemmee ddrraaffttss ccaann aaffffeecctt bbuurrnneerr ooppeerraattiioonn..

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 ﬁeld!

Rigging

HHeeaavvyy OObbjjeecctt!!

FFaaiilluurree ttoo ffoollllooww tthheessee iinnssttrruuccttiioonnss ccoouulldd rreessuulltt iinn ddeeaatthh,, sseerriioouuss iinnjjuurryy,, aanndd pprrooppeerrttyy ddaammaaggee.. MMaakkee cceerrttaaiinn tthhaatt tthhee lliiffttiinngg mmeetthhooddss uusseedd ttoo lliifftt tthhee dduucctt ffuurrnnaaccee aarree ccaappaabbllee ooff ssuuppppoorrttiinngg tthhee wweeiigghhtt ooff tthhee hheeaatteerr dduurriinngg iinnssttaallllaattiioonn.. EEnnssuurree tthhaatt aallll hhaarrddwwaarree uusseedd iinn tthhee ssuussppeennssiioonn ooff eeaacchh dduucctt ffuurrnnaaccee iiss pprrooppeerrllyy rraatteedd ffoorr tthhee jjoobb.. MMaakkee cceerrttaaiinn tthhaatt tthhee ssttrruuccttuurree ttoo wwhhiicchh tthhee dduucctt ffuurrnnaaccee iiss ttoo bbee mmoouunntteedd iiss ccaappaabbllee ooff ssaaffeellyy ssuuppppoorrttiinngg iittss wweeiigghhtt.. UUnnddeerr nnoo cciirrccuummssttaanncceess mmuusstt tthhee ggaass lliinneess,, vveennttiinngg ssyysstteemm,, oorr tthhee eelleeccttrriiccaall ccoonndduuiitt bbee uusseedd ttoo ssuuppppoorrtt tthhee dduucctt ffuurrnnaaccee.. DDoo nnoott aallllooww oobbjjeeccttss ((ii..ee.. llaaddddeerr)) oorr ppeeooppllee ttoo lleeaann aaggaaiinnsstt tthhee ggaass lliinneess,, vveennttiinngg ssyysstteemm,, oorr eelleeccttrriiccaall ccoonndduuiitt ffoorr ssuuppppoorrtt..

GGeenneerraall SSaaffeettyy RReeqquuiirreemmeennttss

NNOOTTIICCEE

WWAARRNNIINNGG

Rig unit using either belt or cable slings. Use spreader bars to protect the top of the unit when it is lifted. See Figure 1, p. 10 and Figure 2, p. 10. Make sure all hardware used in the lifting/ mounting process is tightened and secured.

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. Also see Center of Gravity and Weights sections in this manual prior to lifting and apply accordingly to the lifting process.

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GGeenneerraall SSaaffeettyy RReeqquuiirreemmeennttss

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

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

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Page 11

Installation

Location

WWAARRNNIINNGG

MMoouunnttiinngg IInntteeggrriittyy!!

FFaaiilluurree ttoo ffoollllooww iinnssttrruuccttiioonn bbeellooww ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy oorr ppoossssiibbllee eeqquuiippmmeenntt oorr pprrooppeerrttyy--oonnllyy ddaammaaggee.. EEnnssuurree tthhee rrooooff ssttrruuccttuurree ssuuppppoorrttss aarree ssttrroonngg eennoouugghh ttoo ssuuppppoorrtt tthhee wweeiigghhtt ooff tthhee uunniitt aanndd aannyy aacccceessssoorriieess..

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 Installation and Clearances section for required clearances to combustible material, and

Figure 5, p. 14 for manufacturer’s recommendations.

WWAARRNNIINNGG

PPrrooppeerr IInnssttaallllaattiioonn LLooccaattiioonn RReeqquuiirreedd!!

FFaaiilluurree ttoo ffoollllooww iinnssttrruuccttiioonnss bbeellooww ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy.. DDoo nnoott ppllaaccee uunniitt iinn aa llooccaattiioonn wwhheerree sseerrvviiccee ppeerrssoonnnneell ccaann nnoott ssaaffeellyy sseerrvviiccee tthhiiss eeqquuiippmmeenntt ((ii..ee.. rrooooff eeddggee,, sskkyylliigghhttss,, eettcc..))..

IImmppoorrttaanntt:: When selecting a location for these Make-Up Air Units, both the size of the unit and

the heating requirements of the building must be considered.

If a variable frequency drive (VFD) has been ordered with the unit, consideration should be made for the VFD operating temperature range: 14°F to 130°F. For temperatures below 14°F, VFD must be factory-installed within the VFD Enclosure accessory (Model Digit 22, option 9), or fieldmounted indoors.

Combustion Air Considerations

The presence of chlorine vapors or other corrosive vapors in the combustion air supply for gasﬁred heating equipment presents a potential corrosive hazard. Chlorine will, when exposed to ﬂame, 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 ﬂoor is recommended. Less efﬁcient air distribution results at higher levels.

2. When Gas Fired Indoor Make-Up Air Handlers are installed in airplane hangars, NFPA speciﬁes that the units must be at least ten feet (3.0m) above 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 ﬂoor) to the bottom of the heater. Heaters must be installed at least eight feet (2.4m) above the ﬂoor in shops, ofﬁces, 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 ﬂames are located 18 in. (45mm) above the ﬂoor or protected by a partition not less than 18 in. (457mm) high as speciﬁed 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 speciﬁed in NFPA 88B Repair Garages.

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IInnssttaallllaattiioonn

Suspension

WWAARRNNIINNGG

HHeeaavvyy OObbjjeecctt!!

FFaaiilluurree ttoo ffoollllooww iinnssttrruuccttiioonnss bbeellooww ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy,, aanndd pprrooppeerrttyy ddaammaaggee.. TThhee uunniitt sshhoouulldd nneevveerr bbee lliifftteedd bbyy tthhee ffaann hhoouussiinngg,, mmoottoorr mmoouunnttiinngg,, ggrriillllee oorr fflluuee ccoonnnneeccttiioonn.. TThheessee aarree nnoott ddeessiiggnneedd ttoo ssuuppppoorrtt tthhee ttoottaall wweeiigghhtt aanndd mmaayy bbrreeaakk..

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

IImmppoorrttaanntt:: Any unit that has a side base rail longer than 104" (2.6m) requires additional field

furnished supports by a qualiﬁed 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 ) in the skid rail, and 3/8" or 1/2" threaded rod or pipe.

WWAARRNNIINNGG

HHeeaavvyy OObbjjeecctt!!

Figure 3. Suspension Point Locations

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, p. 13).

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Page 13

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 ﬁeld installed optional outside air hood (if unit is to be connected to one) must be unobstructed. See Figure 5, p. 14.

Every gas appliance should be located with respect to building construction and other equipment so as to permit access to the unit. Clearances between vertical 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 ﬂue collector is 6 inches (152mm). Adequate clearance 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, p. 14 and Tables 5 and 6.

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 jacket. Refer to the maintenance section and the Indoor Duct Furnace manual for more information.

IInnssttaallllaattiioonn

Figure 4. Mounting on Field-Furnished Supports

HHeeaavvyy OObbjjeecctt!!

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Page 14

IInnssttaallllaattiioonn

WWAARRNNIINNGG

HHeeaavvyy OObbjjeecctt!!

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

assembly.

Figure 5. Manufacturer’s Recommended Service Clearances

Access Panel Removal

HHaazzaarrddoouuss VVoollttaaggee aanndd GGaass!!

FFaaiilluurree ttoo ttuurrnn ooffff ggaass oorr ddiissccoonnnneecctt ppoowweerr bbeeffoorree sseerrvviicciinngg ccoouulldd rreessuulltt iinn aann eexxpplloossiioonn oorr eelleeccttrrooccuuttiioonn wwhhiicchh ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy.. TTuurrnn ooffff tthhee ggaass ssuuppppllyy aanndd ddiissccoonnnneecctt aallll eelleeccttrriicc ppoowweerr,, iinncclluuddiinngg rreemmoottee ddiissccoonnnneeccttss,, bbeeffoorree sseerrvviicciinngg tthhee uunniitt.. FFoollllooww pprrooppeerr lloocckkoouutt//ttaaggoouutt pprroocceedduurreess ttoo eennssuurree tthhee ppoowweerr ccaann nnoott bbee iinnaaddvveerrtteennttllyy eenneerrggiizzeedd..

The air handler section(s) of this unit are equipped with hinged access doors. The hinged doors include dual, quick opening tool-less latches and full perimeter gasketing to assure a water resistant seal. Door stops are included to guard against closure while open.

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. SSeeee tthhee mmaaiinntteennaannccee sseeccttiioonn aanndd tthhee dduucctt ffuurrnnaaccee mmaannuuaall ffoorr mmoorree iinnffoorrmmaattiioonn rreeggaarrddiinngg bbuurrnneerr ddrraawweerr rreemmoovvaall//aacccceessssiibbiilliittyy..

WWAARRNNIINNGG

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Page 15

Venting†

IInnssttaallllaattiioonn

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.

WWAARRNNIINNGG

CCaarrbboonn MMoonnooxxiiddee PPooiissoonniinngg!!

FFaaiilluurree ttoo ffoollllooww tthheessee iinnssttrruuccttiioonnss ccoouulldd rreessuulltt iinn CCaarrbboonn MMoonnooxxiiddee PPooiissoonniinngg ((ssyymmppttoommss iinncclluuddee ggrrooggggiinneessss,, lleetthhaarrggyy,, iinnaapppprroopprriiaattee ttiirreeddnneessss,, oorr fflluu--lliikkee ssyymmppttoommss)) wwhhiicchh ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy.. NNeevveerr ooppeerraattee aa uunniitt wwiitthhoouutt ccoommbbuussttiioonn aaiirr aanndd fflluuee ggaass ppiippiinngg iinn ppllaaccee.. EEaacchh uunniitt MMUUSSTT hhaavvee aann iinnddiivviidduuaall vveenntt ppiippee!! EEaacchh uunniitt MMUUSSTT NNOOTT bbee ccoonnnneecctteedd ttoo ootthheerr vveenntt ssyysstteemmss oorr ttoo aa cchhiimmnneeyy.. YYoouurr vveennttiinngg ssyysstteemm mmuusstt nnoott bbee bblloocckkeedd bbyy aannyy ssnnooww,, ssnnooww ddrriiffttss,, oorr aannyy ffoorreeiiggnn mmaatttteerr.. IInnssppeecctt yyoouurr vveennttiinngg ssyysstteemm ttoo eennssuurree aaddeeqquuaattee vveennttiillaattiioonn eexxiissttss aatt aallll ttiimmeess!!

WWAARRNNIINNGG

PPrrooppeerr VVeennttiinngg RReeqquuiirreedd!!

FFaaiilluurree ttoo ffoollllooww iinnssttrruuccttiioonnss bbeellooww ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy.. AAllll vveennttiinngg iinnssttaallllaattiioonnss sshhaallll bbee iinn aaccccoorrddaannccee wwiitthh tthhee NNaattiioonnaall FFuueell GGaass CCooddee,, AANNSSII ZZ222233..11 oorr aapppplliiccaabbllee pprroovviissiioonnss ooff llooccaall bbuuiillddiinngg ccooddeess..

VVeennttiinngg iiss aann iinntteeggrraall ppaarrtt ooff tthhee uunniitt aanndd mmuusstt NNOOTT bbee aalltteerreedd iinn tthhee ffiieelldd..

Power Vented units feature a factory installed power venter and sealed ﬂue collector that controls combustion and excess air during the on-cycle.

Table 1. Vent Systems — Termination Clearance Requirements

Structure/Object

Door, window, or gravity vent inlet;

combustion air inlet for other

appliances

Forced air inlet within 10 feet 3 feet above

Adjoining building or parapet

Adjacent public walkways 7 feet above grade 7 feet (2.1m) above grade

Electric, gas meters & regulators

Above grade level*

9 inches for 10,000 to 50,000 BTU/

Minimum Clearances for Termination Locations

USA CANADA

9 inches (230mm) for 10,000 to

Hr input; 12 inches for input

exceeding 50,000 BTU/Hr.

10 feet

4 feet horizontal

1 foot

50,000 BTU/Hr input; 12 inches

(305mm) for input exceeding

3 feet (0.9m) horizontally from meter/regulator assembly. 6 feet (1.8m), any direction, from a gas

service regulator vent outlet

50,000 BTU/Hr.

6 feet (1.8m)

10 feet (3.04m)

1 foot (0.3m)

NNoottee:: *Minimum above maximum snow depth, or per local code, whichever is greater.

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

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IInnssttaallllaattiioonn

Air For Combustion

CCaarrbboonn MMoonnooxxiiddee PPooiissoonniinngg!!

Appliances shall be installed in a location in which the facilities for ventilation permit 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 conﬁned space. When buildings are so tight that normal inﬁltration 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.

WWAARRNNIINNGG

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 ﬂanges 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 reﬂected 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.

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 ﬂange 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 speciﬁed 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.

NNoottee:: †† For complete Gas Piping installation, see the Indoor Gas-Fired Duct Furnace Installation

Gas piping must be installed to allow for removal of burner drawer for unit maintenance. Refer to

Figure 5, p. 14, and the maintenance section.

and Service Manual.

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Page 17

IInnssttaallllaattiioonn

WWAARRNNIINNGG

FFiirree HHaazzaarrdd!!

FFaaiilluurree ttoo ffoollllooww iinnssttrruuccttiioonnss bbeellooww ccoouulldd rreessuulltt iinn ddaammaaggee ttoo tthhee uunniitt ggaass vvaallvvee aanndd ccaauussee aa ffiirree hhaazzaarrdd wwhhiicchh ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy..

•• DDoo NNOOTT ccoonnnneecctt ggaass ppiippiinngg ttoo tthhiiss uunniitt uunnttiill aa ssuuppppllyy lliinnee pprreessssuurree// lleeaakk tteesstt hhaass bbeeeenn ccoommpplleetteedd..

•• DDoo NNOOTT rreellyy oonn aa ggaass sshhuuttooffff vvaallvvee ttoo iissoollaattee tthhee uunniitt wwhhiillee ccoonndduuccttiinngg ggaass pprreessssuurree//lleeaakk tteessttss.. TThheessee vvaallvveess mmaayy nnoott bbee ccoommpplleetteellyy sshhuuttooffff,, eexxppoossiinngg tthhee uunniitt ggaass vvaallvvee ttoo eexxcceessssiivvee pprreessssuurree..

•• DDoo nnoott oovveerr--ttiigghhtteenn tthhee iinnlleett ggaass ppiippiinngg aatt uunniitt ggaass vvaallvvee..

WWAARRNNIINNGG

EExxpplloossiioonn HHaazzaarrdd!!

FFaaiilluurree ttoo ffoollllooww ssaaffee lleeaakk tteesstt pprroocceedduurreess bbeellooww ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy oorr eeqquuiippmmeenntt oorr pprrooppeerrttyy--oonnllyy--ddaammaaggee.. NNeevveerr uussee aann ooppeenn ffllaammee ttoo ddeetteecctt ggaass lleeaakkss.. UUssee aa lleeaakk tteesstt ssoolluuttiioonn ffoorr lleeaakk tteessttiinngg..

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.

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 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).

IImmppoorrttaanntt:: If the gas duct furnace is to be ﬁred with LP gas, consult local LP gas dealer for piping

size information.

IImmppoorrttaanntt:: 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 existing 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)*

• EElleeccttrroonniicc

– On units equipped with electronic modulating control, follow control manufacturer’s

installation instructions for sensing of outlet air temperature.

– **AAllssoo rreeffeerr ttoo tthhee IInnddoooorr DDuucctt FFuurrnnaaccee IInnssttaallllaattiioonn MMaannuuaall ssuupppplliieedd wwiitthh yyoouurr uunniitt..

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IInnssttaallllaattiioonn

Electrical Connections

HHaazzaarrddoouuss VVoollttaaggee!!

FFaaiilluurree ttoo ddiissccoonnnneecctt ppoowweerr bbeeffoorree sseerrvviicciinngg ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy.. DDiissccoonnnneecctt aallll eelleeccttrriicc ppoowweerr,, iinncclluuddiinngg rreemmoottee ddiissccoonnnneeccttss bbeeffoorree sseerrvviicciinngg.. FFoollllooww

pprrooppeerr lloocckkoouutt//ttaaggoouutt pprroocceedduurreess ttoo eennssuurree tthhee ppoowweerr ccaann nnoott bbee iinnaaddvveerrtteennttllyy eenneerrggiizzeedd.. VVeerriiffyy tthhaatt nnoo ppoowweerr iiss pprreesseenntt wwiitthh aa vvoollttmmeetteerr..

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 Electrical Code, Part I CSA Standard C22.1.

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

All electrical connections, line voltage and thermostat, are made in the Electrical Cabinet (See ). Line voltage connections are made at the High Voltage Terminal Block. Thermostat connections are made at the Main Connection Board (See Figure 7, p. 19).

RRiisskk ooff EElleeccttrrooccuuttiioonn!!

FFaaiilluurree ttoo ffoollllooww iinnssttrruuccttiioonnss bbeellooww ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy.. DDOO NNOOTT uussee aannyy ttoooollss ((ii..ee.. ssccrreewwddrriivveerr,, pplliieerrss,, eettcc..)) aaccrroossss tthhee tteerrmmiinnaallss ttoo cchheecckk ffoorr ppoowweerr.. YYoouu MMUUSSTT uussee aa vvoollttmmeetteerr..

WWAARRNNIINNGG

Locate the thermostat in accordance with the instructions supplied with the thermostat. All ﬁeld wiring 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.

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 ﬁlter section (See Figure 8, p. 20). Electrical conduit must be routed so as not to interfere with removal of any access panel.

WWAARRNNIINNGG

FFiirree HHaazzaarrdd!!

FFaaiilluurree ttoo ffoollllooww iinnssttrruuccttiioonnss bbeellooww ccoouulldd ccaauussee aa ffiirree wwhhiicchh ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy,, aanndd pprrooppeerrttyy ddaammaaggee.. DDOO NNOOTT jjuummppeerr ffaaccttoorryy wwiirriinngg!! MMiiss--wwiirriinngg ooff ssaaffeettyy cciirrccuuiittss ccoouulldd ccaauussee aa ffiirree.. FFoorr aallll wwiirriinngg ccoonnnneeccttiioonnss,, rreeffeerr ttoo tthhee wwiirriinngg ddiiaaggrraamm sshhiippppeedd wwiitthh tthhee uunniitt.. SShhoouulldd aannyy oorriiggiinnaall wwiirree ssuupppplliieedd wwiitthh tthhee uunniitt hhaavvee ttoo bbee rreeppllaacceedd,, iitt MMUUSSTT bbee rreeppllaacceedd wwiitthh wwiirriinngg mmaatteerriiaall hhaavviinngg aa tteemmppeerraattuurree rraattiinngg ooff aatt lleeaasstt 222211°°FF ((110055°°CC))..

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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

IInnssttaallllaattiioonn

Figure 6. Make-Up Air Unit-Standard Blower Cabinet, Single Duct Furnace with Various

Options Shown

Figure 7. Electrical Cabinet

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IInnssttaallllaattiioonn

Figure 8. Disconnect Box Locations

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 ﬁxed 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 blowoff. To calculate the velocity through the coil, apply the following formula:

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 inch (51 mm) is required (See Figure 9, p. 21). 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 the coil cabinet door and cut holes in door to allow chilled water 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:

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IInnssttaallllaattiioonn

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 inch (51 mm) is required (See Figure 9, p. 21). Before unit operation begins, prime P-trap with either water (summer) or glycol (winter).

Figure 9. Drain Pan Connection

Evaporative Cooler Equipped Units (Optional)

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

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Page 22

Operation

General Information

NNoottee:: Refer to Indoor Gas-Fired Duct Furnace Installation and Service Manual for speciﬁc

information regarding the heating operation of this unit.

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

• On natural gas units, the ignitor will continue to spark and pilot gas will continue to ﬂ ow until the pilot ﬂame 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 step-down transformer found in the electrical cabinet that will match the unit line voltage speciﬁed. See Figure 6, p. 19for unit controls location.

IImmppoorrttaanntt:: Do not use a thermostatic fan control switch when either two-stage ﬁring or

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 iiggnniittiioonn ccoonnttrrooll mmoodduullee is the heart of the ignition control system. This control initiates all gas ﬂow, provides means to light the pilot burner, proves and monitors the pilot burner operation.

• The ggaass vvaallvvee 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 ppiilloott bbuurrnneerr includes an ignitor and ﬂame 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 ﬂame through the ﬂame sensing probe.

modulated gas controls are used.

Sequence of Operation

All units follow the same basic sequence of operation and is as follows:

1. Thermostat calls for heat. 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 ﬂame 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 ﬂ ow to the main burners. In addition, draftor operation must be proven by draftor pressure switch 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.

6. Thermostat is satisﬁed and call for heat is removed. Draftor relay de-energizes draftor with removal of call for heat.

7. Ignition control module de-energizes pilot and main burner operators of the gas valve, ceasing all gas ﬂow.

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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 ﬁring for those units equipped with two or three duct furnaces.

• TTwwoo SSttaaggee UUnniittss:: Two stages of heating; ﬁrst stage is 50% of full rate, second stage is 100% of full rate. Main burner ignition is at ﬁrst stage only.

• TThhrreeee SSttaaggee UUnniittss::

– 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 ﬁrst and disengage last.

• FFoouurr SSttaaggee UUnniittss:: Dual duct furnace models only. Each duct furnace is equipped with two stage heating but ﬁred independently, giving four stages. Each stage is 25% of the units full input rate. Duct furnace one will always light ﬁrst and disengage last.

• SSiixx SSttaaggee UUnniittss:: Triple duct furnace models only. Each duct furnace is equipped with two stage heating but ﬁred independently giving six stages. Each stage is 16.5% of the units full input rate. Duct furnace one will always light ﬁrst and disengage last.

• EElleeccttrroonniicc MMoodduullaattiioonn UUnniittss:: These units are equipped with an electronic modulating control which provides unit ﬁring capabilities of 40 to 100% of the units full input rate. This control is found in the gas train downstream of the gas valve and allows main burner ignition only at the maximum rate. A thermostat with remote set point adjustment modulates the gas input.

• MMuullttii--SSttaaggee wwiitthh EElleeccttrroonniicc MMoodduullaattiioonn UUnniittss:: 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 ﬁre ﬁrst 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.

OOppeerraattiioonn

Table 2. Optional Gas Controls Data

Number of Stages

2 25 — 50 50

3 16.5 — 33 33

4 25 — 50 25

6 16.5 — 33 16.5

Air Handling Requirements and Adjustments

UUnniitt DDaammaaggee!!

FFaaiilluurree ttoo ffoollllooww iinnssttrruuccttiioonnss bbeellooww ccoouulldd rreessuulltt iinn uunniitt ddaammaaggee.. RReemmoovvee wwooooddeenn sshhiippppiinngg ssuuppppoorrtt ffrroomm bbeenneeaatthh bblloowweerr hhoouussiinngg ooff bblloowweerr SSeeccttiioonn..

• 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).

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Modulation Capabilities (% of full

input)

NNOOTTIICCEE

Stage Size (% of full input)

Page 24

OOppeerraattiioonn

IImmppoorrttaanntt:: It is important that the ﬁnal temperature leaving the unit does not exceed 160° F (71°

C). When ﬁnal 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.

WWAARRNNIINNGG

FFiirree HHaazzaarrdd!!

FFaaiilluurree ttoo ffoollllooww iinnssttrruuccttiioonnss bbeellooww ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy,, aanndd pprrooppeerrttyy ddaammaaggee.. AA uunniitt sshhoouulldd nneevveerr bbee aalllloowweedd ttoo ccyyccllee oonn tthhee pprriimmaarryy lliimmiitt ffoorr aa pprroolloonnggeedd ppeerriioodd ooff ttiimmee.. IItt iiss aa ssaaffeettyy ccoonnttrrooll ttoo pprreevveenntt aa ffiirree.. IIff ccyycclliinngg oonn tthhee pprriimmaarryy lliimmiitt iiss nnootteedd,, ccoorrrreeccttiivvee mmeeaassuurreess sshhoouulldd bbee ttaakkeenn iimmmmeeddiiaatteellyy..

IImmppoorrttaanntt:: At initial unit installation, unit should be started momentarily to conﬁrm proper

blower wheel rotation as the unit will deliver some air with the blower wheel running backwards.

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

• IInntteerrmmiitttteenntt FFaann OOppeerraattiioonn: 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.

• CCoonnssttaanntt FFaann OOppeerraattiioonn: 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.

IImmppoorrttaanntt:: 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 3/4" deﬂection of the belt when ﬁnger pressure is applied to the middle of the belt (See Figure 10, p. 25). 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,” p. 30 section for belt and pulley adjustments.

• These units are set at the factory for the RPM required to meet the air volume (CFM) and external static pressure ordered. If the estimated external 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 remove 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 1/2" to 3/4" belt play when depressed.

BBlloowweerr MMoottoorr FFaaiilluurree!!

FFaaiilluurree ttoo ffoollllooww iinnssttrruuccttiioonnss bbeellooww ccoouulldd rreessuulltt iinn iimmpprrooppeerr uunniitt ooppeerraattiioonn aanndd mmoottoorr ffaaiilluurree.. BBlloowweerr mmoottoorr ffuullll llooaadd aammppss sshhoouulldd nneevveerr bbee eexxcceeeeddeedd.. RReeffeerr ttoo mmoottoorr ddaattaa ppllaattee ffoorr mmaaxxiimmuumm ffuullll llooaadd aammppss..

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

NNOOTTIICCEE

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Page 25

Lighting

OOppeerraattiioonn

Figure 10. Belt Tension Guide

(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.

EExxpplloossiioonn HHaazzaarrdd!!

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:

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

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

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. Conﬁrm 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.

WWAARRNNIINNGG

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OOppeerraattiioonn

NNOOTTIICCEE

HHeeaatt EExxcchhaannggeerr DDaammaaggee!!

FFaaiilluurree ttoo ffoollllooww iinnssttrruuccttiioonnss bbeellooww ccoouulldd rreessuulltt iinn hheeaatt eexxcchhaannggeerr ddaammaaggee.. HHeeaatt ccoonntteenntt ooff ggaass vvaarriieess bbyy llooccaalliittyy;; cchheecckk tthhee ggaass iinnppuutt aafftteerr iinnssttaallllaattiioonn ooff tthhee uunniitt ttoo eennssuurree pprrooppeerr iinnppuutt.. NNeevveerr eexxcceeeedd tthhee iinnppuutt oonn tthhee rraattiinngg ppllaattee..

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.

MMeetteerr MMeetthhoodd ooff CChheecckkiinngg IInnppuutt RRaattee

1. Obtain the heating value of the gas from the local utility or gas dealer. This should be in units of Btu/ft

2. Determine the gas ﬂow rate as shown in the following 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/ft (37.3 MJ/m3).

(MJ/m3).

Gas Flow Rate =

250,000 Btu/hr

1000 Btu/ft

4.17 ft

/min

x 60 min/hr

3. Before determining the gas ﬂow rate to the unit, all other gas appliances connected to the same meter must be turned off.

4. Fire unit according to instructions.

5. After approximately 15 minutes of unit operation, determine volume of gas used in ﬁve minutes of unit operation. For the Example above the unit should use 4.17 ft

20.8 ft

(1.97 L/s x 5 min x 60 s/min = 591L) of gas. Minor input adjustments can be made by

/min x 5 minor

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 reoriﬁcing.

MMeetthhoodd ttoo CChheecckk MMaanniiffoolldd PPrreessssuurree

1. Close the manual valve of unit gas valve.

2. Install a 1/8" pipe connection in the tapped hole provided in the gas valve body near outlet of the valve.

3. Attach manometer to 1/8" pipe connection by means of a rubber hose.

4. Fire unit according to instructions and observe the pressure and conﬁrm 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

1. 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 ﬂame.

5. A proper pilot burner ﬂame is a soft steady ﬂame that envelopes 3/8 to 1/2 inch (9.5 to

12.7mm) of the ﬂame sense probe tip.

6. Replace the pilot adjustment cap.

7. Reconnect wire to terminal MV.

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Page 27

Primary Air Shutter Adjustment

After the unit has been in operation for at least 15 minutes, adjust the primary air ﬂow to the burners. Turn 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 ﬂame appear. Then open the air shutter to the point just beyond the position where yellow tipping disappears.

Controls

NNoottee:: Also see the Indoor Duct Furnace Manual

• PPrriimmaarryy LLiimmiitt CCoonnttrrooll:: 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 set point, normally caused by insufﬁcient 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 wiring 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.

• CCllooggggeedd FFiilltteerr SSwwiittcchh:: (Optional) The clogged ﬁlter switch monitors the pressure differential across the air ﬁlters. If this pressure differential becomes too great, the switch will alert of this condition. At this point the air ﬁlters must either be cleaned or replaced. The switch will reset itself.

• FFiirreessttaatt:: (Optional) Located in either the return airstream, the supply airstream, or both, this control monitors temperatures with set points which are ﬁeld adjustable. If the temperature exceeds the set point, the control will cease unit operation. To resume unit operation, a manual reset of this control is required.

• FFrreeeezzeessttaatt:: (Optional) Located in either the return airstream, the supply airstream, or both, this control monitors temperatures with set points which are ﬁeld adjustable. If the temperature does not exceed the set point, the control will cease unit operation.

OOppeerraattiioonn

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Page 28

Start-Up

Before starting the unit, use the “Gas Equipment Start Up Sheet” (located at the end of this manual) and read the Outdoor 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.

WWAARRNNIINNGG

CChheecckk ooff SSaaffeettyy DDeevviicceess RReeqquuiirreedd!!

FFaaiilluurree ttoo ddoo ffoollllooww iinnssttrruuccttiioonnss bbeellooww ccoouulldd ccaauussee uunnssaaffee ccoonnddiittiioonnss aanndd rreessuulltt iinn ddeeaatthh,, sseerriioouuss iinnjjuurryy oorr pprrooppeerrttyy ddaammaaggee.. AAllll ssaaffeettyy ccoonnttrroollss MMUUSSTT bbee cchheecckkeedd bbeeffoorree ssttaarrttiinngg tthhee uunniitt aanndd dduurriinngg rreegguullaarr mmaaiinntteennaannccee!! CChheecckk aanndd tteesstt tthhee ooppeerraattiioonnaall ffuunnccttiioonnss ooff aallll ssaaffeettyy ddeevviicceess ssuupppplliieedd wwiitthh tthhiiss uunniitt..

1. Inspect all wiring connections; connections should be clean and tight. TTrraaccee cciirrccuuiittss ttoo iinnssuurree tthhaatt aaccttuuaall wwiirriinngg aaggrreeeess wwiitthh tthhee ““aass wwiirreedd”” ddiiaaggrraammss pprroovviiddeedd wwiitthh tthhee uunniitt. 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.

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.

SSttaarrttiinngg tthhee UUnniitt iinn HHeeaattiinngg MMooddee

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

IImmppoorrttaanntt:: 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.

WWAARRNNIINNGG

LLiivvee EElleeccttrriiccaall CCoommppoonneennttss!!

FFaaiilluurree ttoo ffoollllooww aallll eelleeccttrriiccaall ssaaffeettyy pprreeccaauuttiioonnss wwhheenn eexxppoosseedd ttoo lliivvee eelleeccttrriiccaall ccoommppoonneennttss ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy.. WWhheenn iitt iiss nneecceessssaarryy ttoo wwoorrkk wwiitthh lliivvee eelleeccttrriiccaall ccoommppoonneennttss,, hhaavvee aa qquuaalliiffiieedd lliicceennsseedd eelleeccttrriicciiaann oorr ootthheerr iinnddiivviidduuaall wwhhoo hhaass bbeeeenn pprrooppeerrllyy ttrraaiinneedd iinn hhaannddlliinngg lliivvee eelleeccttrriiccaall ccoommppoonneennttss ppeerrffoorrmm tthheessee ttaasskkss..

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.

NNoottee:: With the thermostat calling for heat, unit operation is automatic.

SSttaarrttiinngg UUnniitt iinn CCoooolliinngg MMooddee

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

IImmppoorrttaanntt:: 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 cooling system switch at either COOL or AUTO;

b. Set the fan switch to AUTO.

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Page 29

SSttaarrtt--UUpp

3. Place the system switch in the ON position.

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

FFiinnaall CChheecckkoouutt

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

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

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

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.

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Maintenance

HHaazzaarrddoouuss VVoollttaaggee!!

CChheecckk ooff SSaaffeettyy DDeevviicceess RReeqquuiirreedd!!

• These units have been developed for indoor installation. Maintenance is required and it is

• Inspect area near unit to be sure that there is no combustible material located within the

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

• The (rear) high limit safety switch is accessible by removing the exterior upper jacket, then

WWAARRNNIINNGG

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.

minimum clearance requirements (See Figure 5, p. 14). 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.

assembly.

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.

Main Burner Drawer Assembly

HHaazzaarrddoouuss VVoollttaaggee aanndd GGaass!!

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.

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 valve wiring taking note of all wire locations. Disconnect ignitor and ﬂame sensing probe wires at ignition control module and any other wires.

4. Remove the locking screws holding the burner drawer assembly in position.

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

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

WWAARRNNIINNGG

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MMaaiinntteennaannccee

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 parts 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.

11. Check the burner adjustment. See the “Primary Air Shutter Adjustment,” p. 27 section of this manual.

12. Check all gas control valves and pipe connections for leaks.

WWAARRNNIINNGG

CCoommbbuussttiibbllee MMaatteerriiaallss!!

FFaaiilluurree ttoo mmaaiinnttaaiinn pprrooppeerr cclleeaarraannccee bbeettwweeeenn tthhee uunniitt aanndd ccoommbbuussttiibbllee mmaatteerriiaallss ccoouulldd ccaauussee aa ffiirree wwhhiicchh ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy oorr pprrooppeerrttyy ddaammaaggee.. RReeffeerr ttoo uunniitt nnaammeeppllaattee aanndd iinnssttaallllaattiioonn iinnssttrruuccttiioonnss ffoorr pprrooppeerr cclleeaarraanncceess..

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 ﬂames.

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

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

High Limit and/or Safety Limit Maintenance

WWAARRNNIINNGG

HHaazzaarrddoouuss VVoollttaaggee aanndd GGaass!!

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

1. Turnoff the manual gas valve and electrical power to the 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. Remove all electrical connections from the High Limit; making note of wire locations for

reconnecting.

c. Reassemble the High Limit by replacing all parts in order; making sure the High Limit is

making proper surface contact when installed.

3. To service the Safety Limit:

a. Remove Mounting Cover located on the access side of the unit toward the front (Air

Outlet) of the furnace section.

b. Remove all electrical connections from the Safety Limit; making note of wire locations for

reconnecting.

c. Reassemble the Safety Limit by replacing all parts in order; making sure the Safety Limit

is making proper surface contact with the side of the heat exchanger.

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MMaaiinntteennaannccee

4. Complete appropriate start-up procedure as given in the Start-Up section of this manual.

5. Check Burner Adjustment.

6. Check gas control valves and pipe connection for leaks.

CCoommbbuussttiibbllee MMaatteerriiaallss!!

7. Check operation of auto gas valve.

8. Check operation of safety devices.

9. Inspect and service blower section of system.

Seasonal Maintenance

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

1. Motors and belts should be inspected.

2. Tighten belts if loose.

3. Check and clean DX or Chilled Water 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).

4. Check air throughput at beginning of heating season to confirm unit operation is within the specified temperature rise range.

5. At beginning of heating season clear Condensate Drain Pan and P-trap of water if unit is equipped with DX or Chilled water coil. Clean out drain pan and ﬁll P-trap with a non-toxic glycol solution.

6. Evaporative cooler must be cleaned and maintained per manufacturer’s instruction frequently during the operating season.

7. Inspect Control Dampers during periodic maintenance. Damper pivot points should be cleaned to ensure free damper operation.

8. Blower wheels should be checked periodically for dirt build-up on blades. Clean as required.

WWAARRNNIINNGG

Filters

• The ﬁlter section has been designed to incorporate (as standard) one-inch washable ﬁlters. Other optional ﬁlter types are also available: two-inch washable throwaways; or one or two inch hi-efﬁciency 30% pleated ﬁlters.

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

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

Table 3. Standard CFM Blower Air Filter Size Requirements

Unit Input

100 MBtuh (29.3 kW)

150 MBtuh (44.0 kW)

Number of Filters Required

16 x 20 (in) 20 x 20 (in)

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Page 33

Table 3. Standard CFM Blower Air Filter Size Requirements (continued)

MMaaiinntteennaannccee

200 MBtuh (58.6 kW)

250 MBtuh (73.2 kW)

300 MBtuh (87.9 kW)

350 MBtuh (102.6 kW)

400 MBtuh (117.2 kW)

500 MBtuh (146.5 kW)

600 MBtuh (175.8 kW)

700 MBtuh (205.1 kW)

800 MBtuh (234.4 kW)

Table 4. High CFM Blower Air Filter Size Requirements

Unit Input

16 x 20 (in) 20 x 20 (in)

100 MBtuh (58.6 kW)

150 MBtuh (58.6 kW)

200 MBtuh (58.6 kW)

250 MBtuh (73.2 kW)

300 MBtuh (87.9 kW)

350 MBtuh (102.6 kW)

400 MBtuh (117.2 kW)

500 MBtuh (146.5 kW)

600 MBtuh (175.8 kW)

700 MBtuh (205.1 kW)

800 MBtuh (234.4 kW)

1,200 MBtuh (351.6kW)

4 2

Number of Filters Required

8 4

Air Blower

Belt Tension Adjustment Standard CFM Blower belt tension can be adjusted by loosening motor mounting bolts marked A (See Figure 11, p. 34). 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 ﬁrst loosening motor mounting plate bolts marked A (See Figure 11, p. 34). To tighten belt tension, turn belt tension adjustment screws marked B (See Figure 11, p. 34) counter-clockwise. To loosen belt tension, turn clockwise. Once belt tension has been adjusted, re-fasten motor mounting plate bolts.

BBlloowweerr RRPPMM AAddjjuussttmmeenntt

To adjust blower RPM:

1. Loosen and remove belt(s).

2. Match driver pulley to one found in Figure 12, p. 35.

3. Loosen setscrew(s) marked A.

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

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MMaaiinntteennaannccee

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 ﬂange projects past the hub end.

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

7. Tighten setscrew(s) marked A.

8. Replace retension belt(s).

9. Realign drive if necessary.

Figure 11. Blower Belt Tension

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Page 35

Figure 12. Blower RPM Adjustment

MMaaiinntteennaannccee

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Page 36

Troubleshooting

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

For additional troubleshooting, see following Troubleshooting Guide.

Troubleshooting Guide — Air Blower

Problem Probable

Cause

Noise

Blower Wheel Hitting Scroll Side

Blower Wheel Hitting Cutoff

Drive

Solution

1. Blower Wheel not centered in blower housing.

2. Damaged blower housing.

3. Damaged blower wheel.

4. Shaft loose in blower bearing.

5. Blower Wheel loose on shaft.

6. Blower bearing loose in bearing support.

1. Cutoff not secure in blower housing.

2. Cutoff damaged.

3. Cutoff improperly positioned.

1. Pulley not tight on shaft (motor and/or blower wheel).

2. Belts too loose. Adjust for belt stretching after 48 hours of operation.

3. Belts too tight.

4. Belts wrong cross section.

5. Belts not matched in length on multi-belt drive.

6. Variable pitch pulleys not adjusted so each pulley has same pitch diameter (multi-belt drives).

7. Misaligned pulleys.

8. Belts worn.

9. Motor or motor base loose.

10.Belts oily or dirty

11.Improper drive selection

Bearing

Shaft Seal Squeal

1. Defective bearing.

2. Needs lubrication.

3. Loose on bearing support.

4. Loose on shaft.

5. Seals misaligned.

6. Foreign material in bearing.

7. Worn bearing.

8. Fretting corrosion between inner race and shaft.

1. Needs lubrication.

2. Misaligned.

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TTrroouubblleesshhoooottiinngg

Problem Probable

Cause

Blower Wheel

Housing

Electrical

Shaft

Solution

1. Loose on shaft

2. Defective blower wheel. Do not run blower. Contact manufacturer.

3. Unbalanced.

4. Worn as a result of contact with abrasive or corrosive material.

1. Foreign material in housing.

2. Cutoff of other part loose (rattling during operation).

1. Lead-in cable not secure.

2. AC hum in motor or relay

3. Starting relay chatter.

4. Noisy motor bearings.

5. Single phasing a 3–phase motor.

1. Bent.

2. Undersized. May cause noise at blower wheel, bearings or pulley.

3. If more than two bearings are on a shaft, they must be properly aligned.

CFM Low Insufcient Air Flow

High Air Velocity

Obstruction in High Velocity Air Stream may cause Rattle

or Pure Tone Whistle

Pulsation or Surge

Rattles and/or Rumbles

Blower

1. Duct work too small for application.

2. Blower selection too small for application.

3. Registers or grilles too small for application.

4. Cooling coil with insufcient face area for application.

1. Dampers.

2. Registers.

3. Grilles.

4. Sharp elbows.

5. Sudden expansion in duct work.

6. Sudden contraction in duct work.

7. Turning vanes.

1. Blower too large for application.

2. Ducts vibrate at same frequency as blower pulsations.

1. Vibrating duct work.

2. Vibrating cabinet parts.

3. Vibrating parts not isolated from building.

1. Forward curved blower wheel installed backwards.

2. Blower operating backwards.

3. Cutoff missing or improperly installed.

4. Blower wheel RPM too low.

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TTrroouubblleesshhoooottiinngg

Problem Probable

Cause

Duct System

Filters Dirty or clogged.

Coil - DX or Chilled Water

Obstructions in High Velocity Air Stream

CFM High - Too Much Air Flow

System

Solution

1. Actual system is more restrictive than expected.

2. Dampers closed.

3. Registers closed.

4. Leaks in supply duct.

Dirty or clogged.

1. Obstruction near unit outlet.

2. Sharp elbows near unit outlet.

3. Improperly designed turning vanes.

4. Projections, dampers or other obstructions in part of duct system where air velocity is high.

1. Oversized duct work.

2. Access door open.

3. Registers or grilles not installed.

4. Filters not in place.

5. System resistance lower than anticipated.

Blower Blower RPM is too great.

Blower Does Not Operate

Installation

Unit

Troubleshooting Guide — Electric Motors

Problem Probable

Motor

Cause

Blown fuse or open circuit breaker

Overload trip Check and reset, if manual.

Improper line connections

Improper current supply

1. Incorrect electrical connection.

2. Wrong voltage.

3. Blown fuse.

1. Broken belt(s).

2. Loose pulleys.

3. Power to unit is disconnected.

4. Motor overload protector has broken circuit.

5. Optional thermostats, restats, freezestats may lockout blower operation if set

incorrect.

Solution

Replace fuse or reset circuit breaker.

Check connections to unit wiring diagram.

Check to determine that power supply agrees with motor nameplate specications.

Mechanical failure. Determine that motor and drive turn freely.

Check bearings

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TTrroouubblleesshhoooottiinngg

Problem Probable

Solution

Cause

Motor overloaded Reduce load or replace motor.

With a 3 phase power source, one

phase may be open

Defective capacitor Replace capacitor.

Motor Stalls Wrong application Consult manufacturer.

Overloaded motor Reduce load or replace motor.

Low line voltage. Check across AC line and correct if possible.

Motor runs and then dies down

Motor does not come up to speed

Motor takes too long to accelerate

Partial loss of line voltage

Motor undersized for application

Voltage too low at motor terminals

Line wiring to motor is too small

Excessive load Replace with larger motor.

Loose connection

Check line for open phase.

Check for loose connections. Determine adequacy of main power supply.

Replace with larger motor.

Check across AC line and correct if possible.

Install larger line wiring.

Check connections and tighten where necessary.

Wrong Rotation (3 Phase)

Motor Overheats Motor overloaded Replace with larger motor.

Motor Vibrates

Improperly wired to AC line (wrong sequence of phases)

Motor ventilation clogged

Motor (3 phase) may have open phase

Line voltage too high or too low

Worn blower bearings.

Motor mounting bolts loose

Driven equipment unbalanced

Worn motor bearings.

3 phase Motor running on single phase

Check unit wiring diagram. Reverse any two line voltage connections.

Clean motor.

Check to insure that all connections are tight.

Check across AC line and correct if possible.

Replace blower bearings.

Tighten mounting bolts.

Balance driven equipment.

Replace motor.

Check for open circuit and correct.

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TTrroouubblleesshhoooottiinngg

Problem Probable

Cause

Bent motor shaft Replace motor.

Rapid Motor Bearing Wear

Excessive overhung load due

to over-tensioned belt

Troubleshooting Guide — Fan Assembly

Problem Probable

Short Belt Life Spin burns from

Belts turn over in grooves

Cause

belt slippage

High ambient temperature

Grease or oil on belts

Worn pulleys Replace pulleys.

Belt Misalignment Realign drive.

Damaged belt Replace belt.

Solution

Reduce belt tension.

Solution

Tension belt.

Use Gripnotch belts.

Clean belts and pulleys.

Excessive vibration Tension belts. Replace belts if damaged.

Worn pulleys Replace pulleys.

Pulley Misalignment

Belt Squeal Excessive load High starting load. Retension drive.

Belt Breakage Foreign material in

Excessive Vibration

Belts mismatched after service

drive

Belts damaged during installation

Extreme Overload Eliminate overload.

Damaged belt cord section

Loose belts Tension drive.

Belts improperly tensioned

Belts improperly tensioned, causing more stretch of

some belts than others

Old belts and new belts used on same drive

Different brand name belts used on same drive

Realign drive.

Provide drive guard.

Replace belts.

Tension drive with slack of each belt on the same side of drive.

Replace belts and tension drive with slack of each belt on the same side of the drive.

Replace with new belts.

Replace with a set of machine-matched belts.

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TTrroouubblleesshhoooottiinngg

Problem Probable

Solution

Cause

Realign drive.

Replace belts and install properly.

Driver pulley must be disassembled, cleaned and lubricated, then reassembled.

Drive fails to adjust

Driver and driven shafts shifted from parallel

Belt cord section damaged during

installation

Fretting corrosion (drive allowed to

operate at one speed over a period of time)

Troubleshooting Guide — DX Cooling Coil

Problem Probable

Cause

No or Insufcient Cooling

Coil icing

Air binding Purge and charge system.

Thermal expansion valve**

Solution

1. Low liquid line pressure.*

2. Thermal expansion valve.**

3. Low air ow across coil.

1. Bulb mounted at incorrect location.

2. Bulb not secured properly.

Insufcient air ow

Air bypassing coil Caulk safe off.

Undersized system, demand

exceeding cooling system capacity

Too much outside air

Refrigerant leak Determine leak location and correct.

Low liquid pressure Determine cause and correct.*

Water in Conditioned Air

NNoottee:: *Refer to condensing unit installation and service manual.

**Refer to thermal expansion valve installation instruction.

Exceeding coil face velocity - 600 fpm.

Drain pan p-trap clogged.

1. See air blower troubleshooting.

2. Clogged coil

Replace system.*

Check outside air dampers.

Reduce unit air ow.

Clean pan and p-trap.

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TTrroouubblleesshhoooottiinngg

Troubleshooting Guide — Chilled Water Cooling Coil

Problem Probable

Cause

No or Insufcient Cooling

Water in Conditioned Air

Circulating pump failure.

Chilled water temperature not

cool enough.

Air binding (air in coil).

Insufcient chilled water ow.

Insufcient air ow.

Air bypassing coil. Caulk safe off.

Undersized system, demand

exceeding cooling system capacity.

Too much outside air.

Exceeding coil face velocity - 600 fpm.

Solution

Repair or replace pump.*

Check chiller.*

Bleed coil.

1. Circulating pump capacity is inadequate.*

2. System piping losses too great.

1. See air blower troubleshooting.

2. Clogged coil

Replace system.*

Check outside air dampers.

Reduce unit air ow.

Drain pan p-trap clogged.

NNoottee:: *Refer to Manufacturer’s Installation and Service Manual.

Clean pan and p-trap.

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Page 43

Dimensional Data — Arrangements

Table 5. Dimensional Data: Unit Type GG, Indoor Arrangements B, D

NNootteess::

• 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; the 4” to 5” reducer adaptor is to be ﬁeld 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 ﬂue).

• Gas Inlet sizes:

– NNaattuurraall GGaass:: Capacities 10 thru 20 = 1/2”; Capacities 25 thru 80 = 3/4”.

– LLPP GGaass:: 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 Tables 5 and 6 accordingly for all capacities.

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Page 44

DDiimmeennssiioonnaall DDaattaa —— AArrrraannggeemmeennttss

Unit Type GG, Indoor Arrangements B, Capacities 10–80

Capacities 50–80 shown

Unit Type GG, Indoor Arrangements D, Capacities 10–80

Capacities 50–80 shown

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DDiimmeennssiioonnaall DDaattaa —— AArrrraannggeemmeennttss

Table 6. Dimensional Data: Unit Type GG, Indoor Arrangements G, K

NNootteess::

• The dimensional data is tabulated for single and dual furnace capacities accordingly.

• 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; the 4” to 5” reducer adaptor is to ﬁeld 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 ﬂue).

• Gas Inlet sizes:

– NNaattuurraall GGaass:: Capacities 10 thru 20 = 1/2”; Capacities 25 thru 12 = 3/4”.

– LLPP GGaass:: Capacities 10 thru 20 = 1/2”; Capacities 25 thru 12 = 1/2” or 3/4”.

Unit Type GG, Indoor Arrangements G, Capacities 20–12

Capacities 12 shown

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DDiimmeennssiioonnaall DDaattaa —— AArrrraannggeemmeennttss

Unit Type GG, Indoor Arrangements K, Capacities 10–80

Capacities 50–80 shown

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Motor Electric Data

Table 7. Full Load Current in Amperes

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Page 48

Unit Shipping Weights

)06/1/032( - C)06/1/802( - B)06/1/511( - A

1 2 3 4 1 2 3 4 1 2 3 4

1/2 HP 3/4 HP

44 04 23 23 23 23 44 04 23 23 PH 1 75 74 84 53 84 75 74 84 53 PH 2/1-1 46 56 84 24 76 46 56 76 24 PH 2 09 27 87 27 87 27 87 PH 3

59 99 78 78 PH 5

831431831431 PH 2/1-7 10 HP 161 15 HP

)06/3/064( -F)06/3/032( - E)06/3/802( - D

1 2 3 4 1 2 3 4 1 2 3 4

1/2 HP 3/4 HP

1 HP

1-1/2 HP

2 HP 3 HP

77 67 77 67 77

PH 5

631711631711631117 PH 2/1-7 851821851821851128 PH 01 552712552712552

217

PH 51

1 2 3 4

1/2 HP 3/4 HP

1 HP

24 04 PH 2/1-1 84 64 PH 2 00166 PH 3 19 47 PH 5 341411 PH 2/1-7 351541 PH 01 843432 PH 51

Table 8. Approximate Motor Shipping Weights (lbs)

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Table 9. Cooling Coil Weight Adder (Approximate)

UUnniitt SShhiippppiinngg WWeeiigghhttss

Capacity

10, 15

20, 25, 50

30, 35, 60, 70

40, 80

Capacity

10, 15

20, 25, 50

30, 35, 60, 70

40, 80

Table 10. VFD Enclosure Weight Adder

Small Enclosure, VFD 1–5 HP

Large Enclosure, VFD 7.5–15 HP

DX COIL

4 Row 6 Row

70 lbs. 95 lbs.

95 lbs. 130 lbs.

119 lbs. 166 lbs.

130 lbs. 182 lbs.

CHILLED WATER COIL

4 Row 6 Row

170 lbs. 222 lbs.

215 lbs. 287 lbs.

264 lbs. 359 lbs.

284 lbs. 389 lbs.

95 lbs.

135 lbs.

Table 11. Indoor Arrangement “B, D, G, K” Shipping Weights (lbs.)

Capacity

B D G K

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

Arrangement

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Page 50

Coil Cabinet Dimensional Data

Figure 13. Coil Cabinet Dimensional Data

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Center of Gravity

Center of Gravity Data

NNootteess::

• Refer to the Center of Gravity diagram

• Values Based on Average Motor Weight and Average Coil Size (Arrangement K) (Actual Center of Gravity and Corner Weights For Speciﬁc Motor Size and Speciﬁc Coil are Available Upon Request)

Table 12. Center of Gravity Data - Arrangements B and D

Figure 14. Center of Gravity

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CCeenntteerr ooff GGrraavviittyy

Table 13. Center of Gravity Data - Arrangement K

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Indoor Make-Up Air Unit Number Description

G G A A 40 P D G F0 N 2 B

1 2 3 4

5, 6

Digit 1 — Gas Heating Equipment

G = Gas

Digit 2 — Unit Type

G = High Efficiency Indoor Make-Up Air

Handler

Z = High Efficiency Indoor Duct Furnace

Digit 3 — Furnace Type

A = Standard Temp Rise (30-80 F) LH B = Standard Temp Rise (30-80 F) RH S = Special Furnace Type

Note: LH= Left Hand, RH = Right Hand

Digit 4 — Development Sequence

A = First Generation

Digit 5, 6 — Input Capacity

Single Furnace

10 = 100 MBh Input 15 = 150 MBh Input 20 = 200 MBh Input 25 = 250 MBh Input 30 = 300 MBh Input 35 = 350 MBh Input 40 = 100 MBh Input

Double Furnace

50 = 500 MBh Input 60 = 600 MBh Input 70 = 700 MBh Input 80 = 800 MBh Input

Triple Furnace

12 = 1,200 MBh Input SS = Special Unit

Digit 7 — Venting Type

P = Power Venting S = Special Venting

Digit 8 — Main Power Supply

A = 115/60/1 B = 208/60/1 C = 230/60/1 D = 208/60/3 E = 230/60/3 F = 460/60/3 G = 575/60/3 S = Special Main Power Supply

7 8 9

Digit 9 — Gas Control Option

A = Single Stage B = Two Stage G = Electronic Modulating w/Room T-Stat H = Electronic Modulating w/Duct T-Stat J = Electronic Modulating w/Duct T-Stat and

Override Room Thermostat K = Electronic Modulating w/External 4-20

mA Input (Furnace 1) L = Electronic Modulating w/External 4-20

mA Input (All Furnaces) M = Electronic Modulating w/External 0-10 VDC Input (Furnace One) N = Electronic Modulating w/External 0-10

VDC Input (All Furnaces)

P = VAV Control Two-Stage R = VAV Control Three-Stage T = VAV Control Four-Stage 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

S = Special Gas Control

Digit 10, 11— Design Sequence

F0 = Design Sequence

Digit 12 — Fuel Type (GT)

N = Natural Gas P = LP Gas (Propane) L = Natural Gas w/100% Lockout S = Special Fuel Type

Digit 13 — Heat Exchanger Material

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) S = Special Heat Exchanger Package

10,-

12 13 14 15 16 17 18 19 20 21

1 0 1 A 0 +

Digit 14 — Indoor Arrangements

A = Indoor Duct Furnace B = Blower (Standard) D = Blower (Standard) Evaporative Cooler G = Blower (High CFM) K = Blower (High CFM) / Cooling S = Special Rooftop Arrangement

Digit 15 — Indoor Heating Unit Motor Selection

0 = No Motor (Duct Furnace) A = 1/2 HP w/Contactor B = 3/4 HP w/Contactor C = 1 HP w/Contactor D = 1-1/2 HP w/Contactor E = 2 HP w/Contactor F = 3 HP w/Contactor G = 5 HP w/Contactor H = 1/2 HP w/Magnetic Starter J = 3/4 HP w/Magnetic Starter K = 1 HP w/Magnetic Starter L = 1-1/2 HP w/Magnetic Starter N = 2 HP w/Magnetic Starter P = 3 HP w/Magnetic Starter Q = 5 HP w/Magnetic Starter R = 7-1/2 HP w/Magnetic Starter T = 10 HP w/Magnetic Starter U = 15 HP w/Magnetic. Starter V = 1 HP w/VFD W = 1-1/2 HP w/VFD X = 2 HP w/VFD Y = 3 HP w/VFD Z = 5 HP w/VFD 1 = 7-1/2 HP w/VFD 2 = 10 HP w/VFD 3 = 15 HP w/VFD

Digit 16 — Motor Speed

0 = No Motor (Duct Furnace) 1 = Single Speed ODP 1800 RPM 2 = Single Speed TEFC 1800 RPM 3 = Single Speed High Efficiency ODP 1800

RPM 4 = Single Speed High Efficiency TEFC 1800

RPM

Digit 17 — Coil Options (CO)

0 = No cooling Coil selection A = DX Coil, 4 Row Single Circuit B = DX Coil, 4 Row Dual Circuit C = DX Coil, 6 Row Single Circuit D = DX Coil, 6 Row Dual Circuit E = Chilled Water Coil, 4 Row G = Chilled Water Coil, 6 Row S = Special Coil

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Digit 18 — Air Inlet Configuration

0 = None (Indoor Duct Furnace) 1 = Outside Air (OA) Horizontal Inlet 2 = Outside Air (OA) w/Air Hood

(a)

3 = Return Air (RA) Bottom Inlet 4 = Outside Air and Return Air (OA/RA) 5 = Outside and Return Air w/Air Hood

(a)

S = Special Air Inlet Configuration

Digit 19 — Air Control & Damper Arrangement

0 = None A = Outside Air 2 Position Motor / Spring

Return B = Return Air 2 Position Motor / Spring

Return

C = OA/RA 2 Position / Spring Return E = OA/RA Mod. Motor w/Mixed Air Control /

Min. Pot. / SR H = OA/RA Mod. Motor w/Mixed Air Control / SR

K = OA/RA Mod. Motor w/Min. Pot. / SR M = OA/RA Mod. Motor w/Dry Bulb / Mixed

Air Control / Min. Pot. /SR N = OA/RA Mod. Motor w/Enthalpy Controlled

Economizer / SR P = OA/RA Mod. Motor w/Pressure Control (Space Pressure) Q = OA/RA Mod. Motor w/ Carbon Dioxide

) R/A Monitor

(CO

R = OA/RA Mod. Motor w/S-350-P Proportional Mixed Air Control / SR

U = OA/RA Mtr. w/External 0-10 VDC and 420 mA Analog Input/SR (External Input) W = ASHRAE Cycle I (OA/RA 2 Pos. w/Warmup Stat/SR) X = ASHRAE Cycle II (OA/RA Mod. w/Warmup Stat / Mixed Air / Min. Pot. / SR) Y = ASHRAE Cycle III (OA/RA Mod. w/Warmup Stat / Mixed Air / SR)

Z = Manual Dampers S = Special Air Control and Damper

Arrangement

(a) Hood shipped separately

Digit 20

0 = Non-California Shipment 1 = California Shipment

Digit 21 — Miscellaneous Options

A = Orifices for Elevation Above 2000 Feet

(Specify Elevation)

B = 12” Evaporative Media (Celdek) C = Moisture Eliminator D = Horizontal Return E = Air Flow Proving Switch F = Freezestat w/Time Delay G = Fan Time Delay (Indoor Duct Furnace) H = Return Firestat J = Supply Air Firestat K = Manual Blower Switch L = 409 Stainless Steel Furnace Drip Pan M = Input Derate N = Double Wall Construction P = Low Leak Dampers Q = Clogged Filter Switch R = High/Low Gas Pressure Limit Switches T = Status Indicator Lamps (Elec Cabinet) V = Manual Reset High Limit Switch W = 8" Evaporative Media (Glasdek) X = 12" Evaporative Media (Glasdek) Y = Ambient Lockout Z = Freezestat for Evaporative Cooler 0 = No Filters 1 = 1” Washable (Standard) Filters 2 = 2" Washable Filters 3 = 2" Throwaway Filters 4 = 1" 30% Pleated Filters 5 = 2" 30% Pleated Filters

Digit 22 — VFD Accessories

1 = Field Installed VFD 2 = Factory Installed VFD 3 = VFD Remote Keypad (Field Installed)

Sensor, 100% Outside Air

4 = CO

Sensor, Mixed Air

5 = CO

6 = Pressure Sensor 7 = 2-Speed VFD Relays 8 = 3-Speed VFD Relays 9 = VFD Enclosure (Only with Factory

Installed VFD)

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Indoor Make-Up Air Products

Figure 15. Indoor Make-Up Air Arrangements

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Legend

B/F/D

B Hi CFM Blower Module

F/D

NNootteess::

• Air Inlet Configurations may vary (Digit #18)

• Refer to complete Model Number Designation for more details.

Indoor Arrangement (Digit #14)

Capacity (Digits #5 and #6)

Standard Blower/Filter/Damper Module

Hi CFM Filter/Damper Module

Cooling Coil Module

Evap. Cooler Module

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Gas Equipment Start-Up

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NNootteess

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NNootteess

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Ingersoll Rand (NYSE: IR) advances the quality of life by creating comfortable, sustainable and efficient environments. Our people and our family of brands — including Club Car

— work together to enhance the quality and comfort of air in homes and buildings; transport and protect

Trane food and perishables; and increase industrial productivity and efficiency. We are a global business committed to a world of sustainable progress and enduring results.

Ingersoll Rand has a policy of continuous product and product data improvements and reserves the right to change design and specifications without notice. We are committed to using environmentally conscious print practices.

MUA-SVX005B-EN 31 May 2017

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