Modine DBS, DCS gas-fired duct furnace Installation and service manual
The DBS/DCS gas-fired duct furnaces are designed to provide heating for commercial and industrial applications. They are available in a variety of sizes to meet your specific heating needs. The unit is equipped with a built-in blower, which circulates heated air throughout your space. The DBS/DCS gas-fired duct furnaces are easy to install and operate, and are backed by a comprehensive warranty.
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5-594.6
5H76856a1
September, 2010
installation and service manual gas-fired indoor separated combustion duct furnaces/make-up air units models dBs/dcs
9900100
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death, and could cause exposure to substances which have been determined by various state agencies to cause cancer, birth defects or other reproductive harm. Read the installation, operating and maintenance instructions thoroughly before installing or servicing this equipment.
CAUTION
To prevent premature heat exchanger failure do not locate ANY gas-fired units in areas where chlorinated, halogenated, or acid vapors are present in the atmosphere.
FOR YOUR SAFETY
if you smell gas:
1. open windows.
2. don’t touch electrical switches.
3. extinguish any open flame.
4. immediately call your gas supplier.
FOR YOUR SAFETY
The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous.
IMPORTANT
The use of this manual is specifically intended for a qualified installation and service agency.
A qualified installation and service agency must perform all installation and service of these appliances.
inspection on arrival
1. Inspect unit upon arrival. In case of damage, report it immediately to transportation company and your local factory sales representative.
2. Check rating plate on unit to verify that power supply meets available electric power at the point of installation.
3. Inspect unit upon arrival for conformance with description of product ordered (including specifications where applicable).
THIS MANUAL IS THE PROPERTY OF THE OWNER.
PLEASE BE SURE TO LEAVE IT WITH THE OWNER WHEN YOU LEAVE THE JOB.
special precautions / taBle of contents
special precautions
THE INSTALLATION AND MAINTENANCE INSTRUCTIONS
IN THIS MANUAL MUST BE FOLLOWED TO PROVIDE
SAFE, EFFICIENT AND TROUBLE-FREE OPERATION.
IN ADDITION, PARTICULAR CARE MUST BE EXERCISED
REGARDING THE SPECIAL PRECAUTIONS LISTED BELOW.
FAILURE TO PROPERLY ADDRESS THESE CRITICAL
AREAS COULD RESULT IN PROPERTY DAMAGE OR LOSS,
PERSONAL INJURY, OR DEATH. THESE INSTRUCTIONS
ARE SUBJECT TO ANY MORE RESTRICTIVE LOCAL OR
NATIONAL CODES.
CAUTION
1. The concentric vent adapter box must be installed inside of the structure or building. Do not install this box on the exterior of a building or structure.
2. Purging of air from gas lines should be performed as described in ANSI Z223.1 - latest edition “National Fuel
Gas Code”, or in Canada in CAN/CGA-B149 codes.
3. Ensure that the supply voltage to the appliance, as indicated on the serial plate, is not less than the rated voltage.
4. Do not attempt to reuse ignition controllers which have been wet. Replace defective controller.
2
HaZard intensity levels
1.
danger: Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.
2.
Warning: Indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.
3.
caution: Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury.
4.
important: Indicates a situation which, if not avoided,
MAY result in a potential safety concern.
dANGER
Appliances must not be installed where they may be exposed to a potentially explosive or flammable atmosphere.
WARNING
1. Gas fired heating equipment must be vented - do not operate unvented.
2. A built-in power exhauster is provided - additional external power exhausters are not required or permitted.
3. All field gas piping must be pressure/leak tested prior to operation. Never use an open flame. Use a soap solution or equivalent for testing.
4. Gas pressure to appliance controls must never exceed 14"
W.C. (1/2 psi).
5. Disconnect power supply before making wiring connections to prevent electrical shock and equipment damage.
6. All appliances must be wired strictly in accordance with wiring diagram furnished with the appliance. Any wiring different from the wiring diagram could result in a hazard to persons and property.
7. Any original factory wiring that requires replacement must be replaced with wiring material having a temperature rating of at least 105°C.
8. To reduce the opportunity for condensation, the minimum sea level input to the appliance, as indicated on the serial plate, must not be less than 5% below the rated input, or
5% below the minimum rated input of dual rated units.
9. Ensure that the supply voltage to the appliance, as indicated on the serial plate, is not 5% greater than the rated voltage.
10. When servicing or repairing this equipment, use only
Modine-approved service replacement parts. A complete replacement parts list may be obtained by contacting Modine
Manufacturing Company. Refer to the rating plate on the appliance for complete appliance model number, serial number, and company address. Any substitution of parts or controls not approved by Modine will be at the owners risk.
IMPORTANT
1. To prevent premature heat exchanger failure, do not locate
ANY gas-fired appliances in areas where corrosive vapors
(i.e. chlorinated, halogenated or acid) are present in the atmosphere.
2. To prevent premature heat exchanger failure, the input to
the appliance, as indicated on the serial plate, must not
exceed the rated input by more than 5%.
3. To prevent premature heat exchanger failure, observe heat exchanger tubes by looking at the heat exchanger through the field installed access openings in connecting ductwork in cooling package units or the unit access doors in blower package units. If the bottom of the tubes become red while blower and duct furnace are in operation, check to be sure the blower has been set to the proper rpm for the application. Refer to page 18 for Blower Adjustments.
4. Start-up and adjustment procedures should be performed by a qualified service agency.
5. To check most of the Possible Remedies in the troubleshooting guide listed in Tables 54.1 and 55.1, refer to the applicable sections of the manual.
table of contents
Inspection on Arrival . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SI (Metric) Conversion Factors. . . . . . . . . . . . . . . . . . . . . . . . . 3
Unit Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Combustible Material and Service Clearances . . . . . . . . . 3
Unit Lifting and Unit Mounting . . . . . . . . . . . . . . . . . . . . . . . . . 4
Duct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Unit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Gas Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cooling Coil Specifications and Installation. . . . . . . . . . . 13
Start-Up Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pilot Burner and Main Burner Adjustment . . . . . . . . . . . . 16
Blower Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lubrication Recommendations . . . . . . . . . . . . . . . . . . . . 18
Damper Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . 19
Control Operating Sequence. . . . . . . . . . . . . . . . . . . . . . 19
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
General Performance Data. . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Unit Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Blower Sheave Assembly Data . . . . . . . . . . . . . . . . . . . . . . . 38
Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Motor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Dimensions Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Service & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Model Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Start-Up Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Model Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Commercial Warranty. . . . . . . . . . . . . . . . . . . . . . . . Back Page
5-594.6
si (metric) conversion factors / unit location
si (metric) conversion factors table 3.1
to convert multiply By to obtain
"W.C. 0.24 kPa psig
°F
6.893
(°F-32) x 0.555 kPa
°C
inches feet
CFM
25.4
0.305
0.028 mm meters m3/min
to convert multiply By to obtain
CFH 1.699 m
3
/min
Btu/ft
3
pound
0.0374
0.453 mJ/m kg
3
Btu/hr
gallons psig
0.000293
3.785
27.7 kW/hr liters
"W.C.
10. All mechanical equipment generates some sound and vibration that may require attenuation. Libraries, private offices and hospital facilities will require more attenuation, and in such cases, an acoustical consultant may be retained to assist in the application. Locating the equipment away from the critical area is desirable within ducting limitations.
Generally, a unit should be located within 15 feet of a primary support beam. Smaller deflections mean lesser vibration and noise transmission.
figure 3.1 - combustible material clearances
model size access side (a)
75 thru 175
200 thru 960
1"
2"
unit location
dANGER
Appliances must not be installed where they may be exposed to a potentially explosive or flammable atmosphere.
IMPORTANT
To prevent premature heat exchanger failure, do not locate
ANY gas-fired appliances in areas where corrosive vapors (i.e. chlorinated, halogenated or acid) are present in the atmosphere.
TOP = 3"
1
NON-ACCESS
SIDE = 0"
location recommendations
1. When locating the furnace, consider general space and heating requirements, availability of gas and electrical supply, and proximity to vent locations.
2. Unit must be installed on the positive pressure side of the circulating blower.
3. Be sure the structural support at the unit location site is adequate to support the weight of the unit. For proper operation the unit must be installed in a level horizontal position.
4. Do not install units in locations where the flue products can be drawn into the adjacent building openings such as windows, fresh air intakes, etc.
5. Be sure that the minimum clearances to combustible materials and recommended service clearances are maintained. Units are designed for installation on noncombustible surfaces with the minimum clearances shown in Figure 3.1 and Table 3.2.
6. Units installed downstream of refrigeration systems, or exposed to inlet air temperatures of 40°F or less, may experience condensation, therefore, provisions should be made for disposal of condensate. Means have been provided in the bottom pan of the unit to accommodate a condensate drain line connection flange.
7. When locating units, it is important to consider that the combustion air and exhaust vent piping must be connected to the outside atmosphere. The maximum equivalent lengths are listed in Table 6.1 on page 6.
8. In garages or other sections of aircraft hangars such as offices and shops which communicate with areas used for servicing or storage, keep the bottom of the unit at least 7" above the floor. In public garages, the unit must be installed in accordance with the Standard for Parking
Structures NFPA #88A and the Standard for Repair Garages
NFPA#88B. In Canada, installation of unit heaters in airplane hangars must be in accordance with the requirements of the enforcing authority, and in public garages in accordance with the current CAN/CGA-B149 codes.
9. Do not install units in locations where gas ignition system is exposed to water spray, rain, or dripping water.
ACCESS
SIDE
A
BOTTOM = 1"
➀
A 3'' minimum clearance to combustible material is required from the vent collar.
table 3.2 - recommended service clearances
model size access side non-access side top
75
100/125
150/175
200/225
250/300
350/400
500/600
700/800
840/960
18"
20"
25"
27"
30"
41"
30"
41"
41"
6"
6"
6"
6"
6"
6"
6"
6"
6"
10"
10"
10"
10"
10"
10"
10"
10"
10"
5-594.6
3
unit lifting / unit mounting
unit lifting
All standard blower system units are shipped fully crated with skid supports below the unit. The unit may be lifted from the bottom by means of a fork lift or other lifting device only if the shipping support skids are left in place. DO NOT attempt to lift the unit from the bottom unless the shipping skid supports are still in place. When lifting units, make sure the load is balanced.
All extended cabinet systems are shipped without a crate and cannot be lifted with a fork truck. Use a crane or other overhead lifting device in conjunction with the lifting holes (refer to page
50 for base rail lifting hole locations) for safe unit relocation. If the unit must be lifted from the bottom for final installation of the unit be sure to properly support the unit over its entire length to prevent damage.
unit mounting
Be sure the method of unit support (suspension or floor mounting) is adequate to support the weight of the unit (see
Weights for base unit and factory installed option weights). For proper operation, the unit must be installed in a level horizontal position. Combustible material and service clearances as specified in Figure 3.1 and Tables 3.2 and 3.3 must be strictly maintained. To assure that flames are directed into the center of the heat exchanger tubes, the unit must be level in a horizontal position. Use a spirit level to ensure that the unit is suspended or floor mounted correctly.
unit suspension
Four 3/4" diameter suspension hanging locations are provided in the base rail assembly of the unit. Refer to Figure 50.1 for
Suspension Hanging Locations and Figure 4.1 demonstrates how the unit should be suspended and fastened to the unit base rail. If required, vibration isolators may be added.
figure 4.1 - unit suspension method
BLOWER
SECTION
DOOR
5/8" SUSPENSION RODS
(BY OTHERS)
floor mounted units
For floor installations, the floor structure must be adequately designed to support the live weight load of the unit and any other required support structure. Additional reinforcement should be provided, if necessary. The floor should include threaded
5/8-inch anchor bolts spaced according to Figure 4.2 and Table
4.1, for securing the unit in place. Anchor bolts should extend at least 1-1/2" above the surface of the floor to allow clearance for mounting washers, nuts and bolts (mounting washers, nuts, and bolts by others).
figure 4.2 - floor mounted units
A
B
C
5/8 Dia. (4)
table 4.1 - floor mounted unit anchor Bolt dimensions (inches)
model Blower type dBs units dcs units all units dBs units
size (digit 16) (a) (a) (B) (c)
75
100/25
All
All
86.27
86.37
110.25
110.25
33.85
36.36
-
-
150/175
200/225
All
All
86.37
86.37
250/300 E,F,G, or H 86.27
250/300 I,J, or K 112.12
110.25
110.25
110.25
146.10
40.61
42.71
45.75
45.75
-
-
-
-
350/400 E,F,G or H 86.27
350/400 I,J, or K 122.2
500/600 G or H
500/600 I,J, or K
127.39
163.25
700/800 G or H 127.39
700/800 I,J,K, or L 163.25
840/960 I,J,K, or L 204.39
110.25
146.10
-
-
-
-
-
57.27
57.27
45.75
45.75
57.27
57.27
57.27
-
-
41.37
41.37
41.37
41.37
82.50
HEATER
SERVICE
DOOR
ELECTRICAL
SECTION DOOR
(1) 3/4" NUT &
LOCKWASHER
(2) 3/4" NUTS &
LOCKWASHER
4
5-594.6
duct installation / utility connections / unit installation
duct connection to unit
1. The furnace discharge (units with Model Digit 2=B) is designed to accept straight ductwork (see Figure 5.1.).
The blower section end and bottom openings (all units) and cooling cabinet section discharge (units with Model Digit 2=C) are designed to accept 90° flanged ductwork (see Figure 5.2).
Provide an airtight seal between the ductwork and the furnace. Seams with cracks in the ductwork should be caulked and/or taped and be of permanent type. All duct connections MUST be airtight to prevent air leakage.
2. Provide uniform air distribution over the heat exchanger.
Use turning vanes where required to obtain uniform air distribution. (See Figure 5.3).
3. Provide removable access panels on the downstream side of the ductwork. (See Figure 5.1.) This opening should be large enough to view smoke or reflect light inside the casing to indicate leaks in the heat exchanger and to check for hot spots on heat exchangers due to poor air distribution or lack of sufficient air (CFM).
figure 5.3 - recommended field installed discharge duct configurations for Blower package units
Dimension "B" should never be less than 1/2 of dimension "A".
3" Min.
Turning
Vanes
3" Max.
Provide leak tight access panels in discharge duct for heat exchanger inspection.
Air
Flow
12" Min.
A
SIDE VIEW
B
Dimension "B" should never be less than 1/2 of dimension "A".
3" Min.
Turning
Vanes
3" Max.
Provide leak tight access panels in discharge duct for heat exchanger inspection.
figure 5.1 - furnace discharge duct connection
STRAIGHT
DUCTWORK
figure 5.2 - Blower section inlet and cooling coil section discharge duct connections
1/2"
DUCT FURNACE
DUCTWORK
90°
FLANGED
DUCTWORK
E
DUCT FURNAC
DUCTWORK
ACCESS
PANEL
A
Air
Flow
TOP VIEW
12" Min.
B
utility connections
Utility and control connections can be made to the unit from the bottom or through the fixed side panels for floor mounted units.
Holes can be made in fixed side panels to accommodate utility connections for any model or as specified according to the unit dimensional drawings. Seating of holes cut in the unit casing for utility connections should be done with care to prevent air leaks.
unit installation
Follow site preparation instructions for Unit Mounting for applicable unit suspension or floor mounted units before installation. Check Model Identification Plate of unit with plans to be sure unit is properly located (See page 57). Also, inspect damper motors and dampers for proper type (e.g., two-position, modulating, fresh air only, fresh and return air, etc.). Although units may look outwardly similar, their function, capacities, options, and accessories will often vary. Check dimensions.
Orient unit to its ductwork and suspend or floor mount unit.
For proper operations, the unit must be installed in a level horizontal position.
Refer to the applicable sections to make Venting, Gas Connections, Electrical Connections, and Cooling Coil Connections.
Make final unit connections to the electric power supply and remote control circuits. Connect the gas lines to the unit heating compartment in accordance with the submittal drawings and architect plans. Caulk all utility line clearance holes on the unit after connections are completed.
5-594.6
5
6 installation - venting
W ARNING
1. Gas fired heating equipment must be vented - do not operate unvented.
2. A built-in power exhauster is provided - additional external power exhausters are not required or permitted.
3. If you are replacing an existing heater, it may be necessary to resize the venting systems. Improperly sized venting systems can result in vent gas leakage or the formation of condensate. Refer to the National Fuel Gas
Code ANSI Z223.1 or CSA B149.1 latest edition. Failure to follow these instructions can result in serious injury or death.
4. Under no circumstances should two sections of double wall vent pipe be joined together within one horizontal vent system due to the inability to verify complete seal of inner pipes.
CAUTION
Installation must conform with local building codes or in the absence of local codes, with Part 7, Venting of Equipment, of the National Fuel Gas Code, ANSI Z223.1 (NFPA 54) - latest edition. In Canada installation must be in accordance with
CSA B149.1.
Model DFS duct furnaces must be vented with the proper passageway as described in these instructions to convey flue gases from the unit or the vent connector to the outside atmosphere. The heaters must also have a separate combustion air intake pipe to bring in fresh air for combustion from the outside atmosphere.
The venting instructions are organized in sections, based on installation type. The sections are identified as follows:
section
A
B
C
D
installation instructions by vent system type
General Instructions for all installations
vertical 2-pipe vent systems
HoriZontal 2-pipe vent systems
HoriZontal and vertical concentric vent systems
The differences between Vertical and Horizontal vent systems in 2-Pipe or
Concentric Vent configurations will be identified in “Section A - General
Instructions – All Units”.
section a - general instructions - all units
A1. If the heater being installed is replacing existing equipment and using the existing vent system from that equipment, inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code ANSI
Z223.1 or CSA B149.1 Installation Code-latest edition and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies, which could cause an unsafe condition.
A2. The combustion air and vent pipes should be galvanized steel or other suitable corrosion resistant material. Follow the National Fuel Gas Code for minimum thickness of vent material. The minimum thickness for connectors varies depending on the pipe diameter. Do not vent unit with PVC or other forms of plastic venting material.
A3. All heaters come with factory installed vent and combustion air adapters for attaching the pipe to the heater. The pipe diameters are 4" for model sizes 75-175 and 6" for model sizes 200-400. All units are classified as Category III vented appliances, which defined by ANSI is positive pressure, non-condensing, and requires the vent system to be gastight. Attach the vent pipe to the adapter with 3 corrosion resistant screws. (Drill pilot holes through the vent pipe and adapter prior to screwing in place). Vent pipe must not be smaller than the connector size.
A4. Limit the total equivalent vent pipe length to a minimum of
5' and a maximum as shown in Table 6.1, making the vent system as straight as possible. Total equivalent vent pipe length must include elbows. The equivalent length of a 4" elbow is 5' and for a 6" elbow is 7'.
table 6.1 - individual total equivalent lengths for combustion air and exhaust vent pipes
minimum (ft) maximum (ft) model size
75
100, 125, 150, 175
200, 225
250, 300
350, 400
5
5
5
5
5
48
55
70
63
70
A5. A minimum of 12" straight pipe is recommended from the flue outlet before turns in the vent pipe.
A6. Horizontal sections of vent and combustion air pipes are to be installed with a minimum downward slope from the appliance of 1/4 inch per foot and suspended securely from overhead structures at points not greater than 3' apart.
A7. Fasten individual lengths of vent together with at least three corrosion resistant sheet metal screws.
A8. Keep single wall vent pipe at least 6" from combustible materials. For double wall vent pipe, follow the vent pipe manufacturer’s clearances to combustibles. The minimum distance from combustible materials is based on the combustible material surface not exceeding 160°F.
Clearance from the vent pipe (or the top of the unit) may be required to be greater than 6" if heat damage other than fire could result (such as material distortion or discoloration).
A9. Avoid venting through unheated space when possible.
When venting does pass through an unheated space or if the unit is installed in an environment that promotes condensation, insulate runs greater than 5' to minimize condensation. Inspect for leakage prior to insulating and use insulation that is noncombustible with a rating of not less than 400°F. Install a tee fitting at the low point of the vent system and provide a drip leg with a clean out cap as shown in Figure 8.1.
A10. When the vent passes through a combustible INTERIOR wall or floor, a metal thimble 4" greater than the vent diameter is necessary. If there is 6' or more of vent pipe in the open space between the appliance and where the vent pipe passes through the wall or floor, the thimble need only be 2" greater than the diameter of the vent pipe. If a thimble is not used, all combustible material must be cut away to provide 6" of clearance. Where authorities have jurisdiction type B vent may be used for the last section of vent pipe to maintain clearance to combustibles while passing through wall or floor. See Figure 7.1. Any material used to close the opening must be noncombustible.
5-594.6
installation - venting
figure 7.1 - venting through combustible roof or Wall
LISTED
THIMBLE
SPECIFIED
CAP
TYPE B VENT
MANUFACTURER
SPECIFIED
CAP
LISTED
THIMBLE
See Instruction A12 for attaching single wall pipe to double wall pipe
A11. All seams and joints of the single wall pipe must be sealed with metallic tape or silastic suitable for temperatures up to
400°F. Wrap the tape two full turns around the vent pipe.
One continuous section of double wall vent pipe may be used within the vent system. Refer to instruction A12 in
“Section A – General Instructions – All Units” for attaching double wall pipe to single wall pipe.
A12. The following are General Instructions for Double Wall
(Type B) Terminal Pipe Installation:
How to attach a single wall vent terminal to double wall (type B) vent pipe:
1. Look for the “flow” arrow on the vent pipe.
2. Slide the vent terminal inside the exhaust end of the double wall vent pipe.
3. Drill (3) holes through the pipe and the vent terminal.
Using 3/4" long sheet metal screws, attach the cap to the pipe. Do not over tighten.
How to connect a single wall vent system to a double wall (type B) vent pipe:
1. Slide the single wall pipe inside the inner wall of the double wall pipe.
2. Drill (3) holes through both walls of the single and double wall vent pipes. Using 3/4" sheet metal screws, attach the two pieces of pipe. Do not over tighten.
3. The gap between the single and double wall pipe must be sealed but it is not necessary to fill the full volume of the annular area. To seal, run a large bead of 400°F silastic around the gap.
A13 Do NOT vent this appliance into a masonry chimney.
A14. Do NOT use dampers or other devices in the vent or combustion air pipes.
A15. The venting system must be exclusive to a single appliance, and no other appliance is allowed to be vented into it.
A16. Precautions must be taken to prevent degradation of building materials by flue products.
A17. Single wall vent pipe must not pass through any unoccupied attic, inside wall, concealed space, or floor.
A18. Uninsulated single wall vent pipe must not be used outdoors for venting appliances in regions where the 99% winter design temperature is below 32°F.
A19. Long runs of horizontal or vertical combustion air pipes may require insulation in very cold climates to prevent the buildup of condensation on the outside of the pipe where the pipe passes through conditioned spaces.
5-594.6
A20. Vent termination clearances must be maintained:
table 7.1 - vent termination clearances
structure minimum clearances for vent terminal location
Forced air inlet within 10 feet
Combustion air inlet of another appliance
Door, window, gravity air inlet, or any building opening
3 feet above
6 feet all directions
4 feet horizontal and below
1 foot above
Electric meter, gas meter, gas 4 feet horizontal (U.S.) regulator, and relief equipment ➀ 6 feet horizontal (Canada)
Gas regulator
➀
3 feet horizontal (U.S.)
6 feet horizontal (Canada)
Adjoining building or parapet wall
Adjacent public walkways
Grade (ground level)
6 feet all directions
7 feet all directions
3 feet above ➁
➀ Do not terminate the vent directly above a gas meter or regulator.
➁ The vent must be at least 6" higher than anticipated snow depth.
A21. Vertical combustion air pipes should be fitted with a tee with a drip leg and a clean out cap to prevent against the possibility of any moisture in the combustion air pipe from entering the unit. The drip leg should be inspected and cleaned out periodically during the heating season.
A22. In addition to following these General Instructions, specific instructions for Vertical and Horizontal vent systems in 2-Pipe or Concentric Vent configurations must also be followed. The following outlines the differences:
vertical vent system determination
• Vertical vent systems terminate vertically (up) (an example is shown in Figure 8.1).
• Determine the venting configuration as follows:
> For two building penetrations through the wall or roof (one for the combustion air inlet pipe and one for the vent pipe), proceed to “Section B -
Vertical 2-Pipe Venting”.
> For a single larger building penetration through the wall or roof, through which both the combustion air inlet and vent pipes will pass, proceed to “Section D - Horizontal and Vertical
Concentric Venting”.
> For all other cases, proceed to the next section for Horizontal Vent System Determination.
Horizontal vent system determination
• Horizontal vent systems terminate horizontally
(sideways) (an example is shown in Figure 9.1).
• Determine the venting configuration as follows:
> For two building penetrations through the wall or roof (one for the combustion air inlet pipe and one for the vent pipe), proceed to “Section C -
Horizontal 2-Pipe Venting”.
> For a single larger building penetration through the wall or roof, through which both the combustion air inlet and vent pipes will pass, proceed to “Section D - Horizontal and Vertical
Concentric Venting”.
7
installation - venting
section B - vertical 2-pipe vent system installation
B1. This section applies to vertically vented 2-pipe (one combustion air inlet pipe and one vent pipe) vent systems and is in addition to “Section A - General Instructions - All
Units”.
B2. Vertical vent systems terminate vertically (up).
B3. It is recommended to install a tee with drip leg and clean out cap as shown in Figures 8.1 or 8.2.
B4. The combustion air and vent pipes must be terminated with
(2) Gary Steel Model 1092 caps.
B5. Vertical vents must terminate a minimum horizontal and vertical distance from roof lines and adjacent walls or obstructions. These minimum distances are outlined in
Figure 8.1 and Table 8.1 or Figure 8.2.
B6. The vent must terminate at least 1 foot above and 16 inches horizontally from the combustion air inlet.
B7. Once venting is complete, proceed section titled “Installation
- Gas Connections”.
figure 8.1 - vertical venting - 2 pipes sloped roof
16" MIN.
LISTED VENT
TERMINAL
LISTED AIR
INLET TERMINAL
table 8.1 - minimum Height from roof to lowest discharge opening
rise X (in)
0-6
6-7
7-8
8-9
9-10
10-11
11-12
12-14
14-16
16-18
18-20
20-21
roof pitch
Flat to 6/12
6/12 to 7/12
7/12 to 8/12
8/12 to 9/12
9/12 to 10/12
10/12 to 11/12
11/12 to 12/12
12/12 to 14/12
14/12 to 16/12
16/12 to 18/12
18/12 to 20/12
20/12 to 21/12
Size according to expected snow depth.
min Height H (ft)
1.00
1.25
1.50
2.00
2.50
3.25
4.00
5.00
6.00
7.00
7.50
8.00
figure 8.2 - vertical venting - 2 pipes flat roof
LISTED VENT
TERMINAL
24" MIN.
TO WALL OR
ADJOINING BUILIDING
16" MIN.
"H" MIN. *
X"
12"
ROOF PITCH = X/12
USE LISTED THIMBLE
THROUGH CEILING
AND ROOF
SEE TABLE 8.1
FOR "H"
DIMENSION
"H" MIN. *
ROOF
FLASHING
* SIZE TO EXPECTED
SNOW DEPTH.
12" MIN.
12" MIN. *
* SIZE TO EXPECTED
SNOW DEPTH.
LISTED AIR
INLET TERMINAL
ROOF FLASING
USE LISTED THIMBLE
THROUGH ROOF
8
12" MIN.
RECOMMENDED
TEE WITH DRIP LEG
AND CLEANOUT CAP
TEE WITH DRIP LEG
AND CLEANOUT CAP
section c - Horizontal 2-pipe vent system installation
C1. This section applies to horizontally vented 2-pipe vent systems (one combustion air inlet pipe and one vent pipe) and is in addition to “Section A - General Instructions - All
Units”.
C2. Horizontal vent systems terminate horizontally (sideways).
C3. All horizontal vents must be terminated with a Gary Steel
1092 vent cap. The cap must terminate a minimum distance from the external wall, as summarized in
Figure 9.1.
C4. The termination of horizontally vented system must extend
12 inches beyond the exterior surface of an exterior wall.
C5. The combustion air pipe must be a minimum of 16 inches below the vent pipe, and 24 inches from the exterior wall.
C6. Construct the vent system as shown in Figure 9.1.
5-594.6
installation - venting
figure 9.1 - Horizontal 2-pipe venting
24'' MIN.
TERMINAL
ADJACENT
BUILDING
MUST USE THIMBLE
THROUGH WALL
12''
SUPPORT BRACKET
(See Fig. 9.2 for detail)
EXHAUST
TERMINAL
16'' MIN.
24'' MIN.
COMBUSTION AIR
PITCH COMBUSTION AIR
PIPE DOWNWARD FROM
APPLIANCE 1/4" PER FOOT
SUPPORT BRACKET
(See Fig. 9.2 for detail)
TEE WITH DRIP
LEG AND
CLEANOUT CAP
AT LOW POINT
OF VENT SYSTEM
PITCH VENT PIPE DOWNWARD
FROM APPLIANCE 1/4" PER FOOT
C7. When horizontal vents pass through a combustible wall (up to 8 inches thick), the vent passage must be constructed and insulated as shown in Figure 9.2.
C8. The vent must be supported as shown in Figure 9.2.
C9. When condensation may be a problem, the vent system shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief openings, or other equipment.
figure 9.2 - exhaust vent construction through combustible Walls and support Bracket
FIBER GLASS
INSULATION
MIN. 2"
2" MIN.
METAL
SLEEVE
VENT PIPE
DIAMETER
METAL FACE
PLATE
1"
2" MIN.
METAL
SLEEVE
1"
45
°
9"
9"
VENT TERMINATION
SUPPORT BRACKET
(where required)
(Make from 1" x 1" steel angle)
for vertically vented units (refer to figure 9.3):
Concentric adapter assembly (same for horizontal and vertical kits)
Standard Gary Steel 1092 vent termination
Specially designed inlet terminal (part #5H75154)
figure 9.3 - vertical concentric vent Kit components
Combustion Air
Inlet Terminal
Concentric
Vent Adapter
Box
Combustion Air
6" Min.
Outlet Vent
Termination Cap
12" Min.*
* Size according to expected snow depth.
Exhaust
Building
Roof / Ceiling
for Horizontally vented units (refer to figure 9.4):
Concentric adapter assembly (same for horizontal and vertical kits)
Special vent termination cap (part #5H75150)
Special inlet air guard
figure 9.4 - Horizontal concentric vent Kit components
Concentric
Vent Adapter
Box
14" Min.
1" Min.
Outlet Vent
Termination Cap
C10. Maintain a 1/4" per foot downward slope away from the heater and place a drip leg with clean out near the exit of the vent as shown in Figure 9.1, or allow the condensate to drip out the end.
C11. For a vent termination located under an eave, the distance of the overhang must not exceed 24". The clearance to combustibles above the exterior vent must be maintained at a minimum of 12". Consult the National
Fuel Gas Code for additional requirements for eaves that have ventilation openings.
C12. Once venting is complete, proceed section titled
“Installation - Gas Connections”.
Combustion Air
Intake Guard
CAUTION
Building Side Wall
The concentric vent adapter box must be installed inside of the structure or building. Do not install this box on the exterior of a building or structure.
section d - concentric vent system installation
D1. This section applies to both horizontally and vertically vented concentric vent systems as defined in “Section A –
General Instructions – All Units”, and is in addition to the instructions in that section.
D2. When utilizing the concentric vent option, it should have been predetermined whether the appliance will be horizontally or vertically vented. Before proceeding, verify that the concentric vent kit received contains the correct components for the installation:
5-594.6
D3. Once the kit contents have been verified as correct for the direction of venting, the concentric vent adapter box is to be installed. Determine the location of the box. Be sure to maintain all clearances as listed in these instructions.
D4.
The adapter box is to be mounted on the interior side of the building. It must not be mounted outside the building. The adapter box has integral mounting holes for ease of installation. When horizontal venting multiple units, the minimum spacing between any sides of the adapter boxes must be 18" and boxes must not overlap in the vertical plane (above or below). When condensation may be a problem, the vent system shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief openings, or other equipment.
9
installation - venting
D5. The adapter box can be mounted flush to the wall (for horizontal kits) or to the ceiling (for vertical kits). The box can also be offset from the wall or ceiling by using field supplied brackets. When mounting the box, consider serviceability and access to the vent and combustion air pipes. If the box is to be mounted using field supplied brackets, these brackets must be strong enough to rigidly secure the box to the wall or ceiling, and should be made from corrosion resistant material.
D6. Determine the length of the vent pipe and combustion air inlet pipe for the selected location. THE VENT PIPE WILL
PASS THROUGH THE CONCENTRIC VENT BOX. THE
LAST SECTION OF VENT PIPE IS A CONTINUOUS
LENGTH OF DOUBLE WALL “B” VENT. See section A12 for attaching and terminating double wall pipe. Begin with pipe lengths on the concentric pipe side of the adapter box referring to Figure 10.1. These pipes will extend through the building wall or roof as well as any added length for the thickness of the wall and the offset from any field installed brackets.
for vertical concentric vent Kits
(refer to figure 9.3):
• The bottom of the combustion air intake pipe must terminate above the snow line, or at least 12 inches above the roof, whichever distance is greater.
• The bottom of the vent cap must terminate at least 6 inches above the top of the combustion air intake cap.
for Horizontal concentric vent Kits
(refer to figure 9.4):
• The combustion air intake pipe must terminate at least
1 inch from the wall to prevent water from running down the wall and into the pipe.
• The back of the vent cap must terminate at least 14 inches from the combustion air intake pipe.
D7. Cut the concentric side vent and combustion air pipes to the proper length as determined in the previous step. Note that the vent pipe diameter is 4" and the combustion air intake pipe diameter is 6" for model sizes 75-175, and 6” and 8” respectively for model sizes 200-400. The pipes must be single wall galvanized or stainless steel material, except for the last section of vent pipe, which must be one continuous length of double wall B-vent extended through the concentric vent box and combustion air inlet pipe on the concentric side of the box.
D8. Allow the concentric side vent pipe to pass through the concentric vent adapter box, as shown in Figure 10.1.
Attach the double wall vent pipe to the single wall vent pipe that goes to the unit. Be sure to seal the joint and the open area around the double wall vent. Seal all joints and seams using sealant suitable for temperatures up to
400°F.
D9. Slide the combustion air pipe over the vent pipe and attach to the air inlet of the concentric adapter box, as shown in Figure 10.1, using at least 3 corrosion resistant sheet metal screws. Seal the joint and seam using sealant suitable for temperatures up to 400°F.
D10. Place this assembly (the adapter box, vent pipe and combustion air pipe) through the wall or roof and verify that the distance requirements as defined in Step D7 are met. Securely attach the assembly building.
D11. From outside the building, caulk the gap between the combustion air intake pipe and the building penetration.
D12. Attach the combustion air intake and vent pipe terminations as follows:
figure 10.1 - adapter Box with combustion air intake pipe attached
Outlet Vent
Pipe Extended
Through Box
Combustion Air
Pipe Attached
A
B
4.57”
model sizes
75-175
a B
13.33" 18.84"
200-400 17.00" 15.27"
for vertical concentric vent Kits
(refer to figure 9.3):
• Slide the combustion air cap down over the vent pipe and fasten it to the combustion air pipe with at least 3 corrosion resistant sheet metal screws.
• Attach the vent cap to the vent pipe using at least 3 corrosion resistant sheet metal screws. Refer to instruction A12 for connecting terminal to double wall pipe.
• Caulk the gap between the combustion air cap and the vent pipe with silicone sealant, or other appropriate sealants suitable for metal to metal contact and for temperatures up to 400° F.
for Horizontal concentric vent Kits
(refer to figure 9.4):
• Attach the combustion air intake guard using corrosion resistant screws at the end of the combustion air intake pipe to prevent animals and debris from entering.
• Attach the vent cap to the vent pipe using at least 3 corrosion resistant sheet metal screws.
D13. Install vent pipe and combustion air pipe between unit heater and concentric vent adapter box as outlined in
“Section A – General Instructions – All Units”.
D14. Once venting is complete, proceed to the section titled
“Installation - Gas Connections”.
10
5-594.6
unit installation
gas connections
WARNING
1. All field gas piping must be pressure/leak tested prior to operation. Never use an open flame. Use a soap solution or equivalent for testing.
2. Gas pressure to appliance controls must never exceed 14"
W.C. (1/2 psi).
3. To reduce opportunity for condensation, the minimum sea
level input to the appliance, as indicated on the serial plate,
must not be less than 5% below the rated input, or 5% below
the minimum rated input of dual rated units.
figure 11.1 - recommended sediment trap/manual shut-off valve installation — side or Bottom gas connection
GAS
SUPPLY LINE
GROUND
JOINT
UNION
W/ BRASS
SEAT
MANUAL GAS
➀
SHUT-OFF VALVE
GAS
SUPPLY LINE
3"
MIN.
PLUGGED
1/8" NPT TEST
GAGE CONNECTION
TO
CONTROLS
CAUTION
Purging of air from gas supply line should be performed as described in ANSI Z223.1 - latest edition “National Fuel Gas
Code”, or in Canada CAN/CGA-B149 codes.
IMPORTANT
To prevent premature heat exchanger failure, the input to the appliance, as indicated on the serial plate, must not exceed the rated input by more than 5%.
SEDIMENT
TRAP
TO
CONTROLS
PLUGGED 1/8"
NPT TEST GAGE
CONNECTION
1. Installation of piping must conform with local building codes, or in the absence of local codes, with the National Fuel Gas
Code, ANSI Z223.1 (NFPA 54) - Latest Edition. In Canada, installation must be in accordance with CAN/CGA-B149.1 for natural gas units and CAN/CGA-B149.2 for propane units.
2. Piping to units should conform with local and national requirements for type and volume of gas handled, and pressure drop allowed in the line. Refer to Table 18.1 to determine the cubic feet per hour (cfh) for the type of gas and size of unit to be installed. Using this cfh value and the length of pipe necessary, determine the pipe diameter from Table
11.1. Where several units are served by the same main, the total capacity, cfh and length of main must be considered.
Avoid pipe sizes smaller than 1/2". Table 11.1 allows for a
0.3" W.C. pressure drop in the supply pressure from the building main to the unit. The inlet pressure to the unit must be 6-7" W.C. for natural gas and 11-14" W.C. for propane gas. When sizing the inlet gas pipe diameter, make sure that the unit supply pressure can be met after the 0.3" W.C. has been subtracted. If the 0.3" W.C. pressure drop is too high, refer to the Gas Engineer’s Handbook for other gas pipe capacities.
3. The gas piping to the unit can enter the unit from the side of the unit or from below. Install a ground joint union with brass seat and a manual shut-off valve external of the unit casing, and adjacent to the unit for emergency shut-off and easy servicing of controls, including a 1/8" NPT plugged tapping accessible for test gauge connection. Verify the manual shutoff valve is gas tight on an annual basis (See Figure 11.1).
4. Provide a sediment trap before each unit in the line where low spots cannot be avoided. (See Figure 11.1).
5. When Pressure/Leak testing, pressures above 14" W.C.
(1/2 psi), close the field installed shut-off valve, disconnect the appliance and its combination gas control from the gas supply line, and plug the supply line before testing. When testing pressures 14" W.C. (1/2 psi) or below, close the manual shut-off valve on the appliance before testing.
GAS
SUPPLY LINE
3"
MIN.
MANUAL GAS
➀
SHUT-OFF VALVE
Through hole in bottom of unit.
(caulk hole to prevent water leakage.)
GROUND
JOINT
UNION
W/ BRASS
SEAT
SEDIMENT
TRAP
➀
Manual gas shut-off valve is in the “OFF” position when handle is perpendicular to pipe.
table 11.1 - gas pipe capacities (cu. ft. per Hour) ➀
80
90
100
125
150
pipe length
(feet)
10
20
30
40
50
60
70
1/2”
132
92
73
63
56
50
46
43
40
38
34
31
natural gas ➁
1”
520
350
285
245
215
195
180
170
160
150
130
120
3/4”
278
190
152
130
115
105
96
90
84
79
72
64
350
320
305
275
250
1-1/4” 1-1/2”
1050
730
1600
1100
590
500
440
400
370
890
760
670
610
560
530
490
460
410
380
2”
3050
2100
1650
1450
1270
1150
1050
990
930
870
780
710
➀
Gas pipe capacities based on gas pressure up to 14" W.C. through Schedule 40 pipe with a pressure drop of 0.3" W.C. for Natural gas with a specific gravity of
0.60.
➁
For gas pipe capacities when using Propane gas (specific gravity of 1.50), multiply the value shown for Natural gas at the applicable pipe diameter and length by 0.63.
5-594.6
11
unit installation
electrical connections
WARNING
1. Disconnect power supply before making wiring connections to prevent electrical shock and equipment damage.
2. All appliances must be wired strictly in accordance with wiring diagram furnished with the appliance. Any wiring different from the wiring diagram could result in a hazard to persons and property.
3. Any original factory wiring that requires replacement must be replaced with wiring material having a temperature rating of at least 105°C.
4. Ensure that the supply voltage to the appliance, as indicated on the serial plate, is not 5% greater than rated voltage.
CAUTION
Ensure that the supply voltage to the appliance, as indicated on the serial plate, is not 5% less than the rated voltage.
1. Installation of wiring must conform with local building codes, or in the absence of local codes, with the National Electric
Code ANSI/NFPA 70 - Latest Edition. Unit must be electri cally grounded in conformance to this code. In
Canada, wiring must comply with CSA C22.1, Part 1,
Electrical Code.
2. Two copies of the job specific wiring diagram are provided with each unit, one located in the duct furnace electrical junction box and one in the electrical section of the unit.
Refer to this diagram for all wiring connections.
3. The wire gauge must be sized according to the National
Electric Code or CSA code based on the power supply voltage, amp draw, and length of run. Refer to the Table 12.1 for maximum wire lengths for the number of wires that can be wired to each low voltage terminal block.
table 12.1 - low voltage (24v) maximum Wire length (ft.) ➀
Wire gauge
model no. trans.
digit 15 va 18 ga 16 ga 14 ga 12 ga 10 ga
1
2
40
75
162
86
216
115
315
168
360
192
495
264
3
4
150
250
43
26
58
35
84
50
96
58
132
79
maximum # Wires per terminal
5 4 3 2 1
➀
NEC-1996, Table 310-17, Copper wire with 90°C insulation, conductors in free space (not in conduit), 86°F ambient. For other wire types, refer to the NEC or
CSA code.
4. Make sure all multi-voltage components (motors, transform ers, etc.) are wired in accordance with the power supply voltage.
5. The power supply to the unit must be protected with a fused or circuit breaker disconnect switch. Refer to the Factory
Mounted Option Locations (Figure 21.1) for the factory mounted disconnect switch location and then review the unit to determine if a factory installed dead front disconnect switch was provided. Accessory field installed disconnect switches should be mounted where shown in Figure
12.1. For fusible disconnect switches, refer to the Model
Identification plate for the fuse size and type.
figure 12.1 - recommended accessory field installed disconnect switch mounting locations
BLOWER
SERVICE
DOOR
HEATER
SERVICE
DOOR
ELECTRIC SUPPLY
COMPONENTS MUST BE
CLEAR OF SERVICE DOORS
DISCONNECT
SWITCH WIRING,
AND CONNECTOR
ELECTRIC
SUPPLY
LEFT HAND ACCESS
UNIT SHOWN
6. The power supply must be within 5% of the voltage rating and each phase must be balanced within 2 percent of each other. If not, advise the utility company.
7. External electrical service connections that must be installed include: a. Supply power connection (120, 208, 240, 480, or 600 volts).
b. Connection of thermostats, remote monitoring panels, building pressure sensors, CO detectors, time clocks, or any other accessory control devices that may be supplied
(24 volts).
8. All outdoor electrical connections must be weatherized to prevent moisture from entering the electrical compartment.
9. Refer to the unit dimensional drawings on Figures 48.1 through 49.1 for the electrical knock-out locations.
10. All supply power electrical connections are made in the electrical section of the unit. The low voltage (thermostat and accessory control devices) can be wired to either the electrical section or the duct furnace electrical junction box.
Refer to the wiring diagram for the terminal location of all low voltage wiring.
12
5-594.6
unit installation
cooling coil units
Models with a cooling section can be provided with either a factory installed direct expansion (DX) evaporator, a chilled fluid
(for use with water, ethylene glycol, or propylene glycol fluids) coil, or the coil can be field supplied and installed by others. For units equipped with a factory installed cooling coil (Digit 23 = 1), refer to the packing slip to determine the coil type provided.
The cooling section is located downstream of the duct furnace heat exchanger in a blow-through configuration, preventing condensation on the heat exchanger in the cooling mode. Thus,
figure 13.1 - cooling section
Optional double wall construction
DX single circuit (shown) and dual circuit coils available
Right or left hand coil header access to match gas controls
Optional Factory
Installed
DX or Chilled
Water coil.
Fin spacings of 6,8,10,12 or 14 fins per inch
Adjustable mounting bracket for 2,3,4 and 6 row coils
Full coverage
3-way sloping
409 stainless steel drain pan
1” stubbed drain connection a stainless steel heat exchanger is not required when a cooling section is used. (However, a stainless steel heat exchanger is still recommended when the combined entering/return air to the unit is below 40°F.)
The cooling section includes a full coverage, 3-way sloping
409 stainless steel drain pan to remove condensate from coil headers, thermal expansion valves, and refrigerant piping.
Insulation is standard on outdoor units and optional on indoor units and double wall construction is optional on all units. The cabinet includes two doors, a removable upper door for service access to the coil once the plumbing has been installed and a lower door which includes a factory supplied 1" stubbed drain connection to the exterior of the cabinet. Field connections for coil inlet and outlet piping can be made through the cabinet corner post or back of the unit. The cooling section duct transition includes 1-1/2" flanges for fastening the sides of the coil. The bottom duct transition is angled to remove any condensation that may be entrained in the supply air stream.
For field supplied coils, do not exceed the maximum coil dimensions listed in Literature 82-135. The dimensions listed are for the maximum coil dimensions. If the coil supplied is smaller than the listed dimensions, field supplied blank off plates are required to prevent air bypass around the coil. The coil is supported by two 14 gauge support rails which contain mounting provisions for fastening 4", 5", 6", 7.5", 8.5", and 10" deep coils.
When obtaining the specifications from a coil manufacturer, it is important to obtain the pressure drop through the coil so that the proper motor horsepower can be selected.
For Both Chilled Water and Direct Expansion Coils: The condensate drain line needs to include a P-trap immediately downstream of the connection to the unit. This trap should extend at least two inches below the connection to prevent air pressure from forcing air into the unit. The trap should be primed with a water/glycol solution to prevent freezing. All points where refrigerant, water or condensate lines enter the structure should be sealed and vibration dampened. Include shut-off valves to isolate the cooling coil from the system in order to remove the coil for service or replacement without draining the entire system. For additional guidelines, refer to the ASHRAE
Fundamentals Handbook section of piping recommendations.
table 13.1 - cooling coil performance limits
model size
75
100
125
150
175
200
225
250
300
350
400
dX - single circuit dX - dual circuit chilled Water
1891
2206
2206
2521
2521
3352
3352
3724
3724
5214
5214
3.44
4.01
4.01
4.58
4.58
6.09
6.09
6.77
6.77
9.48
9.48
1707
2048
2048
2416
2416
3165
3165
3538
3538
4996
4996
3.10
3.72
3.72
4.39
4.39
5.76
5.76
6.43
6.43
9.08
9.08
1676
2011
2011
2372
2372
3214
3214
3592
3592
5073
5073
3.05
3.66
3.66
4.31
4.31
5.84
5.84
6.53
6.53
9.22
9.22
min max coil area max coil area max coil area cfm
➀
(sq. ft.) cfm
➀
(sq. ft) cfm
➀
(sq. ft.) cfm
(all units) max. cooling tons
➁ ➂
dX chilled coils Water coils
609
➃
9.38
741
➄
11.43
926
1111
1296
1481
1667
1852
2222
2593
2963
11.43
13.42
13.42
18.12
18.12
20.24
20.24
27.26
27.26
10.56
12.62
12.62
14.77
14.77
19.28
19.28
21.33
21.33
29.25
29.25
➀
Based on 550 feet per minute (FPM) coil face velocity.
➁
1 Ton = 12,000 Btu/Hr
➂
Based on 95°F Entering Dry Bulb, 75°F Entering Wet Bulb.
➃
Model Size 75 CFM listed for Chilled Water - DX Single Circuit CFM minimum is 688 and DX Dual Circuit CFM min is 621.
➄
Model Size 100 CFM listed for Chilled Water - DX Single Circuit CFM minimum is 802 and DX Dual Circuit CFM min is 745.
5-594.6
13
unit installation
direct expansion (dX) piping
The refrigerant lines should be insulated to prevent warming or cooling of the refrigerant. If the suction line is allowed to be cooled, liquid will condense in the line and can severely damage the compressor. If the liquid line is warmed, the refrigerant can "flash" into a gas. This will cause erratic operation of the expansion device and impair the heat transfer ability of the cooling coil. Long runs of piping need to be periodically supported to prevent excess vibration that can damage the piping and joints. It is recommended to provide dampening supports at intervals of length equivalent to 15 tube diameters.
figure 14.1 - general dX piping
Liquid Line
Suction Header
Distributor
Equalizer Line
Nozzle
Coil
Expansion Valve
(By Others)
A steady rise in microns would indicate that moisture is still present and that the coil should be further vacuumed until the moisture has been removed.
9. Failure to obtain a high vacuum is indicative of a great deal of moisture or a small leak. Break the vacuum with a charge of dry nitrogen or other suitable gas and recheck for leaks (soapy water works well). If no leaks are found, continue vacuuming the coil until the desired vacuum is reached.
10. All field piping must be self-supporting.
chilled fluid piping
To prevent noise within a system, an air vent is necessary to bleed off the accumulated air in the system. The vent should be located on the top of the inlet manifold where the air collects.
This vent should be opened twice a year. Air in the system will generate noise and may cause water hammer than can damage the joints of the piping and the cooling coil.
The outlet manifold should have a drain installed on the bottom of the manifold to allow for periodic flushing of the system to remove sediments and corrosion products from the cooling coil. This drain should be opened to allow some fluid to drain twice a year. Check coloration and viscosity of the effluent for indications of corrosion in the system. The lines between the unit and the structure should be insulated to prevent freezing of the water.
figure 14.1 - general chilled fluid piping
Suction Line
Remote Sensing Bulb
Straps
Suction Connection
1. Inspect the refrigerant distributor and verify that the nozzle is in place.
2. All field brazing and welding should be performed using high quality materials and an inert gas purge (such
as nitrogen) to reduce oxidation of the internal surface ot the coil.
3. Connect the suction line and suction connection.
4. Install the expansion valve (By Others). Follow the expansion valve manufacturer's recommendations for installation to avoid damaging the valve.
5. The expansion valve's remote sensing bulb should be securely strapped to the horizontal run of the suction line at the 3 or 9 o'clock position and insulated.
6. Connect the liquid line to the expansion valve. Pressurize the coil, expansion valve assembly and suction connection to 100 psig with dry nitrogen or other suitable gas. The coil should be left pressurized for a minimum of 10 minutes.
7. If the coil holds pressure, the hook-up can be considered leak free. If the pressure drops by 5 psi or less, repressurize the coil and wait another 10 minutes. If the pressure drops again, there are more than likely one or more small leaks, which should be located and repaired.
Pressure losses greater than 5 psi would indicate a larger leak, which should be isolated and repaired. Be sure to check valves and fittings as potential sites for leakage or bleed. If the coil is found to be leaking, contact your local
Modine representative.
8. Use a vacuum pump to evacuate the coil and any interconnecting piping that has been open to atmosphere.
Measure the vacuum in the piping using a micron gauge located as far from the pump as possible (the vacuum at the pump will be greater than the rest of the system).
Evacuate the coil to 500 microns or less then close the valve between the pump and the system. If the vacuum holds to 500 microns or less for one minute, the system is ready to be charged or refrigerant pumped down in another portion of the system can be opened to the coil.
14
5-594.6
Air Vent
Gate Valve
Tee
Dirt Leg
Cap
Re turn
Vent Plug
Air F low
Union
Drain Plug
1. Once installed, the coil should be pressurized to 100 psig with dry nitrogen or other suitable gas. The coil should be left pressurized for a minimum of 10 minutes. If the coil holds the pressure, the hook-up can be considered leak free. If the pressure drops by 5 psig or less re-pressurize the coil and wait another 10 minutes. If the pressure drops again, there is more than likely one or more small leaks which should be located and repaired. Pressure losses greater than 5 psig would indicate a larger leak that should be isolated and repaired. If the coil itself is found to be leaking, contact your local factory representative.
unit installation
2. All field brazing and welding should be performed using high quality materials and an inert gas purge (such as nitrogen) to reduce oxidation of the internal surface of the coil.
3. All field piping must be self supporting. System piping should be flexible enough to allow for thermal expansion and contraction of the coil.
operation general - all coils
1. Proper air distribution is vital to coil performance. Air flow anywhere on the coil face should not vary by more than
20%.
2. Air velocities should be maintained between 200 and 550 feet per minute.
3. For chilled fluid coils, fluid velocities should be maintained within the recommended values of 1 to 8 fps for Water and
1 to 6 fps for Glycol solutions.
chilled fluid coils - initial start-up
1. Open all air vents so that air is eliminated from within the coil circuitry and headers. Verify that all vents and drains are not obstructed and do discharge a stream of water.
2. Fill the coil with water then close all vents.
3. Perform an initial hydrostatic leak test of all brazed, threaded or flanged joints, valves and interconnecting piping. Recheck the coil level and correct if necessary.
When the setup is found to be leak free, discharge and discard initial water charge. It is important that all grease, oil, flux and sealing compounds present from the installation be removed.
maintenance general
1. Filters should be inspected on a regular basis and changed as needed. Maintaining clean filters is a cost- effective way to help maintain maximum coil performance and service life.
2. Periodic inspection of the coil for signs of corrosion and for leaks is recommended. For DX coils, Small leaks can be detected using a Halide torch. Repair and replacement of the coil and the connecting piping, valves, etc., should be performed as needed by a qualified individual(s).
3. Should the coil surface need cleaning, caution should be exercised in selecting the cleaning solution as well as the cleaning equipment. Improper selection can result in damage to the coil and/or health hazards. Clean the coil from the leaving air-side so that foreign material will be washed out of the coil rather than pushed further in. Be sure to carefully read and follow the cleaning fluid manufacturer's recommendations before using any cleaning fluid.
4. For DX coils, the use of filter-dryers in the system piping is recommended along with a sight glass that has a moisture indicator. Replace the filter dryer(s) as needed.
5. For chilled fluid coils,
A) Maintain the circulated fluid free of sediment, corrosive
products and biological contaminants. Periodic testing
of the fluid followed by any necessary corrective
measures along with maintaining adequate fluid
velocities and proper filtering of the fluid will help to
satisfy this goal.
B) Automatic air vents must be utilized to remove
accumulated air.
C) Freeze Protection - During the winter, chilled water coils
need to be protected against freezing. The two
predominant protective measures are 1) Blowing-out
the coils with air or 2) Flushing coils with inhibited
glycol. It is recommended to use inhibited glycol
designed for HVAC applications for corrosion
protection. Select an inhibited glycol solution that will
protect the coil from the lowest possible temperatures
that can occur at the particular coil's locality.
5-594.6
15
start-up procedure
start-up procedure
IMPORTANT
1. To prevent premature heat exchanger failure, observe heat exchanger tubes by looking at the heat exchanger through the field installed access openings in connecting ductwork in blower package units or the unit access doors in cooling package units. If the bottom of the tubes become red while blower and duct furnace are in operation, check to be sure the blower has been set to the proper rpm for the application. Refer to page 18 for Blower Adjustments.
2. Start-up and adjustment procedures should be performed by a qualified service agency.
1. Turn off power to the unit at the disconnect switch. Check that fuses or circuit breakers are in place and sized correctly. Turn all hand gas valves to the “OFF” position.
2. Remove the duct furnace and blower exterior panels and open the electrical compartment door.
3. Check that the supply voltage matches the unit supply voltage listed on the Model Identification plate. Verify that all wiring is secure and properly protected. Trace circuits to insure that the unit has been wired according to the wiring diagram.
4. Check to insure that the venting system is installed and free from obstructions.
5. Check to see that there are no obstructions to the intake and discharge of the unit.
6. Check the belt tension and sheave alignment. Refer to
Blower Adjustments for proper belt tension.
7. Check bearings for proper lubrication. For units provided with pillow block bearings (See Model Nomenclature), refer to Lubrication Recommendations for lubrication requirements.
8. Check to make sure that all filters are in place and that they are installed properly according to direction of air flow.
9. Perform a visual inspection of the unit to make sure no damage has occurred during installation.
10. Turn on power to the unit at the disconnect switch. Check to insure that the voltage between duct furnace electrical box terminals 1 and 2 is 24V.
11. Check the thermostat, ignition control, gas valve, and supply fan blower motor for electrical operation. If these do not function, recheck the wiring diagram. Check to insure that none of the Control Options have tripped.
12. For units with a return air damper, the return air damper linkage needs to be adjusted. Refer to Damper Linkage
Adjustment.
13. Check to make sure that the damper opens properly without binding.
14. Check the blower wheel for proper direction of rotation when compared to the air flow direction arrow on the blower housing. Blower wheel rotation, not air movement, must be checked as some air will be delivered through the duct furnace with the blower wheel running backwards.
15. Check the blower speed (rpm). Refer to Blower Adjustments for modification.
16. Check the motor speed (rpm).
17. Check the motor voltage. On three phase systems, check to make sure all legs are in balance.
18. Check the motor amp draw to make sure it does not exceed the motor nameplate rating. On three phase systems, check all legs to insure system is balanced.
19. Recheck the gas supply pressure at the field installed manual shut-off valve. The minimum inlet pressure should be 6" W.C. on natural gas and 11" W.C. on propane gas. The maximum inlet pressure for either gas is 14" W.C. If inlet pressure exceeds 14" W.C., a gas pressure regulator must be added upstream of the combination gas valve.
20. Open the field installed manual gas shut-off valve.
21. Open the manual main gas valve on the combination gas valve. Call for heat with the thermostat and allow the pilot to light. On a call for heat the power exhauster relay will energize the power exhauster motor. Once the power exhauster motor reaches full speed, a differential pressure switch will close before the pilot can light. If the pilot does not light, purge the pilot line. If air purging is required, disconnect the pilot line at outlet of pilot valve. In no case should line be purged into heat exchanger. Check the pilot flame length (See Pilot Flame Adjustment).
22. Once the pilot has been established, check to make sure that the main gas valve opens. Check the manifold gas pressure (See Main Gas Adjustment) and flame length
(See Air Shutter Adjustment) while the supply fan blower is operating.
23. Check to insure that gas controls sequence properly
(See Control Operating Sequence). Verify if the unit has any additional control devices and set according to the instructions in the Control Options.
24. Once proper operation of the unit has been verified, remove any jumper wires that were required for testing.
25. Close the electrical compartment door.
26. Replace all exterior panels.
Refer to page 58 for the Start-up Checklist.
pilot Burner adjustment
The pilot burner is orificed to burn properly with an inlet pressure of 6-7" W.C. on natural gas and 11-14" W.C. on propane gas, but final adjustment must be made after installa tion. If the pilot flame is too long or large, it is possible that it may cause soot and/or impinge on the heat exchanger causing failure. If the pilot flame is shorter than shown, it may cause poor ignition and result in the controls not opening the combina tion gas control. A short flame can be caused by a dirty pilot orifice. Pilot flame condition should be observed periodically to assure trouble-free operation.
to adjust the pilot flame
1. Create a call for heat from the thermostat.
2. Remove the cap from the pilot adjustment screw. For location, see the combination gas control literature supplied with unit.
3. Adjust the pilot length by turning the screw in or out to achieve a soft steady flame 3/4" to 1" long and encompassing 3/8"-1/2" of the tip of the thermocouple or flame sensing rod (See Figure 17.1).
4. Replace the cap from the pilot adjustment screw.
16
5-594.6
start-up procedure
figure 17.1 - correct pilot flame
3/4" to 1" h. Disconnect power.
i. Replace cover plate (2) and re-install all wires from duct furnace terminal “43”.
7. After adjustment, move the field installed manual shut-off valve to the “OFF” position and replace the 1/8" pipe plug.
8. After the plug is in place, move the field installed manual shut-off valve to the “ON” position and recheck pipe plugs for gas leaks with soap solution.
figure 17.2 - checking manifold pressure with “u” tube manometer main Burner adjustment
The gas pressure regulator (integral to the combination gas control) is adjusted at the factory for average gas conditions.
It is important that gas be supplied to the duct furnace in accordance with the input rating on the serial plate. Actual input should be checked and necessary adjustments made after the duct furnace is installed. Over-firing, a result of too high an input, reduces the life of the appliance and increases maintenance. Under no circumstances should the input exceed that shown on the serial plate.
Measuring the manifold pressure is done at the tee in the manifold (See Figure 17.2).
to adjust the manifold pressure
1. Move the field installed manual shut-off valve to the “OFF” position.
2. Remove the 1/8" pipe plug in the pipe tee and attach a water manometer of “U” tube type which is at least 12" high.
3. Move the field installed manual gas shut-off valve to the
“ON” position.
4. Create a high fire call for heat from the thermostat.
5. Determine the correct high fire manifold pressure. For natural gas 3.5” W.C., for propane gas 10” W.C. Adjust the main gas pressure regulator spring to achieve the proper manifold pressure (for location, see the combination gas control literature supplied with unit).
6. If the unit has Electronic Modulation gas controls (determine from the Model Identification Digit 12), the low fire gas pressure needs to be adjusted. Using Figure 17.3 for item number locations, this is accomplished as follows: a. Disconnect power.
b. Remove all wires from duct furnace terminal “43” and remove cover plate (2).
c. Turn on power at the disconnect switch.
d. Remove the maximum adjustment screw (4), spring
(5), and plunger (8). A small magnet is useful for this purpose. CAUTION - The plunger is a precision part.
Handle carefully to avoid marring or picking up grease and dirt. Do not lubricate.
e. Using minimum adjusting screw (9), adjust low fire manifold pressure to 0.56" W.C. for natural gas and
1.6" W.C. for propane gas.
f. Replace plunger and spring retainer, spring, and maximum adjusting screw in proper order.
g. Using maximum adjustment screw (4), adjust high fire manifold pressure to 3.5" W.C. for natural gas and 10"
W.C. for propane gas.
manifold tee
figure 17.3 - maxitrol modulating valve adjustments air shutter adjustment
Proper operation provides a soft blue flame with a well-defined inner core. A lack of primary air will reveal soft yellow-tipped flames. Excess primary air produces short, well-defined flames with a tendency to lift off the burner ports. For both natural and propane gas, the air shutters can be adjusted to control the burner flame height. The air shutters can be accessed by reaching behind the manifold tee shown in Figure 17.2. The larger models may require the removal of the manifold (see
Manifold Assembly Removal).
5-594.6
17
start-up procedure
natural gas flame control
Control of burner flames on duct furnaces utilizing natural gas is achieved by resetting the primary air shutters (See Figure
53.2) to either increase or decrease primary combustion air.
Prior to flame adjustment, operate duct furnace for about fifteen minutes. The main burner flame can be viewed after loosening and pushing aside the gas designation disc on the side of the burner box.
To increase primary air, loosen the air shutter set screws and move the air shutters closer to the manifold until the yellowtipped flames disappear. (See Figure 53.2 for air shutter and heat exchanger support locations.) To decrease primary air, move the air shutters away from the manifolds until flames no longer lift from burner ports, but being careful not to cause yellow tipping. Retighten set screws after adjustment.
propane gas flame control
An optimum flame will show a slight yellow tip. Prior to flame adjustment, operate furnace for at least fifteen minutes. Loosen air shutter set screws and move the air shutters away from the manifold to reduce the primary air until the yellow flame tips appear. Then increase the primary air until yellow tips diminish and a clean blue flame with a well defined inner cone appears.
table 18.1 - manifold pressure and gas consumption
model size type of gas
Btu/cu. ft.
specific gravity
High fire manifold pressure
inches of Water column
75
100
125
150
175
200
225
250
300
350
400
500
600
700
800
840
960
➀
➀
➀
➀
➁
➁
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
propane
2500
1.53
10
60.0
45
70.0
43
80.0
40
90.0
37
30.0
37
40.0
45
50.0
42
100.0
42
120.0
37
140.0
43
160.0
40
100.0
42
➀
120.0
37
➀
140.0
43
➀
160.0
40
➀
140.0
43
➁
160.0
40
➁
➀
Model contains 2 furnaces. Values shown are per furnace.
➁
Model contains 3 furnaces. Values shown are per furnace.
natural
1040
0.60
3.5
240.4
25
288.7
20
336.5
27
384.6
23
240.4
25
288.7
20
336.5
27
384.6
23
336.5
27
384.6
23
72.1
20
96.1
30
120.2
25
144.2
30
168.3
27
192.3
23
216.3
20
18 no. of orifices
1
2
2
3
3
3
3
4
4
6
6
4 ➀
4 ➀
6 ➀
6 ➀
6 ➁
6 ➁
Blower adjustments
If blower fan speed changes are required, adjust motor sheave as follows:
1. Refer to page 38 to determine correct blower speed according to job requirements, then proceed with steps 2 through 8.
2. Loosen motor base and take belt off of motor sheave.
3. Loosen set screw on outer side of adjustable motor sheave.
figure 18.1 - motor sheave adjustment
4. Turn outer side of motor sheave clockwise until motor sheave is fully closed.
5. From fully closed position, turn outer side of motor sheave counterclockwise until the proper number of turns open are achieved.
6. Retighten motor sheave set screw, replace belt and retighten motor base. Motor base should be shifted for proper belt tension which is 3/4" deflection with about 5 lbs. of force.
figure 18.2 - Belt tension adjustment
➪
3/4" deflection with 5 lbs. of force
7. Recheck blower rpm after adjustment.
note: Do not fire unit until blower adjustment has been made or unit may cycle on high limit control.
8. Check motor amps. Do not exceed nameplate amps shown on motor nameplate.
lubrication recommendations
The blower can be provided with either spider or pillow block bearings. Spider bearings are permanently lubricated and do not require lubrication. Pillow block bearings are shipped greased from the factory but will require lubrication. The bearings should be checked and lubricated before each heating season but a more frequent lubrication schedule may be required based on the environment in which the unit is installed, and the frequency of the equipment operation. Shell Alvania #2 lubricant is recommended.
5-594.6
Toward Motor
Set Screw
Adjustable Half of Sheave
start-up procedure
damper linkage adjustment
If the unit is provided with a return air damper, to prevent shipping damage, the return air damper linkage is disconnected and the damper closed. Before operating the unit, the fresh and return air dampers must be connected. This is accomplished by the following:
1. The damper actuator should be de-energized and the fresh air damper in a fully closed position.
2. Open the return air damper in a fully open position.
3. Slide the connecting rod into the ball joint on the blade arm with the return air damper fully open. See Figure 19.1.
4. Tighten the 5/16" hex head screw on the ball joint.
figure 19.1 - damper linkage adjustment
Ball Joint
Damper Blade
control operating sequence
Connecting Rod
Blade Arm
Indoor separated combustion units are supplied with intermittent pilot ignition systems. These systems are offered with 100% shut-off with continuous retry for operation on natural gas and propane gas. On all systems, both the main burner and pilot burner are turned off 100% when the thermostat is satisfied.
For both natural and propane gas units, the ignition controller is 100% shut-off with continuous retry. On a call for heat, the system will attempt to light the pilot for 70 seconds. If the pilot is not sensed for any reason, the ignition control will wait for approx imately six minutes with the combination gas control closed and no spark. After six minutes, the cycle will begin again. After three cycles, some ignition controllers lockout for approx imately one hour before the cycle begins again. This will continue indefinitely until the pilot flame is sensed or power is interrupted to the system.
note: Factory Installed Options (see page 21) could change the listed sequence of operation based on their function. The descriptions given are for the basic unit.
single-stage gas controls
Utilizes a single-stage combination gas control, an ignition control, and a single-stage low voltage thermostat.
1. The thermostat calls for heat.
2. The power exhauster relay is energized starting the power exhauster motor. Once the motor has reached full speed, the differential pressure switch closes. The power exhauster relay pre-purge timer closes after 20 to 40 seconds energizing the gas control circuit.
3. The pilot valve opens and the spark ignitor sparks in an attempt to light the pilot.
4. Once the pilot is lit, the flame sensor proves the pilot and stops the spark ignitor from sparking.
5. The main gas valve is opened and the main burner is lit to
100% full fire.
6. The time delay relay starts the blower after 30 to 45 seconds.
7. The unit continues to operate until the thermostat is satis fied, at which time both the main and pilot valves close 100%.
8. The time delay relay stops the blower after 30 to 45 seconds.
5-594.6
two-stage gas controls
Utilizes a two-stage combination gas control, an ignition control, and a two-stage low voltage thermostat. The unit fires at 50% fire on low stage and 100% fire on high stage.
1. The thermostat calls for low stage heat.
2. The power exhauster relay is energized starting the power exhauster motor. Once the motor has reached full speed, the differential pressure switch closes. The power exhauster relay pre-purge timer closes after 20 to 40 seconds energizing the gas control circuit.
3. The pilot valve opens and the spark ignitor sparks in an attempt to light the pilot.
4. Once the pilot is lit, the flame sensor proves the pilot and stops the spark ignitor from sparking.
5. The main gas valve is opened and the main burner is lit to
50% fire.
6. The time delay relay starts the blower after 30 to 45 seconds.
7. If the temperature at the thermostat continues to fall, the thermostat will call for high stage heat.
8. The main gas valve is opened completely and the main burner is lit to 100% full fire.
9. The unit continues to operate until the high stage of the thermostat is satisfied, at which time the main valve closes to 50% fire.
10. The unit continues to operate until the low stage thermostat is satisfied, at which time both the main and pilot valves close 100%.
11. The time delay relay stops the blower after 30 to 45 seconds.
electronic modulating gas controls single furnace - model sizes 75-400
Utilizes an electronic modulating/regulating gas control, combination gas valve, an ignition control, modulating amplifier, and either a modulating room thermostat or modulating duct thermo stat with remote temperature set point adjuster. The thermostat controls can modulate the gas flow between 40% through 100% full fire. When the thermostat is satisfied, the amplifier cuts power to the combination gas valve which prevents gas flow to both the main and pilot burners.
When duct sensing is utilized, a room override thermostat can be added. When calling for heat, the room override thermostat provides full fire operation until the space temperature is satisfied. Control is then returned to the duct sensing control. In this situation, either the duct sensor or the room override thermostat can call for heat.
1. The thermostat calls for heat.
2. The power exhauster relay is energized starting the power exhauster motor. Once the motor has reached full speed, the differential pressure switch closes. The power exhauster relay pre-purge timer closes after 20 to 40 seconds energizing the gas control circuit.
3. The pilot valve opens and the spark ignitor sparks in an attempt to light the pilot.
4. Once the pilot is lit, the flame sensor proves the pilot and stops the spark ignitor from sparking.
5. The main gas valve is opened and the main burner is lit to
100% full fire.
6. The time delay relay starts the blower after 30 to 45 seconds.
7. The modulating gas valve can be controlled by either an electronic modulating room or duct thermostat. The thermo stat can modulate the firing rate between 40% through 100% full fire.
The call for heat is created by a resistance signal (8000 to 12000 ohms) in the thermostat. The amplifier converts this resistance into a DC voltage (0 to 12 volts DC with 0 volts high fire and 12 volts low fire). The output voltage is applied to the modulating gas valve to control the gas flow to the main burner. As the temperature drops, the voltage drops causing the modulating valve to open further. If the discharge air temperature increases, the voltage increases causing the modulating valve to close allowing less gas flow to the main burner. For further information regarding the operation of the electronic modulating system, consult the literature provided with the unit.
19
start-up procedure
8. The unit continues to operate in this manner until the thermostat is satisfied, at which time both the main and pilot valves close 100%.
9. The time delay relay stops the blower after 30 to 45 seconds.
8. The unit continues to operate in this manner until the thermostat is satisfied, at which time the BMS heat contact opens resulting in both the main and pilot valves closing
100%. (If the unit was not provided with a time delay relay, the blower stops at this time.)
9. The time delay relay stops the blower after 30 to 45 seconds.
electronic modulating gas controls two and three furnaces - model sizes 800-960
One Master furnace is provided with up to two Slave furnaces that utilize electronic modulating/regulating gas controls, combination gas valves, ignition controls, one multiple furnace modulating amplifier, and either a modulating room thermostat or modulating duct thermostat with remote temperature adjustment. The thermostat controls can modulate the gas flow of all the furnaces between 40% through 100% full fire. The amplifier sends a signal to all of the gas valves so that they modulate at the same percentage. When the thermostat is satisfied, the amplifier cuts power to the combination gas valves which prevents gas flow to both the main and pilot burners.
When duct sensing is utilized, a room override thermostat can be added. When calling for heat, the room override thermostat pro vides full fire operation until the space temperature is satisfied. Control is then returned to the duct sensing control.
In this situation, either the duct sensor or the room override thermostat can call for heat.
The sequence of operation for Electronic Modulating Gas
Controls — Two and Three furnaces is the same as Electronic
Modulating Gas Controls — Single Furnace.
electronic modulating gas controls — Building management control (0-10 vdc or 4-20 ma signal)
Utilizes an electronic modulating/regulating gas control, combination gas valve, an ignition control, modulating signal conditioner, and an inverted (0 Vdc or 4 mA being high fire and 10 Vdc or 20 mA being low fire) 0-10 Vdc or 4-20 mA input signal provided by a Building
Management System (BMS). The signal conditioner can modulate the gas flow between 40% through 100% full fire. When the BMS thermostat (field supplied) is satisfied, the BMS heat contact (field supplied) opens to cut power to the combination gas valve which prevents gas flow to both the main and pilot burners.
1. The BMS thermostat (field supplied) calls for heat and closes the BMS heat contact (field supplied).
2. The power exhauster relay is energized starting the power exhauster motor. Once the motor has reached full speed, the differential pressure switch closes. The power exhauster relay pre-purge timer closes after 20 to 40 seconds energizing the gas control circuit.
3. The pilot valve opens and the spark ignitor sparks in an attempt to light the pilot.
4. Once the pilot is lit, the flame sensor proves the pilot and stops the spark ignitor from sparking.
5. The main gas valve is opened and the main burner is lit to
100% full fire.
6. The time delay relay starts the blower after 30 to 45 seconds.
7. The modulating gas valve is controlled by the BMS thermostat. The thermostat can modulate the firing rate between 40% through 100% full fire by modulating the input signal between either 0-10 Vdc or 4-20 mA (The signal conditioner can accept a 0-10 Vdc signal when all the dip switches are in the “OFF” position and 4-20 mA signal when all the dip switches are in the “ON” position). The signal conditioner converts the input signal into a DC voltage (0 to 12 volts DC with 0 volts high fire and 12 volts low fire).
The output voltage is applied to the modulating gas valve to control the gas flow to the main burner. As the temperature drops, the voltage drops causing the modulating valve to open further.
If the discharge air temperature increases, the voltage increases causing the modulating valve to close allowing less gas flow to the main burner. For further information regarding the operation of the electronic modulating system, consult the literature provided with the unit.
20
5-594.6
variable air movement applications
Units may be supplied with variable frequency drives for applications where variable air volume is required. The minimum air flow may be varied between 30 and 100% of the full speed air flow depending on the controls selection of the unit. Due to the extra restrictions of the controller all selections must be performed with Accuspec configuration software.
Within Accuspec, three variable frequency drive speed control changeover options are available:
1. Two speed which may be controlled by a manual high/ low switch which may be factory mounted on the control panel or shipped loose for field installation or by exhaust fan interlocks.
2. Floating building pressure sensing which utilizes a photohelic pressure controller to adjust the building pressure by varying the amount of makeup air supplied to the space.
3. Building management control which allows for an external signal of 0-10VDC of 4-20mA to adjust the unit air flow.
Additionally, when the unit is equipped with a two-speed motor, the allowable minimum CFM of the duct furnace can be 66% of the minimum listed CFM in Table 30.1 if the unit is applied as follows:
1. The unit is provided with 2-stage or electronic modulating gas controls. (see Model Identification).
2. The unit is provided with a factory installed discharge air controller.
3. The system does not include a room thermostat.
The factory installed discharge air thermostat will prevent the unit from firing above the allowable 100°F rise when the unit is at or above the minimum CFM by monitoring the discharge air and going to low fire. A room thermostat, because it is located remote from the unit, could cause the unit to over-fire.
options - factory installed
figure 21.1 - factory mounted option locations
1. Discharge Thermostat
2. Low Gas Pressure Switch
3. High Gas Pressure Switch
4. Power Exhauster Assembly
5. Timed Freeze Protection
6. Ignition Controller
7. Differential Pressure Switch
8. Control Relay
9. Time Delay Relay
10. Power Exhauster Relay
11. Furnace Low Voltage Terminal Strip
12. Furnace Supply Power Terminal Strip
13. Control Step Down Transformer
14. Control Relay
15. Blower Low Voltage Terminal Strip
16. Dead Front Disconnect Switch
17. Step Down Transformer Fuses
18. Step Down Transformer
19. Factory Installed Minimum Positioner
20. Extended Grease Line Zerk Fittings
21. Extended Grease Lines
22. Return Air Fire Stat
23. Blower Housing
24. Pillow Block Bearings
25. Blower Motor
26. Filters
27. Fresh Air Damper
28. Direct Drive Damper Actuator
29. Enthalpy Controller
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
49
48
47
31. Return Air Damper
34. Blower Support
37. Dirty Filter Switch
46
35. Convenience Outlet
36. Blower Door Switch
45
38. Motor Starter/VFD Control
44
30. Damper to Damper Linkage
43
42
32. Proportional Temp Controller Sensor
33. Motor and Blower Vibration Isolation
39. Proportional Temp Controller
41
40
39
38
37
36 34
35 33
32
31
30
40. Warm-Up Stat
41. Blower Supply Power Terminal Strip
42. Service Switches
43. Electronic Modulating Gas Valve
44. Electronic Modulating Amplifier
45. Air Flow Proving Switch
46. High Limit Switch
47. Main Gas Valve
48. Supply Air Fire Stat
49. Burner Box
29
28
All units include the standard (STD) features. The unit must be reviewed to determine the optional (OPT) features that may have been supplied with the unit.
(1) discharge thermostat – (opt)
The discharge thermostat is factory installed in the discharge air stream of the unit. For additional information, refer to the thermostat vendor literature provided in the literature packet with the unit.
note: Model Sizes 500-960 contain multiple furnaces so multiple thermostats/sensors may be included.
figure 21.2 - two-stage capillary type thermostat
The thermostat(s) provided can be one of the following: a) Two-stage Capillary Type Thermostat – The thermostat includes a thermostat body that is factory installed below the unit junction box. The thermostat body contains the discharge air set point adjuster that must be field set.
b)
Two-stage Electronic Thermostat - Includes a factory installed discharge air sensor. The thermostat body is field installed remotely and includes the discharge air set point adjuster that must be field set. Refer to Literature
5-577.
figure 21.3 - two-stage electronic thermostat
Setpoint
Adjuster
Right
R B
R B
W
W
Left
Duct Furnace
Electrical
Duct
Furnace
Electrical
Control
Box
Thermostat body
(Shown with cover removed)
Duct
Furnace
Box
Electrical
Control
Box
5-594.6
21
options
c)
Electronic Modulating Discharge Air Thermostat –
Includes a factory installed mixing tube and discharge air sensor. The set point adjuster is field installed remotely and must be field set. Refer to Literature 5-578 latest revision.
figure 22.1 - electronic modulating discharge air thermostat
Air flow
1
2
3
Mixing Tube
Discharge air
Sensor Terminals
Duct
Furnace
Electrical
Control
Box
(4) power exhauster assembly – (std)
The power exhauster is factory installed in the duct furnace section. On a call for heat, the power exhauster creates a combustion draft through the duct furnace prior to the pilot being energized. The draft is proven through a differential pressure switch that closes when the motor reaches full speed. For information about venting, refer to the Installation – Venting section.
(5) timed freeze protection – (opt)
The timed freeze protection system is factory installed in the duct furnace electrical junction box with the sensor (30°-75°F adjustable) factory installed in the discharge air stream. On initial start-up, the timed delay in the system allows the unit to go through the normal ignition sequence. The timed delay is an automatic reset switch and adjustable for 1-10 minutes. In the event that the unit fails to fire after this period, the discharge air sensor will sense the cold air and will shut down the entire unit.
figure 22.3 - timed freeze protection module
(2) low gas pressure switch – (opt)
The low gas pressure switch is factory installed in the duct furnace above the gas train. The switch monitors the gas pressure upstream of all the gas controls and shuts off the electric supply to the ignition controller and combination gas valve if low gas pressure is experienced. This will shut off all gas flow to the burner. The switch has an automatic reset so that if the gas pressure is interrupted and then is returned, the switch will automatically allow the unit to operate when gas conditions are returned to the allowable range of the pressure switch. The pressure switch range is 2" to 14" W.C. and should be set to insure that the minimum inlet gas pressure is available
(6" W.C. for natural gas, 11" W.C. for propane gas).
figure 22.2 - low or High gas pressure switch
NC
NO
C
Reset Switch
Reset Switch
Top: cover removed
Top cover removed
(3) High gas pressure switch – (opt)
The high gas pressure switch is factory installed in the duct furnace above the gas train. The switch monitors the gas pressure downstream of all the gas controls and shuts off the electric supply to the ignition controller and combination gas valve if high gas pressure is experienced right before the manifold. This will shut off all gas flow to the burner. The switch has a manual reset so that if the gas pressure is too high, a service person must check the unit to make sure that none of the gas controls have been damaged by the high gas pressure and then reset the switch to allow the unit to operate when gas conditions are returned to the allowable range of the pressure switch. The pressure switch range is 2" to 16" W.C. and should be set to insure that the maximum manifold gas pressure is not exceeded (3.5" W.C. for natural gas, 10" W.C. for propane gas).
22
5-594.6
(6) ignition controller – (std)
The ignition controller is factory installed in the duct furnace electrical junction box with the spark ignitor and sensor located on the burner. All units are supplied with intermittent pilot ignition systems.
For both natural and propane gas units, the ignition controller is 100% shut-off with continuous retry. On a call for heat, the system will attempt to light the pilot for 70 seconds. If the pilot is not sensed for any reason, the ignition control will wait for approx imately six minutes with the combination gas control closed and no spark. After six minutes, the cycle will begin again. After three cycles, some ignition controllers lockout for approximately one hour before the cycle begins again. This will continue indefinitely until the pilot flame is sensed or power is interrupted to the system.
(7) differential pressure switch – (std)
The differential pressure switch is factory installed in the duct furnace electrical junction box. The differential pressure switch monitors the pressure differential between the duct furnace vent discharge and the atmosphere. The purpose of the differential pressure switch is to cut power to the gas controls if a positive vent pressure is not measured by the switch. This could be caused by a blocked combustion air inlet vent pipe.
(8) control relay – (opt)
The control relay is factory installed in the duct furnace electrical junction box. The relay has a 24V coil with double-pole, double throw (DPDT) contacts. Refer to the unit wiring diagram for the
options
function of the switching operation of the relay. The two normally open and two normally closed contacts are rated for a maximum of 30 amps @ 115V/1Ph.
(9) time delay relay – (std)
The time delay relay is factory installed in the duct furnace electrical junction box. The time delay relay allows the gas controls to operate for approximately 30 seconds before the blower starts. This allows the heat exchanger a warm up period so that the initial delivered air coming out of the ductwork is not cool. The time delay relay also keeps the motor running for approximately 30 seconds after the call for heat has been satisfied to remove the residual heat from the heat exchanger. For single phase units below 2 Hp, the time delay relay controls the motor directly. For single phase units 2 Hp and greater and all three phase units, the time delay relay controls the motor starter.
(10) power exhauster relay – (std)
The control relay is factory installed in the duct furnace electrical junction box. The relay has a 24V coil with single-pole single throw (SPST) contacts. On a call for heat, the relay coil is energized resulting in the contacts energizing the power exhauster motor.
(11) furnace low voltage terminal strip – (std)
The furnace low voltage terminal strip is located in the duct furnace electrical junction box. The terminal strip is labeled to match the electrical wiring diagram provided with the unit.
Low voltage labeling ranges from terminal numbers 1 to 79. All field wiring connections should be made to the top side of the terminals to prevent miswiring by modifying the factory wiring which is made to the bottom of the terminal strip.
(12) furnace supply power terminal strip – (std)
The furnace supply power terminal strip is located in the duct furnace electrical junction box. The terminal strip is labeled to match the electrical wiring diagram provided with the unit.
Supply power labeling ranges from terminal numbers 80 to 99.
All field wiring connections should be made to the bottom side of the terminals to prevent miswiring by modifying the factory wiring which is made to the top of the terminal strip.
(13) control step down transformer – (std)
The control step down transformer is located in the duct furnace electrical junction box. The transformer is used to step down the supply power (115V, 208V, 230V, 460V, 575V) to 24V. This transformer is used to control the gas controls, damper actuator, motor starter, etc. Refer to the unit model number to determine the volt- amp (VA) capacity of the duct furnace. The 15th digit indicates the VA (See Model Nomenclature).
(14) control relay – (opt)
The control relay is factory installed in the electrical section.
The relay has a 24V coil with double-pole, double throw (DPDT) contacts. Refer to the unit wiring diagram for the function of the switching operation of the relay. The two normally open and two normally closed contacts are rated for a maximum of 30 amps
@ 115V/1Ph.
(15) Blower low voltage terminal strip – (std)
The blower low voltage terminal strip is located in the electrical section. The terminal strip is labeled to match the electrical wiring diagram provided with the unit. Low voltage labeling ranges from terminal numbers 1 to 79. All field wiring connections should be made to the right side of the terminals to prevent miswiring by modifying the factory wiring which is made to the left side of the terminal strip.
(16) dead front disconnect switch – (opt)
The dead front disconnect switch is factory installed in the electrical section. The disconnect switch is designed so that it must be turned “OFF” before entry to the electrical control cabinet can be obtained (See Figure 23.1). When in the “OFF” position, power is disconnected to all unit wiring electrically following the switch (See Warning). For servicing the unit, the disconnect switch can be manually overridden by using a wrench and turning the disconnect switch shaft 90° clockwise (See
Figure 23.1). Fusible and circuit breaker switches available.
For fusible switches, Class “J” time delay fuses must be field provided matching the fuse size listed on the Model Identification plate.
WARNING
When the dead front disconnect switch is in the “OFF” position, supply power remains energized at the blower supply power terminal strip and the top of the dead front disconnect switch. When providing service on or near these terminals, building supply power to the unit should be de-energized.
figure 23.1 - dead front disconnect switch assembly
BLOWER SECTION
ELECTRICAL
COMPARTMENT
ACCESS DOOR
DISCONNECT
SWITCH HANDLE
OPERATION
INSTRUCTION
LABEL
DISCONNECT
SWITCH HANDLE
SHOWN IN THE
"ON" POSITION
DISCONNECT
SWITCH HANDLE
SHOWN IN THE
"OFF" POSITION
BLOWER SECTION
ELECTRICAL
COMPARTMENT
STAND-OFF PANEL
SUPPLY POWER
WIRING TERMINALS
(SEE WARNING)
(
17) step down transformer fuses – (opt)
The transformer fuses are factory installed in the electrical section. The fuses are included to protect the transformer.
Fuses included.
5-594.6
23
options
(18) step down transformer – (opt)
The step down transformer is factory installed in the electrical section. The transformer is only required for 460V/3Ph and
575V/3Ph. When the supply power voltage is 460V/3Ph or
575V/3Ph, the transformer is provided to step down from supply power voltage to 115V. In this case, the power exhauster motor operates at 115V.
(19) factory installed minimum positioner – (opt)
The factory installed minimum positioner is installed in the electrical section and is used with a modulating damper actuator to set the minimum percentage of outside air. The minimum positioner dial is manually set between 0 to 100% resulting in a
2 to 10 VDC signal being sent to the damper actuator. When used in conjunction with the Proportional Temp Controller, the positioner sets the minimum outside air percentage and the
Proportional Temp Controller then modulates between the minimum position and 100% outside air.
figure 24.1 - minimum positioner
80
(20) extended grease line Zerk fittings – (opt)
The extended grease line zerk fittings are factory installed on the exterior corner post between the electrical and blower sections.
The zerk fittings allow pillow block bearings to be lubricated with a grease gun. Refer to Lubrication Recommendations for lubricant recommendations.
60
Belimo
%
40
20
(21) extended grease lines – (opt)
The extended grease lines are factory installed in the blower section from the Extended Grease Line Zerk Fittings to the
Pillow Block Bearings. The grease lines allow the pillow block bearings to be lubricated without requiring the service personnel to remove both blower doors to access the bearings. The grease lines will require filling at the time of first lubrication.
(
22) return air fire stat – (opt)
The return air fire stat is factory installed in the electrical section with the sensor in the return air stream. In case of elevated temperatures in the return air stream, the manual reset switch shuts down the entire unit. If the limit temperature is exceeded, a service person must inspect the unit for the cause of the high discharge temperature, take corrective action, and then reset the switch.
(
23) Blower Housing – (std)
The blower housing is factory installed in the blower section.
The blower housing contains a double width, double inlet
(DWDI) blower wheel so both sides of the blower must be free from obstructions for proper operation. For Right Hand units
(Digit 9 = R), during operation the blower wheel should rotate in the clockwise direction when viewed from the service side of the unit. For Left Hand units (Digit 9 = L), during operation the blower wheel should rotate in the counterclockwise direction when viewed from the service side of the unit. If necessary, interchange supply power wiring to reverse blower rotation.
24
5-594.6
(24) pillow Block Bearings – (opt)
The blower bearings are factory installed in the blower section.
The blower can be provided with either spider or pillow block bearings. Spider bearings are permanently lubricated and do not require lubrication. Pillow block bearings are shipped non-greased from the factory and require lubrication before start-up. For lubrication recommendations, see Lubrication
Recommendations.
(25) Blower motor – (std)
The blower motor is factory installed in the blower section. The blower motor can be provided in a variety of supply voltages, frame types, and motor horsepowers. Refer to the model nomenclature to determine the type of motor provided. The blower motor is supplied with an adjustable sheave that can be used to increase/decrease the blower RPM. For instructions on changing the blower RPM, refer to Blower Adjustments.
(26) filters – (opt)
When filters are supplied with the unit, a rack and the filters are factory installed in the blower section. The unit can be supplied with 1" or 2" permanent filters, 2" FARR® Aeropleat or 2" FARR®
30/30 filters. For filter replacement, refer to Maintenance.
(27) fresh air damper – (opt)
When a fresh air damper is supplied with the unit, the damper is factory installed in the blower section. The fresh air damper is used as an outside air shut-off damper so ultra low leak, Class
II leakage resistance (less than 10 CFM/ft 2 at 1" W.C.) dampers with self-compensating stainless steel side seals and santoprene and galvanized steel blade seals are used.
(28) direct drive damper actuator – (opt)
The direct drive damper actuator is factory installed in the blower section on the side of the fresh air damper. The actuator controls the position of the fresh air damper. The return air damper, if provided, is controlled by the damper linkage between the two dampers. All damper actuators are low voltage (24V). For Right
Hand units (Digit 9 = R), during operation the actuator should rotate in the counterclockwise direction when viewed from the service side of the unit. For Left Hand units (Digit 9 = L), during operation the actuator should rotate in the clockwise direction when viewed from the service side of the unit. Three different types of dampers actuators can be provided: Two-position,
Modulating, and Floating.
Two-position Damper Actuator: A two-position damper actuator is provided with Air Control options DA, EA, EQ, and FA (Digits
20 & 21). The two-position damper actuator provides open/ closed operation of the fresh air damper. When the damper is energized, the fresh air damper is opened to 100% outside air in 75 seconds (For units with a two-position damper limiter, the outside air percentage would be the set by the damper limiter.
See Two-Position Damper Limiter below). All two-position damper actuators are spring return, so when the damper is de-energized, the fresh air damper will spring closed. All twoposition dampers include auxiliary switches (one normally open and one normally closed) that reverse when the damper actuator is at 85° rotation (adjustable).
Two-Position Damper Limiter: The two-position damper limiter is factory set to prevent the outside air damper from opening 100%.
The outside air percentage and the actuator end switch is set based on the unit order.
Field adjustment of the two-position damper limiter is accomplished by the following:
1. Determine the amount of damper rotation required
(Percentage of outside air).
options
2. Locate the angle of rotation limiter on the actuator so that its edge lines up with the degree graduation on the actuator face which corresponds with the required rotation. (See
Figure 25.1 which is shown at 50% rotation limit.)
3. Find the appropriate cross-hair location through the slot of the limiter. This is the screw mounting location.
4. Pierce through the label material to allow easy fastening of the retaining screw.
5. Position the limiter back to the desired position, making sure the locating “teeth” on the limiter are engaged into the locating holes on the actuator.
6. Fasten the limiter to the actuator using the self tapping screw provided.
7. Test the damper rotation either manually with the manual crank or apply power and if required, a control signal.
Re-adjust if necessary.
(
29) enthalpy controller – (opt)
An enthalpy controller is provided with Air Control option GJ
(Digits 20 & 21) and factory installed in the blower section.
The purpose of the enthalpy controller is to use outside air for cooling, whenever possible, to reduce compressor operation of the mechanical cooling system. The economizer functions as a true first stage of cooling and provides maximum fuel economy during the cooling cycle.
HEATING and VENTILATING MODE
When the space thermostat calls for heat or it is in the fan
ON position without a call for cooling (ventilation mode), the economizer is automatically locked out. It holds the outdoor air damper at the minimum position setting.
COOLING MODE
When the space thermostat calls for cooling, the system operates as follows:
figure 25.1 - two-position damper actuator and limiter
Lock down with screw as shown
L
R
Adjustable end switch set to angle of rotation
Actuator clamp at
50% rotation limit
Modulating Damper Actuator: A modulating damper actuator is provided with Air Control options GA, GB, GC, GD, GE, GF,
GG, GH, GJ, GK, GM, and GN (Digits 20 & 21). The modulating damper actuator provides incremental operation of the fresh air damper (The return air damper is controlled by the fresh air damper position). Full 90° rotation of the modulating actuator requires 150 seconds. All modulating damper actuators operate using a 0-10 Vdc input signal (Air Control GB utilizes a resistor to convert from a 4-20 mA to 0-10 Vdc) from a damper controller.
All modulating damper actuators are spring return, so when the damper is de-energized, the fresh air damper will spring closed.
Floating Damper Actuator: A floating damper actuator is provided with Air Control option HP (Digits 20 & 21). The floating damper actuator provides forward and reversing damper operation in response to contact closures from the space pressure controller.
When the space pressure is above the desired set point, a high pressure contact on the space pressure controller energizes the damper to drive the fresh air damper closed. When the space pressure is below the desired set point, a low pressure contact on the space pressure controller energizes the damper to drive the fresh air damper open. When the space pressure is between the high and low set points, the damper “floats” at the fresh air percentage that satisfied the space pressure controller. Full
90° rotation of the floating actuator requires 150 seconds. For additional information on the space pressure controller, refer to
Literature 5-585 latest revision.
The damper actuator is designed to “float” and therefore it is not spring return. When the unit is de-energized under normal operation, the fresh air damper is closed by a relay contact closure which electrically drives the damper closed. If the supply power to the unit is interrupted before the damper actuator can drive closed, the fresh air damper will remain open. The damper can be manually closed through the use of the manual override switch on the floating damper actuator.
5-594.6
Outdoor Air Enthalpy is Below Changeover Set Point
1. The outdoor air damper is proportioned open (and the return air damper is proportioned closed) to maintain between 50°F and 56°F at the mixed air temperature sensor.
2. During economizer operation, mechanical cooling is operated by the second stage of the cooling on the space thermostat.
Outdoor Air Enthalpy is Above Changeover Set Point
1. The outdoor air damper is closed to its minimum position.
2. A call for cooling from the space thermostat brings on mechanical cooling.
The enthalpy controller is used in conjunction with the Enthalpy
Sensor (not shown and field installed) and a mixed air temperature sensor (not shown). The mixed air temperature sensor is factory installed in the blower section to sense the combined temperature of the fresh and return air streams. The sensor is non-adjustable and when in the free cooling mode, modulates the dampers to maintain between 50°F and 56°F at the sensor.
The enthalpy controller contains a minimum position adjustment and an enthalpy changeover set point that must be field set.
figure 25.2 - enthalpy controller
25
options
Minimum Position Adjustment:
The minimum position adjustment keeps the outdoor air damper from closing completely during system operation to provide ventilation in both the heating and cooling modes.
To set the minimum position adjustment:
1. Disconnect mixed air sensor from terminals T and T1 on the enthalpy controller.
2. Make sure the factory installed jumper is in place across terminals P and P1.
3. Connect 24 Vac across terminals TR and TR1.
4. Adjust the minimum position adjustor with a screwdriver for the desired minimum position.
figure 26.1 - enthalpy changeover set point control points
Outdoor Enthalpy Changeover Set Point
The outdoor enthalpy changeover set point returns the outdoor air damper to the minimum position when the enthalpy rises above its set point. Enthalpy set point scale markings, located on the enthalpy controller, are A, B, C, and D. See Figure 26.1 for the corresponding control point. The factory installed 620ohm jumper placed across terminals S and + is required for
R proper operation and should not be removed. Refer to suppliers literature supplied with the unit for additional information.
enthalpy sensor – (opt) (not shown and field installed)
An enthalpy sensor is provided with Air Control option GJ (Digits
20 & 21) and field installed in the inlet air stream. The enthalpy sensor senses and combines the temperature and humidity of the outdoor air to provide the 4-20 mA input signal to the
Enthalpy Controller. The enthalpy sensor is used in conjunction with the Enthalpy Controller (Item 29 in Figure 21.1) and a mixed air temperature sensor (not shown).
(30) damper to damper linkage – (opt)
Units with fresh and return air dampers include a damper actuator that controls the fresh air damper. The return air damper position is controlled by the fresh air damper through the connecting rod. For adjustment, refer to Damper Linkage
Adjustment.
(
31) return air damper – (opt)
When a return air damper is supplied with the unit, the damper is factory installed in the blower section. The return air damper is used as an air balancing damper so low leak, Class III leakage resistance (less than 40 CFM/ft 2 at 1" W.C.) dampers with selfcompensating stainless steel side seals and santoprene blade seals are used.
(32) proportional temperature controller sensor – (opt)
A proportional temperature controller sensor is provided with Air
Control options GF, GG, GH, GK, GM, or GN (Digits 20 & 21) and factory installed in the blower section. The sensor provides the mixed air temperature signal to the A350P Proportional
Temperature Controller which is mounted in the electrical section.
(
33) motor and Blower vibration isolation – (opt)
The motor vibration isolation is factory installed in the blower section below the blower support bracket. The four (4) 13/32"-
neoprene vibration mount grommet provides isolation of the blower housing and motor from the blower support channels.
The blower vibration isolation is factory installed in the blower section between blower discharge and the blower duct connection. The blower duct connection is not rigidly mechanically fastened and the 1/4'' thick gasketing around the duct transition provides vibration isolation.
(34) Blower support – (std)
The blower supports are factory installed in the blower section.
The blower supports are used to rigidly support the weight of the blower and motor during operation and shipping.
(35) convenience outlet – (opt)
WARNING
Do not perform service on the convenience outlet without disconnecting its power supply. The convenience outlet power supply is separate from main power supply to the unit. When the main disconnect switch is de-energized, the convenience outlet power supply remains energized.
The convenience outlet is factory installed in the blower section for providing power for 115V service equipment (trouble light, power tools, etc.). The 115V ground fault circuit interrupter
(GFCI) is rated for 15 amps and includes test and reset switches. A separate field supplied 115V/1Ph power supply must be routed through the electrical section wall into the back of the convenience outlet junction box.
(36) Blower door switch – (opt)
The blower door switch is factory installed inside the blower section door on the access side of the unit. When the blower section door is removed, the momentary switch is released and interrupts power to the low voltage circuit. For single phase units 1-1/2 Hp and less, the door switch de-energizes a relay that controls blower motor operation. For three phase units and single phase units 2 Hp and greater, the door switch de-energizes the motor starter that controls blower motor operation.
26
5-594.6
options
For servicing, the switch is equipped with an override position that can be manually pulled out to override the switch. See
Figure 27.1
figure 27.1 - Blower door switch with manual override
COM
NC NO
REST POSITION
OPERATING POINT
OVERRIDE
POSITION
(
37) dirty filter switch – (opt)
The dirty filter pressure switch is factory installed in the electrical section. The dirty filter pressure switch monitors the pressure differential between the two sides of the filters. When the filters become dirty, the differential pressure increases and trips the pressure switch which energizes a light on the remote monitoring panel. The pressure differential switch must be field set because setting the switch requires the blower to be in operation and the ductwork to be installed.
setting the dirty filter switch
The range of the dirty filter pressure switch is adjustable between 0.17" to 5.0" W.C.
1. Ensure that the unit filters are clean. Clean or replace if necessary.
2. Connect the leads of a continuity tester to the NO and C terminals of the dirty filter pressure switch. See Figure 27.2
3. Set the thermostat so that there is a call for heat. This should fire the burner and the blower should start.
4. Turn the set screw of the pressure switch clockwise until it stops. This will set the pressure at 5.0" W.C. and the continuity tester should be sensing an open circuit.
5. Begin turning the screw counterclockwise until the continuity tester senses a closed circuit. This determines the base pressure of the system.
6. Turn the screw clockwise until the continuity tester senses an open circuit and then one additional full turn (This is approx imately 0.25" W.C.) This will allow for the increase in static pressure due to dirty filters.
figure 27.2 - dirty filter pressure switch and air flow proving switch
Positive pressure connector
Negative pressure connector
Pressure adjustment set screw
(38) motor starter – (opt)
The motor starter is factory installed in the electrical section.
A motor starter is required for all three phase motors and single phase motors 2 Hp and greater. The motor starter current set point dial is factory set to the motor full load amp draw listed on the motor nameplate.
The overload module of the motor starter is designed to trip to protect the motor from exceeding the nameplate amps. If the motor exceeds the amp draw on the current set point dial, the trip condition is indicated by a red color in the trip indicator window.
The motor starter can be placed in the automatic or manual reset positions. Automatic reset is accomplished by depressing the “RESET” button and turning the button 1/4 turn. When in the automatic reset position, if the overload module trips, the module will reset itself once the overload relay has cooled. In the manual reset position, if the overload module trips, the “RESET” button must be depressed before the blower can operate.
The contractor module includes one (1) normally open auxiliary contact. The contact rating is 10 amps.
(38) variable frequency drive – (opt)
The VFD controller adjusts the motor rpm to vary the unit air flow. The minimum air flow may be varied between 30 and 100% of the full speed air flow depending on the controls selection of the unit. The control changeover options are two speed, floating building pressure sensing, and building management control.
If the factory installed motor starter option or a VFD was not ordered with a unit that has a three phase motor or single phase motor 2 Hp or greater, it must be field supplied and installed.
figure 27.3 - motor starter
A1
1 L1 3 L2 5 L3 13 NO
A2
CONTACTOR
MODULE
CURRENT
SET POINT
DIAL
TRIP
INDICATOR
WINDOW
2
T1
4
T2
6
T3
14
NO
A2
RESET
OVERLOAD
MODULE
H
95
NC
96
E
T
E
S
98
NO
97
2
T1
4
T2
6
T3
(39) proportional temperature controller – (opt)
A proportional temperature controller is provided with Air Control options GF, GG, GH, GK, GM, or GN (Digits 20 & 21) and factory installed in the electrical section. The controller compares the mixed air temperature set point and the mixed air temperature from the Proportional Temperature Controller Sensor. The controller sends a 2-10 Vdc signal to the modulating damper actuator in order to maintain the set point. The controller includes a set point dial that must be field set to the desired mixed air temperature (typically 55°F).
5-594.6
27
options
figure 28.1 - proportional temperature controller
A350 P
VOLTS
2 4 6 8 10
ON
4 8 12 16 25
MILLIAMPS
JOHNSON
CONTROLS
Set Point
Dial
(40) Warm-up stat – (opt)
A warm-up stat is provided with Air Control options GK, GM, or
GN (Digits 20 & 21) and factory installed in the electrical section with the sensor in the return air stream. The warm-up thermostat monitors the return air temperature to the unit and prevents the fresh air dampers from opening until the temperature of the return air has reached the desired set point (typically 65°F or 5°F below the room temperature).
(41) Blower supply power terminal strip – (std)
The blower supply power terminal strip is located in the electrical section. The terminal strip is labeled to match the electrical wiring diagram provided with the unit. Supply power labeling ranges from terminal numbers 80 to 99. All field wiring connections should be made to the bottom side of the terminals to prevent miswiring by modifying the factory wiring which is made to the top of the terminal strip.
(42) service switches – (opt)
The service switches are factory installed in the electrical section. The service switches allow for service personnel to independently test operation of the damper, blower, and furnace without using jumper wires. The switches override the remote monitoring panel and/or thermostats to energize each component directly. All switches need to be reset to the “OFF” position after testing otherwise the components will remain energized.
figure 28.2 - service switches
(43) electronic modulating gas valve – (opt)
An electronic modulating gas valve is provided factory installed in the duct furnace gas train when the unit is equipped with
Electronic Modulating Gas Controls (Digit 12 = 4, 5, 6, 7, or 8).
The gas valve modulates the firing rate between 40% to 100% full fire based on the input signal from the Electronic Modulation
Amplifier or Signal Conditioner. For additional information, refer to Control Operating Sequence.
(44) electronic modulation amplifier – (opt)
An electronic modulation amplifier is provided factory installed in the duct furnace electrical junction box when the unit is equipped with Electronic Modulating Gas Controls (Digit 12 = 4 or
5). The amplifier processes the thermostat temperature and set point signals to modulate the firing rate between 40% to 100% full fire. For additional information, refer to Control Operating
Sequence.
(45) air flow proving switch – (opt)
The air flow proving switch is factory installed in the duct furnace electrical junction box. The air flow proving switch monitors the pressure differential between the duct furnace and the atmosphere. The purpose of the air flow proving switch is to cut power to the gas controls if a positive pressure is not measured by the switch. This could be caused by a lack of air movement through the heat exchanger.
NOTE: The air flow proving switch will prevent any heat exchanger warm-up because the gas controls can not be energized until air flow is proven.
setting the air flow proving switch
The range of the air flow proving switch is adjustable between 0.17" to 5.0" W.C.
1. Set the thermostat so that there is a call for heat. This should fire the burner and the blower should start.
2. Turn the set screw of the pressure switch clockwise until it stops. This will set the pressure at 5.0" W.C.
3. Turn the screw counter-clockwise until the gas controls light and then one additional full turn (This is approximately 0.25''
W.C.). This will allow for dirty filters or any other slight static pressure increases in the system.
(46) High limit switch
Automatic – (STD)
The automatic reset high limit switch is factory installed in the duct furnace electrical junction box. If the limit temperature is exceeded, the gas controls are de-energized until the switch is cooled.
Manual – (OPT)
The manual reset high limit switch is factory installed in place of the standard automatic reset high limit switch located in the duct furnace electrical junction box. In case of a failure of the blower motor, blockage of the inlet air, etc., the manual reset switch prevents the unit from cycling on the high limit. If the limit temperature is exceeded, a service person must inspect the unit for the cause of the high discharge temperature, take corrective action, and then reset the switch.
28
5-594.6
options
(47) main gas valve – (std)
The main gas valve is factory installed in the duct furnace gas train. The main gas valve provides the pilot, regulator, main gas, and manual shutoff functions. For additional information, see the supplier literature included with the unit.
(48) supply air fire stat – (opt)
The supply air fire stat is factory installed in the duct furnace electrical junction box with the sensor in the discharge air stream. In case of elevated temperatures in the supply air stream, the manual reset switch shuts down the entire unit. If the limit temperature is exceeded, a service person must inspect the unit for the cause of the high discharge temperature, take corrective action, and then reset the switch.
(49) Burner Box – (std)
The burner box is located in the duct furnace section and contains the burner and pilot assembly. The burner box includes an access panel for removal of the burner for inspection and servicing.
(not shown) circuit analyzer – (opt)
The circuit analyzer is factory installed on the door of the electrical section. The circuit analyzer is used to quickly assist service personnel in troubleshooting by monitoring the unit firing sequence and vital operating steps. Lights will come on as a point of electrical operation is passed and proven. If any light is not lit, that is the point where failure occurred.
figure 29.1 - circuit analyzer
Circuit analyzer tagging will vary based on the unit ordered.
Circuit analyzer shown is for reference only.
5-594.6
29
general performance data
table 30.1 - general performance data - models With Blower
model size (digits 4-6)
Btu/Hr input
➀
Btu/Hr output
➀
Blower style (digit 16 letter)
max. temp. rise (°f)
min. temp. rise (°f)
max. cfm
min. cfm
➁
75 100 125 150 175
75,000 75,000 100,000 100,000 125,000 125,000 150,000 150,000 175,000 175,000
60,000 60,000 80,000 80,000 100,000 100,000 120,000 120,000 140,000 140,000
A or B C or D
100 100
C or D E or F
100 85
C or D
100
E or F
100
C or D E or F
100 100
C or D E or F
100 100
28 20
1980 2778
556 556
21
3450
741
20
3704
875
27
3450
926
20
4630
926
33
3350
1111
20
5556
1111
39
3350
1296
23
5556
1296
model size (digits 4-6)
Btu/Hr input
➀
Btu/Hr output
➀
Blower style (digit 16 letter)
max. temp. rise (°f)
min. temp. rise (°f)
max. cfm
min. cfm
➁
model size (digits 4-6)
Btu/Hr input
➀
Btu/Hr output
➀
Blower style (digit 16 letter)
max. temp. rise (°f)
min. temp. rise (°f)
max. cfm
min. cfm
➁
200 225 250
200,000 200,000 200,000 225,000 225,000 225,000 250,000 250,000 250,000
160,000 160,000 160,000 180,000 180,000 180,000 200,000 200,000 200,000
C or D E or F
100 85
G or H C or D
85 100
E or F
95
G or H
95
E or F
100
G or H
100
I, J, or K
96
44 28
3400 5250
1481 1750
23
6500
1750
49
3400
1667
32
5250
1750
26
6500
1750
31
6000
1852
26
7250
1852
20
9259
1925
300 350 400
300,000 300,000 300,000 350,000 350,000 350,000 400,000 400,000 400,000
240,000 240,000 240,000 280,000 280,000 280,000 320,000 320,000 320,000
E or F G or H I, J, or K E or F G or H I, J, or K E or F G or H I, J, or K
100 100
37 31
6000 7250
2222 2222
100
20
100
45
11111 5700
2222 2593
100
37
100
22
7000 12000
2593 2593
100
52
100
42
5700 7000
2963 2963
100
25
12000
2963
model size (digits 4-6)
Btu/Hr input ➀
Btu/Hr output ➀
Blower style (digit 16 letter)
max. temp. rise (°f)
min. temp. rise (°f)
max. cfm
min. cfm ➁
500 600 700
500,000 500,000 500,000 600,000 600,000 600,000 700,000 700,000 700,000
400,000 400,000 400,000 480,000 480,000 480,000 560,000 560,000 560,000
G or H I, J, or K
120 120
L
120
G or H I, J, or K
120 120
L
120
G or H I, J, or K
120 120
L
120
53 40
7000 9259
3086 3086
40
9259
3086
63
7000
3704
40
11111
3704
40
11111
3704
76
6850
4321
40
12963
4321
40
12963
4321
model size (digits 4-6)
Btu/Hr input ➀
Btu/Hr output ➀
Blower style (digit 16 letter)
max. temp. rise (°f)
min. temp. rise (°f)
max. cfm
min. cfm ➁
800 840 960
800,000 800,000 800,000 1,050,000 1,050,000 1,200,000 1,200,000
640,000 640,000 640,000 840,000 840,000 960,000 960,000
G or H I, J, or K
120 120
L
120
I, J, or K
120
L
120
I, J, or K
120
L
120
87
6850
4938
46
13000
4938
41
14500
4938
60
13000
6481
60
13000
6481
68
13000
7407
63
14000
7407
➀
Ratings are shown for elevations up to 2000 ft. For higher elevations the input rating should be reduced at the rate of 4% for each 1000 feet above sea level.
For Canada, in elevations between 2000 and 4500 feet, the unit must be derated to 90% of the rating listed above.
➁
For Variable Air Movement Applications, see page 20.
30
5-594.6
general performance data
table 31.1 - air temperature rise
Btu/Hr
➀
input output 20 max
25 30 35 40 air temperature rise through unit (°f)
45 50 55 60 cfm
65 70 75 80 85 90 95 100 min
➁
75,000 60,000 2778 2222 1852 1587 1389 1235 1111 1010 926 855 794 741 694 654 617 585 556
100,000 80,000 3704 2963 2469 2116 1852 1646 1481 1347 1235 1140 1058 988 926 871 823 780 741
125,000 100,000 4630 3704 3086 2646 2315 2058 1852 1684 1543 1425 1323 1235 1157 1089 1029 975 926
150,000 120,000 5556 4444 3704 3175 2778 2469 2222 2020 1852 1709 1587 1481 1389 1307 1235 1170 1111
175,000 140,000 - 5185 4321 3704 3241 2881 2593 2357 2160 1994 1852 1728 1620 1525 1440 1365 1296
200,000 160,000 - 5926 4938 4233 3704 3292 2963 2694 2469 2279 2116 1975 1852 1743 1646 1559 1481
225,000 180,000 - 6667 5556 4762 4167 3704 3333 3030 2778 2564 2381 2222 2083 1961 1852 1754 1667
250,000 200,000 9259 7407 6173 5291 4630 4115 3704 3367 3086 2849 2646 2469 2315 2179 2058 1949 1852
300,000 240,000 11111 8889 7407 6349 5556 4938 4444 4040 3704 3419 3175 2963 2778 2614 2469 2339 2222
350,000 280,000 - 10370 8642 7407 6481 5761 5185 4714 4321 3989 3704 3457 3241 3050 2881 2729 2593
400,000 320,000 - 11852 9877 8466 7407 6584 5926 5387 4938 4558 4233 3951 3704 3486 3292 3119 2963
in
➀
input output 40 max
45 50 55 60 air temperature rise through unit (°f)
65 70 75 80 cfm
85 90 95 100 105 110 115 120 min
➁
500,000 400,000 9259 8230 7407 6734 6173 5698 5291 4938 4630 4357 4115 3899 3704 3527 3367 3221 3086
600,000 480,000 11111 9877 8889 8081 7407 6838 6349 5926 5556 5229 4938 4678 4444 4233 4040 3865 3704
700,000 560,000 12963 11523 10370 9428 8642 7977 7407 6914 6481 6100 5761 5458 5185 4938 4714 4509 4321
800,000 640,000 14500 13000 11852 10774 9877 9117 8466 7901 7407 6972 6584 6238 5926 5644 5387 5153 4938
1,050,000 840,000
-
1,200,000 960,000
-
-
-
-
-
-
-
12963 11966 11111 10370 9722 9150 8642 8187 7778 7407 7071 6763 6481
- 13675 12698 11852 11111 10458 9877 9357 8889 8466 8081 7729 7407
➀
Ratings are shown for elevations up to 2000 ft. For higher elevations the input rating should be reduced at the rate of 4% for each 1000 feet above sea level.
For Canada, in elevations between 2000 and 4500 feet, the unit must be derated to 90% of the rating listed above.
➁
For Variable Air Movement Applications, see page 20.
air temperature limits
The maximum allowable discharge air temperature is 150°F. The maximum allowable air temperature rise per furnace for Low Air
Temperature Rise Units is 60°F. All system units are designed for a maximum allowable total static pressure of 3.0" W.C.
5-594.6
31
unit selection
selection procedure
In order to properly select an indirect-fired heating, ventilating, cooling, or make-up air unit, it is necessary to have the following basic information.
1. required air handling capacity (cfm).
The air capacity of the unit is usually determined by the ventilation air requirements, exhaust load of the building, infiltration losses, or the air turns/changes of the space.
2. outdoor and indoor design temperature.
The outdoor design temperature is determined by using the ASHRAE Guide design temperatures for the city where the equipment is to be installed. For heating and ventilating units, the desired room temperature would be used as the indoor design temperature. In the case of 100% make-up air units, the discharge air temperature should be at least equal to the temperature of the air being exhausted.
3. required heating output capacity (Btu/Hr).
The heating output capacity of the unit is determined by using the formula:
BTU/HR = CFM x Temp. Rise (°F) x 1.08
4. external static pressure to unit.
The external static pressure (E.S.P.) is determined using the ASHRAE Guide for duct losses, or may be provided by the design engineer.
5. unit configuration with options and accessories (filters or dampers).
The unit configuration is determined by the location where the unit is to be installed. The critical options and accessories are those that add internal static pressure
(I.S.P.) to the unit. Once these items are determined, the pressure drop curves would be used to calculate the total pressure drop (T.S.P.)
Total Static Pressure = Internal + External Static Pressure
6. Heat exchanger material.
The heat exchanger type is determined by the application.
The standard heat exchanger material is aluminized steel. A 409 stainless steel heat exchanger and burner is recommended when the unit is installed downstream of a cooling coil or evaporative cooler, and when the combined entering/return air to the unit is below 40°F.
7. type of fuel.
Either natural or propane gas determined by the design engineer.
8. gas control staging method.
Either single stage, two stage, mechanical modulation, or electronic modulation determined by the design engineer.
9. main power supply voltage to unit.
10. altitude at which unit is to be installed.
With this information a basic unit can be selected as shown in the following example.
selection example conditions
Select an indirect-fired, 100% make-up air unit to meet the following conditions:
1. CFM at sea level = 6,000 cfm
2. Outdoor design temp. = 10°F
Indoor design temp. = 70°F
3. Heating output capacity =
5000 cfm x (70°F -10°F) x 1.08 = 324,000 Btu/Hr
4. External Static Pressure = 0.65
5. The separated combustion unit with the controls on the
Right Hand Side is to be provided with the following:
2" Permanent Filters, and Fresh Air Damper.
6. Heat exchanger and burner = 409 Stainless Steel.
7. Gas Type = Natural
8. Gas Controls = Electronic Modulating with Duct Sensing.
9. Supply Voltage: 460V/60Hz/3Ph
10. Altitude: 1000 feet
With the information listed above, the basic model, using the
Model Nomenclature shown on page 59, can be selected as shown in the following example:
1. determine the model configuration and venting:
The Model Configuration is determined by the required sections of the unit (Blower only) and the venting style
(separated combustion) that are obtained from item #5.
Using the Model Nomenclature on page 59, the Model
Configuration and Venting = DBS.
2. determine the furnace input rating (mBH):
Using the Heating output capacity, the Furnace Input
Rating is determined from Table 30.1. The closest model to 324,000 Btu/Hr output has an Btu/Hr Input rating of
400,000 Btu/Hr so the Furnace Input Rating = 400.
3. determine the Heat exchanger/Burner/drip pan material:
From item #2 in selection example conditions, the Heat
Exchanger and Burner required are 409 Stainless Steel.
Because the Drip Pan material is not specified, the standard Aluminized Steel drip pan will be used. Thus, the
Heat Exchanger/Burner/Drip Pan Material = S.
4. determine the development sequence:
From item #8 in selection example conditions, the modulating gas controls result in the Development
Sequence = M.
5. determine the access side:
From item #5 in selection example conditions, the Right
Hand Gas controls result in the Access Side = R.
6. determine the air temperature rise:
From item #2 in selection example conditions, the Air
Temperature Rise is 60°F (70°F - 10°F). However, using the output capacity of the IFS400 @ 5000 cfm, the resulting temperature rise is 59.3°F (320,000/(5000 x 1.08)). Since the rise is less than 60°F, the Air Temperature Rise = L.
7. determine the gas type:
From item #7 in selection example conditions, the Natural
Gas results in the Gas Type = N.
8. determine the gas valve:
From item #8 in selection example conditions, the Electronic
Modulating with Duct Sensing results in the Gas Valve = 4.
9. determine the additional safety switches:
Since no additional safety switches were specified, the
Additional Safety Switches = 0.
32
5-594.6
unit selection
10. determine the supply voltage:
From item #9 listed above, the 460V/60Hz/3Ph results in the Supply Voltage = F.
11. determine the transformer:
For DBS/DCS models, a 75VA Transformer is required.
Thus, the Transformer = 2.
12. determine the Blower size and Bearing type:
Using Table 30.1, the Model Size 400 has three available blowers for which the performance table are shown on page
36. Since all of the blower performance curves can provide the required 5000 cfm, the total static pressure for each blower performance curve must be determined.
A) The Pressure Drop of the filters is determined by entering the bottom of the curve at the desired cfm and reading up the graph until the cfm intersects the desired item. For this example, in Table 34.1 the 2'' Permanent Filter line is used. At the point of intersection, read the table to get the pressure drop, in inches of water column for the filters.
For this example, the pressure drop is 0.06'' W.C. As a result:
For the Model Size 400 with Digit 16 = E,F,G, or H:
2'' Permanent Filters: 0.06" W.C.
Internal Static Pressure Drop 0.06" W.C.
The Total Static Pressure for the system is determined by
Internal Static + External Static = Total Static Pressure
For this example 0.06'' + 0.65'' = 0.71'' W.C. T.S.P.
From page 34, for the Model Size 400 with Digit 16 = I, J, or K:
2'' Permanent Filters:
Internal Static Pressure Drop
0.04'' W.C.
0.04'' W.C.
The Total Static Pressure for the system is determined by
Internal Static + External Static = Total Static Pressure
For this example 0.04'' + 0.65'' = 0.69'' W.C. T.S.P.
B) Using the total static pressure (T.S.P.) calculated in step
12a, use blower performance tables for the Model Size
400 (Tables 36.1).
Using Table 36.1, enter the table at the required
5000 cfm for E.F blowers, and follow the cfm line to the right until it intersects with the T.S.P. line of 0.75'' W.C. which is shown at the top of the table. At the point of intersection of these two columns, read the required horsepower and blower rpm. repeat the process for 1.00”
T.S.P. and literate to determine the BHP and rpm for
0.89” W.C. For this example the horsepower is 5 and the blower rpm is 1280.
Following this procedure for G, H blowers (Using 5000 cfm and 0.71'' W.C. T.S.P), the horsepower is 3 hp and
870 rpm. Following this procedure for the I, J, K blowers
(Using 5000 cfm and 0.69'' W.C. T.S.P), the horsepower is 2 hp and 642 rpm. Although I, J, K blower results in a
2 hp motor, this blower requires the use of the extended cabinet length. As a result, for purposes of this selection example G, H blowers will be used.
Since the Bearing Type was not specified, the standard spider bearings will be used. Thus, using Table 36.1 with spider bearings, the Blower Size and Bearing Type = G.
13. determine the motor Horsepower:
The motor horsepower determined in step 12 was a 3 Hp.
Since the supply voltage is 460V/60Hz/3Ph, a motor starter will need to be provided either with the unit or by others. For purposes of this selection, a motor starter by others will be used so the Motor Horsepower = G.
14. determine the motor type:
The motor type was not specified so for purposes of this selection the standard open drip proof motor will be used so the Motor Type = 1.
15. determine the sheave arrangement:
To establish the Sheave Arrangement, the motor frame size must be determined. The Motor Data tables on pages 42 to
46 contain the motor frame size.
A) Using the Supply Voltage (460V/60Hz/3Ph), enter the correct Motor Data table (Table 45.1). Using Model
Nomenclature Digits 17 and 18 (G1) determined in steps
13 and 14, find the motor frame size (182T).
B) Using the Motor Frame Size enter the Sheave Selection table for the selected blower determined by step 13
(Table 38.2). Using the rpm calculated in step 12
(870 rpm), select the sheave range that contains the required rpm. Find the intersection with the Motor
Frame Size to determine the Sheave Selection. For this example with a 182T frame with 870 rpm, from Table
39.2, the Sheave Arrangement = I.
16. determine the air control:
The Air Control option is selected based on the required damper configuration. The available damper selections are detailed on page 24. For this selection, a 100% fresh air unit without return air was required so the Air Control = DA.
17. determine the evaporative cooler:
An evaporative cooler is not available, so for purposes of this selection the Evaporative Cooler = 0.
18. determine the cooling coil:
A cooling coil cabinet was not specified so for purposes of this selection the Cooling Coil = 0.
Based on the previous steps, the model number for the base unit is the following:
DBS400SMRLN40F2GG1IDA00
Once the basic model has been determined, the additional options and accessories outlined on page 21 to 29 can be added to the unit.
5-594.6
33
option & accessory pressure drop data
table 34.1 - option & accessory pressure drop tables (in ''W.c.)
➀
all units Weatherproof unit only
unit size
75
100/125
150/175
200/225
250/300
500/600
350/400
700/800
840/960 digit 16 a,B,c,d c,d,e,f c,d,e,f c,d,e,f,g,H e,f,g,H i,J,K,l e,f,g,H i,J,K,l cfm
2000 0.03
2500 0.04
3000 0.05
3500 0.07
4000 0.08
4500 0.10
5500 0.14
6500 0.19
7250 0.23
1925 0.02
3000 0.03
4000 0.05
5000 0.08
6000 0.11
7000 0.15
8000 0.19
9000 0.24
10400 0.32
3500 0.08
4000 0.11
4500 0.13
5000 0.16
5200 0.17
5556 0.19
1481 0.01
2000 0.01
2500 0.02
3000 0.03
3500 0.03
4000 0.05
4500 0.06
5000 0.07
5500 0.09
6000 0.11
6500 0.13
1852 0.03
556 0.01
600 0.01
800 0.02
1000 0.02
1200 0.03
1400 0.03
1600 0.04
1800 0.04
2000 0.05
2300 0.06
2778 0.08
741 0.01
1000 0.02
1500 0.03
2000 0.05
2500 0.07
3000 0.09
3500 0.11
4000 0.14
4500 0.17
4630 0.17
1111 0.01
1500 0.02
2000 0.03
2500 0.05
3000 0.06
11111 0.36
2593 0.02
3000 0.02
3500 0.03
4000 0.03
4500 0.04
5000 0.05
5500 0.06
6000 0.06
6500 0.07
7000 0.08
2593 0.02
3000 0.02
4000 0.03
5000 0.04
6000 0.06
7000 0.07
8000 0.09
9000 0.11
10000 0.13
11050 0.15
12000 0.18
13000 0.20
0.32
0.01
0.03
0.05
0.08
0.11
0.15
0.20
0.25
0.33
0.03
0.04
0.06
0.08
0.10
0.13
0.19
0.26
0.04
0.05
0.06
0.08
0.10
0.11
0.14
0.16
0.18
0.02
0.11
0.13
0.16
0.19
0.21
0.23
0.02
0.02
0.11
0.13
0.16
0.20
0.21
0.02
0.03
0.04
0.06
0.08
0.05
0.07
0.09
0.02
0.02
0.04
0.06
0.08
0.01
0.01
0.01
0.02
0.02
0.03
0.04
0.04
0.08
0.10
0.11
0.01
0.02
0.03
0.04
0.05
0.38
0.02
0.02
0.03
0.04
0.05
0.06
0.07
0.07
0.09
0.12
0.14
0.17
0.20
0.24
0.51
0.03
0.05
0.09
0.12
0.16
0.21
0.27
0.33
0.42
0.06
0.09
0.11
0.15
0.18
0.22
0.31
0.42
0.06
0.08
0.10
0.12
0.15
0.18
0.21
0.25
0.28
0.05
0.18
0.23
0.27
0.32
0.34
0.38
0.03
0.04
0.19
0.24
0.30
0.37
0.39
0.04
0.05
0.08
0.11
0.15
0.11
0.13
0.16
0.02
0.04
0.07
0.10
0.14
0.03
0.03
0.04
0.05
0.06
0.07
0.09
0.10
0.17
0.19
0.22
0.02
0.03
0.04
0.06
0.08
0.47
0.04
0.05
0.06
0.08
0.10
0.12
0.14
0.11
0.13
0.16
0.19
0.23
0.27
0.31
0.41
0.03
0.05
0.08
0.11
0.15
0.19
0.24
0.30
0.38
0.05
0.07
0.10
0.12
0.15
0.18
0.25
0.34
0.05
0.07
0.09
0.11
0.13
0.16
0.19
0.22
0.25
0.05
0.14
0.18
0.21
0.25
0.27
0.30
0.03
0.04
0.13
0.16
0.20
0.25
0.26
0.03
0.04
0.06
0.09
0.11
0.10
0.11
0.15
0.02
0.03
0.05
0.07
0.10
0.02
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.14
0.16
0.18
0.02
0.02
0.04
0.05
0.07
0.43
0.04
0.05
0.06
0.07
0.09
0.10
0.12
0.10
0.12
0.15
0.18
0.22
0.26
0.30
0.12
0.16
0.23
0.01
0.02
0.04
0.08
0.12
0.17
0.23
0.30
0.01
0.01
0.02
0.03
0.04
0.06
0.08
0.10
0.30
0.37
0.51
0.06
0.08
0.14
0.21
0.30
0.40
0.51
0.63
0.05
0.05
0.08
0.11
0.14
0.17
0.21
0.25
0.01
0.03
0.04
0.07
0.10
0.14
0.18
0.23
0.28
0.30 0.63 0.60
5200 Max CFM for Evap
0.02
0.03
0.05
0.08
0.10
0.13
0.17
0.21
0.25
0.30
0.07
0.10
0.15
0.20
0.27
0.34
0.41
0.50
0.59
0.08
0.12
0.17
0.22
0.27
0.33
0.40
0.47
0.55
0.63
0.03
0.05
0.09
0.14
0.20
0.27
0.35
0.45
0.55
0.04
0.07
0.10
0.15
0.20
0.27
0.34
0.42
0.50
0.60
6000 Max CFM for Evap
0.02 0.10 0.05
0.03
0.04
0.06
0.09
0.11
0.15
0.22
0.30
0.11
0.15
0.19
0.24
0.29
0.35
0.48
0.63
6500 Max CFM for Evap
0.01 0.05 0.02
0.03
0.04
0.10
0.15
0.05
0.09
0.07
0.10
0.14
0.18
0.23
0.30
0.20
0.26
0.34
0.41
0.50
0.64
0.14
0.20
0.27
0.35
0.45
0.60
0.06
0.09
0.13
0.17
0.23
0.29
0.43
0.60
0.15
0.17
0.20
0.02
0.02
0.04
0.06
0.09
10400 Max CFM for Evap
0.03 0.10 0.05
0.04
0.05
0.13
0.16
0.07
0.10
0.06
0.08
0.10
0.12
0.19
0.23
0.27
0.31
0.13
0.16
0.20
0.24
0.12
0.16
0.20
0.36
0.40
0.45
0.08
0.09
0.14
0.19
0.25
0.31
0.38
0.46
0.29
0.34
0.39
0.03
0.04
0.08
0.12
0.18
0.24
0.32
0.40
0.25
0.31
0.54
0.64
0.50
0.61
11050 Max CFM for Evap
1.04
1.24
0.64
0.74
0.85
0.11
0.14
0.22
0.31
0.42
0.16
0.20
0.25
0.32
0.39
0.47
0.55
0.55
0.70
0.86
0.08
0.15
0.23
0.34
0.46
0.61
0.77
0.95
1.23
0.17
0.24
0.32
0.41
0.52
0.64
0.91
1.23
0.27
0.36
0.47
0.60
0.73
0.89
1.05
1.23
0.15
0.61
0.77
0.95
1.15
1.23
0.12
0.19
0.73
0.97
1.23
0.09
0.15
0.24
0.34
0.46
0.53
0.68
0.96
0.08
0.12
0.23
0.36
0.53
0.07
0.07
0.12
0.17
0.22
0.29
0.36
0.44
0.23
0.31
0.45
0.02
0.04
0.08
0.15
0.23
0.34
0.46
0.60
0.02
0.02
0.04
0.06
0.08
0.11
0.15
0.19
0.37
0.07
0.12
0.16
0.22
0.28
0.35
0.42
0.51
0.64
0.08
0.09
0.12
0.14
0.16
0.19
0.25
0.31
0.08
0.10
0.14
0.18
0.22
0.27
0.32
0.38
0.45
0.07
0.14
0.18
0.22
0.27
0.29
0.33
0.03
0.05
0.16
0.19
0.22
0.25
0.26
0.02
0.03
0.05
0.08
0.10
0.08
0.11
0.15
0.03
0.05
0.07
0.10
0.13
0.01
0.01
0.02
0.03
0.03
0.04
0.06
0.07
0.17
0.20
0.23
0.03
0.04
0.07
0.11
0.17
0.71
0.03
0.04
0.05
0.07
0.09
0.11
0.14
0.23
0.30
0.38
0.48
0.58
0.69
0.81
0.27
0.02
0.04
0.08
0.12
0.18
0.25
0.33
0.42
0.57
0.02
0.03
0.04
0.06
0.08
0.10
0.15
0.21
0.04
0.06
0.09
0.11
0.14
0.18
0.21
0.26
0.30
0.02
0.10
0.13
0.17
0.21
0.23
0.26
0.02
0.03
0.11
0.15
0.19
0.25
0.26
0.02
0.02
0.04
0.05
0.07
0.06
0.08
0.12
0.00
0.01
0.02
0.04
0.07
0.00
0.00
0.01
0.01
0.02
0.03
0.04
0.05
0.10
0.12
0.14
0.02
0.03
0.05
0.07
0.10
0.66
0.02
0.03
0.04
0.05
0.06
0.07
0.09
0.14
0.19
0.24
0.30
0.36
0.43
0.51
0.23
0.02
0.04
0.07
0.11
0.16
0.21
0.28
0.35
0.47
0.02
0.03
0.04
0.06
0.07
0.09
0.13
0.18
0.02
0.04
0.05
0.06
0.08
0.10
0.12
0.14
0.16
0.02
0.05
0.06
0.08
0.10
0.11
0.13
0.01
0.01
0.05
0.07
0.09
0.11
0.11
0.01
0.01
0.02
0.02
0.04
0.03
0.04
0.06
0.01
0.01
0.02
0.03
0.04
0.00
0.01
0.01
0.01
0.01
0.02
0.02
0.03
0.04
0.04
0.05
0.01
0.01
0.01
0.02
0.04
0.53
0.01
0.01
0.01
0.01
0.02
0.02
0.03
0.05
0.08
0.10
0.14
0.17
0.21
0.26
➀
Accessory / Option static pressure losses are approximate values only. Please consult the Accuspec selection software for static pressure losses at other than listed CFM.
34
5-594.6
BloWer performance data air digit temp. unit size 16 rise cfm
table 35.1 - unit performance tables
➀ ➁
75 a,B
100°F / -
79°F / -
0.25 0.50 0.75 total static pressure, ''W.c.
.
1.00 1.25 1.50 2.00 2.50 3.00
BHp rpm BHp rpm BHp rpm BHp rpm BHp rpm BHp rpm BHp rpm BHp rpm BHp rpm
556 0.09 679 0.15 871 0.22 1031 0.29 1170 0.37 1296 0.45 1411 0.63 1617 0.81 1800 1.01 1968
700 0.14 747 0.21 924 0.29 1074 0.37 1206 0.46 1327 0.55 1438 0.75 1638 0.95 1818 1.17 1982
69°F / 800 0.18 801 0.26 966 0.35 1109 0.44 1237 0.54 1354 0.64 1462 0.84 1658 1.06 1832 1.30 1996
75
100/125 c,d
start 125
100/125
end 100 e,f
150/175 c,d
start 175
200/225 c,d
start 225 c,d
150/175 e,f
200/225 e,f
56°F / -
46°F / -
40°F / -
35°F / -
31°F / -
69°F / -
56°F / -
46°F / -
1000 0.29 917 0.39 1062 0.50 1192 0.60 1310 0.72 1419 0.83 1522 1.07 1709 1.32 1879
1200 0.45 1042 0.57 1171 0.69 1289 0.82 1397 0.94 1499 1.08 1595 1.35 1773 - -
1400 0.66 1173 0.80 1288 0.94 1395 1.08 1495 1.23 1589 1.38 1680 - - - -
1600 0.93 1308 1.09 1412 1.25 1509 1.42 1601
1800 1.28 1445 1.46 1539 - - - -
800
1000
-
-
-
-
0.15
0.20
795
822
0.21
0.28
960
975
- -
0.36 1112
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
1200 0.19 705 0.27 862 0.35 1003 0.44 1131 0.54 1250 0.65 1361
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
40°F / -
35°F / -
31°F / -
28°F / -
24°F / -
20°F / -
100°F / -
80°F/100°F
62°F/77°F
1400 0.27 770 36.00 912 0.45 1041 0.55 1161 0.66 1273 0.77 1377 1.00 1572 - - - -
1600 0.37 839 0.47 968 0.57 1087 0.68 1199 0.80 1304 0.92 1403 1.17 1589 1.44 1760 1.72 1920
1800 0.49 912 0.60 1030 0.72 1139 0.84 1244 0.96 1343 1.09 1437 1.36 1613 1.65 1777 1.94 1931
2000 0.65 987 0.77 1095 0.90 1197 1.03 1295 1.16 1388 1.30 1477 1.59 1645 1.89 1802 2.20 1950
2300 0.94 1104 1.08 1200 1.22 1292 1.37 1380 1.52 1465 1.67 1547 1.98 1703 2.31 1850 2.65 1990
2778 1.59 1296 1.75 1377 1.92 1456 2.09 1532 2.26 1606 2.44 1679 2.80 1818
741 - - 0.15 808 0.23 962 0.30 1093 0.38 1212 0.47 1320 0.60 1514
-
0.86
-
1686
-
1.07
-
1840
926 0.13 670 0.21 846 0.29 993 0.38 1121 0.47 1236 0.56 1342 0.77 1532 0.99 1702 1.22 1856
1200 0.22 758 0.31 916 0.41 1052 0.52 1173 0.62 1282 0.74 1384 0.97 1568 1.22 1733 1.48 1884
53°F/66°F 1400 0.30 828 0.41 975 0.53 1103 0.64 1218 0.76 1323 0.89 1422 1.15 1600 1.42 1762 1.70 1910
-
-
-
-
-
-
-
-
41°F/51°F
34°F/42°F
28°F/36°F
25°F/31°F
41°F/51°F
1800 0.55 982 0.69 1108 0.83 1220 0.98 1325 1.12 1422 1.27 1513 1.58 1681 1.90 1834 2.23 1976
2200 0.93 1145 1.10 1254 1.27 1354 1.44 1449 1.61 1537 1.79 1621 2.15 1778 2.52 1923 2.90 2057
2600 1.45 1315 1.65 1410 1.85 1500 2.05 1585 2.25 1666 2.46 1744 1.35 1638
3000 2.16 1489 2.39 1573 2.61 1654 2.84 1731 - - - - - -
1800 0.28 497 0.41 622 0.56 735 0.72 837 - - - - - -
-
-
-
-
-
-
-
-
-
-
-
-
34°F/42°F
28°F/36°F
25°F/31°F
22°F/27°F
2200 0.43 553 0.58 662 0.75 762 0.93 855 1.12 942 1.33 1025
2600 0.63 614 0.81 710 1.00 800 1.20 885 1.41 965 1.63 1042
-
-
-
-
-
-
-
-
-
- -
-
3000 0.91 680 1.11 766 1.32 847 1.54 1731 1.77 997 2.01 1068 2.51 1202 3.04 1328 3.60 1446
3400 1.26 748 1.48 825 1.72 899 1.96 970 2.21 1038 2.47 1104 3.01 1229 3.58 1347 4.17 1459
20°F/25°F 3704 1.58 802 1.83 873 2.08 942 2.34 1008 2.60 1072 2.88 1135 3.45 1254 4.04 1367 4.67 1474
- / 23°F
- / 20°F
4100 2.09 873 2.35 938 2.63 1001 2.91 1062 3.20 1122 3.49 1180 4.10 1291 4.74 1398
4630 2.93 969 3.23 1028 3.53 1085 3.84 1140 4.16 1194 4.48 1247 - - - -
-
- -
-
100°F/117°F
86°F/100°F
1111 0.19 727 0.28 884 0.38 1023 0.48 1148 0.59 1262 0.70 1369 0.94 1563 1.21 1738 1.48 1899
1296 0.27 793 0.37 937 0.47 1066 0.59 1184 0.71 1293 0.83 1395 1.09 1582 1.37 1752 1.66 1909
79°F/93°F 1400 0.32 832 0.42 970 0.54 1093 0.66 1208 0.78 1313 0.91 1412 1.18 1596 1.47 1763 1.78 1917
62°F/72°F
51°F/59°F
43°F/50°F
37°F/43°F
86°F/100°F
1800 0.59 994 0.72 1109 0.86 1216 1.00 1316 1.15 1410 1.30 1500 1.62 1667 1.95 1823 2.29 1967
2200 1.00 1166 1.16 1264 1.32 1356 1.49 1444 1.66 1529 1.84 1610 2.20 1762 2.57 1906 2.96 2041
2600 1.58 1344 1.76 1429 1.95 1510 2.14 1589 2.34 1664 2.54 1737 2.95 1877
3000 2.35 1526 2.57 1600 2.78 1673 3.00 1743 - - - - - -
1296 - - 0.25 609 0.37 734 - - - - - - - -
-
-
-
-
-
-
-
-
-
-
-
-
79°F/93°F
62°F/72°F
51°F/59°F
43°F/50°F
1400 0.17 474 0.28 615 0.40 737 - - - -
1800 0.28 526 0.41 650 0.55 760 0.70 859 0.85 952
-
-
-
-
-
-
-
-
-
-
-
-
-
- -
-
2200 0.44 588 0.59 697 0.75 796 0.91 887 1.09 972 1.27 1052 1.67 1201 - - - -
2600 0.67 657 0.83 753 1.01 842 1.19 925 1.39 1004 1.59 1078 2.02 1218 2.47 1348 2.96 1469
37°F/43°F 3000 0.96 729 1.15 815 1.35 895 1.55 972 1.76 1044 1.98 1114 2.45 1245 2.94 1368 3.45 1483
33°F/38°F
29°F/34°F
26°F/31°F
24°F/28°F
21°F/25°F
3400 1.35 804 1.55 881 1.77 955 2.00 1025 2.23 1092 2.47 1157 2.96 1280 3.49 1396 4.03 1505
3800 1.82 880 2.05 951 2.29 1018 2.53 1083 2.79 1146 3.04 1206 3.58 1322 4.14 1431 4.72 1535
4200 2.40 959 2.66 1023 2.92 1085 3.18 1145 3.45 1204 3.73 1260 4.30 1369 4.90 1472
4700 3.30 1058 3.58 1116 3.87 1172 4.16 1227 4.46 1281 4.76 1333 - - - -
5200 4.40 1158 4.71 1212 - - - - - - - - - - - -
-
-
-
-
-
-
100°F/113°F
89°F/100°F
1481 0.36 871 0.48 1016 0.60 1144 0.73 1259 0.85 1366 0.99 1465 1.26 1646 1.54 1808 1.84 1958
1667 0.48 943 0.61 1078 0.75 1198 0.88 1309 1.03 1411 1.17 1507 1.47 1682 1.77 1842 2.09 1988
85°F/95°F
74°F/83°F
66°F/74°F
1750 0.54 975 0.68 1106 0.82 1224 0.96 1332 1.11 1433 1.26 1527 1.57 1700 1.88 1857 2.21 2003
2000 0.76 1077 0.92 1197 1.08 1306 1.24 1407 1.40 1502 1.57 1592 1.91 1758 2.26 1910 2.62 2051
2250 1.04 1181 1.21 1291 1.39 1393 1.57 1488 1.75 1577 1.94 1663 2.31 1822 2.69 1969 - -
59°F/67°F
54°F/61°F
49°F/56°F
85°F/95°F
2500 1.38 1288 1.57 1389 1.77 1484 1.97 1573 2.17 1658 2.37 1739 2.78 1892
2750 1.79 1396 2.00 1490 2.22 1579 2.44 1663 2.66 1743 2.88 1820 - -
-
-
-
-
-
- -
-
3000 2.28 1506 2.51 1593 2.75 1677 2.98 1756 - - - - - - - - - -
1750 0.29 594 0.43 723 0.58 838 0.75 944 0.94 1042 1.14 1134 1.58 1303 2.07 1458 2.60 1600
74°F/83°F 2000 0.40 642 0.54 759 0.71 866 0.88 966 1.08 1058 1.28 1146 1.74 1309 2.23 1458 2.78 1595
200/225 g,H
59°F/67°F
49°F/56°F
42°F/48°F
37°F/42°F
33°F/37°F
2500 0.68 746 0.85 845 1.04 938 1.23 1025 1.45 1108 1.67 1188 2.15 1337 2.67 1475 3.24 1604
3000 1.09 857 1.29 942 1.50 1024 1.72 1101 1.95 1176 2.19 1248 2.71 1384 3.27 1511 3.86 1632
3500 1.66 972 1.88 1047 2.12 1119 2.36 1188 2.61 1255 2.88 1320 3.43 1455 4.03 1563
4000 2.40 1091 2.65 1157 2.91 1221 3.18 1284 3.46 1345 3.75 1404 4.35 1518 4.98 1628
4500 3.34 1211 3.62 1270 3.91 1329 4.21 1385 4.51 1441 4.82 1495 - - - -
-
-
-
-
-
-
30°F/33°F
85°F/95°F
74°F/83°F
59°F/67°F
5000 4.52 1332 4.82 1387 - -
1750 0.20 425 0.33 546 0.48 653
-
-
-
-
-
-
-
-
-
-
-
-
2000 0.26 449 0.40 562 0.56 662 0.74 754 - - - -
2500 0.42 507 0.58 603 0.75 692 0.94 774 1.16 851 1.38 925
49°F/56°F 3000 0.65 571 0.83 654 1.02 732 1.23 807 1.45 877 1.69 944
-
-
-
-
-
-
-
-
2.21 1071
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
42°F/48°F
37°F/42°F
33°F/37°F
30°F/33°F
3500 0.97 639 1.17 713 1.38 782 1.60 850 1.84 914 2.10 975 2.64 1093 3.23 1202 3.86 1307
4000 1.38 710 1.60 776 1.83 839 2.08 899 2.34 958 2.60 1014 3.18 1123 3.80 1226 4.46 1324
4500 1.90 783 2.14 842 2.40 899 2.66 955 2.94 1008 3.23 1061 3.84 1161 4.48 1258
5000 2.54 858 2.81 911 3.08 963 3.37 1014 3.67 1064 3.98 1112 4.62 1206 - -
-
-
-
-
27°F/30°F
25°F/28°F
5500 3.32 933 3.61 982 3.91 1030 4.22 1077 4.54 1123 4.87 1168
6000 4.25 1009 4.57 1054 4.89 1099 - - - - - -
-
-
-
-
-
-
-
-
-
-
-
-
➀
Total static pressure should include external static pressure and accessory / option static pressure from Table 34.1. Unit internal resistance has been included in the unit performance tables.
➁
Brake Horsepower and RPM values are approximate values only. Please consult the AccuSpec selection software for values at other than listed CFM / static pressures.
5-594.6
35
BloWer performance data
table 36.1 - unit performance tables
➀ ➁
air digit temp. unit size 16 rise cfm
250/300 e,f start 300
100°F / 120°F
83°F / 100°F
74°F / 89°F
0.25 0.50 0.75
BHp rpm BHp rpm BHp rpm BHp rpm BHp rpm BHp rpm BHp rpm BHp rpm BHp rpm
1852
m
0.26 532 0.39 665 0.54
2222 0.39 582 0.54 703 0.70
2500 0.51 625 0.68 736 0.85
782
810
836
total static pressure, ''W.c.
.
1.00
0.69
0.87
1.04
887
909
930
1.25
0.85
1.05
1.23
985
1.50
1.03
1000 1.24
1016 1.43
1074
1085
1099
2.00 2.50
1.39 1239 1.79 1387
1.64 1242 2.06 1385
1.85 1250 2.30 1389
3.00
2.21 1523
2.52 1517
2.78 1517
250/300 g,H start 300
62°F / 74°F
53°F / 63°F
46°F / 56°F
41°F / 49°F
37°F / 44°F
34°F / 40°F
100°F / 120°F
83°F / 100°F
74°F / 89°F
62°F / 74°F
53°F / 63°F
46°F / 56°F
41°F / 49°F
37°F / 44°F
34°F / 40°F
31°F / 37°F
28°F / 34°F
250/300
end 250
350/400 start 400 i, J, K
46°F / 56°F
37°F / 44°F
31°F / 37°F
26°F / 32°F
23°F / 28°F
20°F / 24°F
- / 22°F
e,f
- / 20°F
100°F / -
96°F / -
87°F / 100°F
74°F / 85°F
65°F / 74°F
58°F / 66°F
52°F / 59°F
350/400 start 400 g,H
350/400 i,J,K start 400
47°F / 54°F
100°F / -
87°F / 100°F
74°F / 85°F
65°F / 74°F
58°F / 66°F
52°F / 59°F
47°F / 54°F
43°F / 49°F
40°F / 46°F
100°F / -
87°F / 100°F
65°F / 74°F
52°F / 59°F
43°F / 49°F
37°F / 42°F
32°F / 37°F
29°F / 33°F
26°F / 30°F
24°F / 27°F
23°F / 26°F
3000 0.80 706 0.99 803 1.19 893
3500 1.19 793 1.41 878 1.64 959
4000 1.69 882 1.94 958 2.20 1032
4500 2.34 974 2.62 1043 2.90 1109
5000 3.14 1067 3.44 1130 3.76 1191
5500 4.11 1161 4.44 1219 4.78 1275
1852 - - 0.34 519 0.49 623
2222 0.28 424 0.43 537 0.61
2500 0.35 447 0.52 553 0.71
3000 0.53 492 0.72 588 0.93
3500 0.76 542 0.98 878 1.21
4000 1.07 594 1.31 673 1.57
4500 1.45 649 1.72 721 2.00
5000 1.92 706 2.22 771 2.52
5500 2.50 767 2.81 824 3.14
634
646
674
707
746
789
834
882
0.79
0.90
1.15
1.45
1.83
2.29
2.84
3.49
1.40 978
1.87 1036
2.46 1102
3.19 1174
4.08 1250
-
0.66
-
713
721
730
752
780
814
852
894
938
6000 3.16 822 3.52 878 3.87
6500 3.96 881 4.34 934 4.72
4000
5000
-
-
-
-
0.97 507 1.25
1.51 560 1.84
6000 1.94 559 2.29 620 2.66
7000 2.93 632 3.33 686 3.75
8000 4.24 707 4.69 755 5.16
9259 6.40 804 6.91 846 7.45
933
984
583
626
679
738
802
887
4.24
-
1.56
2.19
3.06
4.19
5.64
7.99
984
-
654
688
734
788
847
927
10000 7.97 862 8.52 901 9.09 939 9.67 977 10.27
11111 10.79 949 11.40 985 12.03 1020 12.66 1054 13.31
2593 0.61 668 0.80 781 1.01
2700 0.67 686 0.87 796 1.08
882
895
1.22
1.30
975
986
1.45
1.53
2963 0.85 730 1.06 834 1.28 928
3500 1.30 826 1.54 917 1.80 1002
4000 1.86 918 2.13 1000 2.42 1078
4500 2.57 1012 2.87 1087 3.18 1158
1.52
2.07
2.71
3.51
1015
1081
1151
1226
1.76
2.34
3.01
3.84
4.61
-
1.89
2.56
3.46
4.64
6.14
8.55
0.99
1.11
1.38
1.71
2.11
2.59
3.16
3.83
1.62
2.12
2.73
3.49
4.40
-
0.85
5000 3.44 1109 3.78 1177 4.12 1242
5500 4.50 1206 4.87 1269 - -
2593 0.43 479 0.62 585 0.84
2963 0.57 516 0.79 614 1.02
679
702
3500 0.85 574 1.09 662 1.35
4000 1.19 631 1.45 710 1.74
4500 1.61 690 1.91 762 2.22
5000 2.22 767 2.46 817 2.80
742
784
830
880
5500 2.77 813 3.12 874 3.49
6000 3.53 876 3.91 933 4.30
6500 4.42 939 4.82 992
2593 - - - -
-
0.77
2963
4000
-
-
-
-
-
1.07
-
533
0.89
1.37
5000 1.37 515 1.69 590 2.04
6000 2.20 588 2.58 654 2.97
933
987
-
561
571
609
658
715
4.47 1305
- -
1.09
1.28
1.63
2.04
2.55
3.15
764
782
815
853
895
940
3.87 989
4.70 1040
-
1.04
-
639
1.18
1.69
2.41
3.39
646
679
721
772
7000 3.34 665 3.77 723 4.22
8000 4.84 744 5.33 796 5.83
778
845
9000 6.75 824 7.29 871 7.85 917
10000 9.13 906 9.72 948 10.33 990
4.68
6.34
830
893
5.16
6.87
8.41 960 8.99
10.95 1030 11.58
11000 12.01 988 12.66 1027 13.32 1065 14.00 1103 14.68
11500 13.66 12.09 14.34 1067 - - - - -
4.25
-
-
1.34
1.49
2.03
2.79
3.82
4.84
-
1.35
1.56
1.93
2.36
2.89
3.52
800
806
824
848
878
912
950
991
1058 1.84
1109 2.36
1170 3.01
1236 3.79
1308 4.73
-
795
-
1.05
1.20
1.33
1.62
1.97
2.39
2.90
3.50
4.19
872
877
892
912
939
969
1004
1042
1133
1179
1234
1296
1364
-
870
2.31 1275 2.81 1406
2.88 1312 3.42 1435
3.58 1358 4.17 1474
4.41 1412
- -
-
-
-
-
- - - -
1.47 1005 1.94 1126
1.65 1005 2.14 1123
1.81 1006 2.32 1123
2.13 1016 2.68 1129
2.52 1031 3.11 1140
2.99 1052 3.62 1156
3.54 1077 4.22 1177
4.18 1107 4.90 1202
4.93 1140 - -
1035 5.00
- -
719
748
2.24
2.95
787
836
891
966
3.89
5.11
6.65
9.12
1084
-
781
804
-
-
-
-
-
-
-
-
- - - -
3.77 908 4.67 1005
-
-
-
-
838
882
4.79
6.09
935
971
5.75
7.13
1025
1055
6.77
8.22
1110
1134
933 7.72 1015 8.83 1093 10.00 1167
1004 10.30 1079 11.52 1150 12.79 1218
-
-
-
-
1014 10.87 1050 12.12 1120 13.41 1187 14.74 1252
1087 13.97 1121 - - - - - -
1061 1.69
1071 1.78
1142
1151
2.19 1290 2.73 1425
2.29 1297 2.84 1431
3.30 1550
3.42 1555
1097 2.02
1157 2.62
1221 3.32
1291 4.18
1174
1228
1288
1353
2.56
3.22
3.97
4.88
1316
1362
1414
1472
3.13
3.84
4.65
-
1446
1486
1531
-
3.74
4.50
-
-
1568
1602
-
-
3.33 1529
3.99 1552
4.78 1584
-
-
-
-
- -
2.44 1237
2.67 1231
2.87 1230
3.27 1232
3.74 1240
4.28 1253
4.92 1270
-
- -
-
1366
-
841
856
885
918
956
998
1042 4.66
- -
-
709
-
1.66
715
742
779
826
1.81
2.40
3.19
4.26
-
-
1.64
1.86
2.25
2.70
3.25
3.90
-
-
1142
926
951
980
1014
1053
1095
-
-
774
779
802
835
877
-
-
-
-
-
-
-
-
2.26 1046 2.94 1165
2.50 1053 3.20 1170
2.93 1072 3.66 1183
3.41 1096 4.19 1202
4.00 1124 4.81 1226
4.70 1157 - -
-
-
-
-
-
-
- - -
2.36 891 3.14
-
-
-
995
2.54 894 3.34 997
3.18 910 4.04 1009
4.05 937 4.98 1030
5.20 973 6.21 1061
879
938
5.65
7.41
927
982
6.68
8.53
1016
1066
7.77
9.70
1099
1144
8.90 1178
10.92 1219
1002 9.58 1043 10.80 1121 12.07 1194 13.37 1265
1069 12.22 1107 13.54 1180 14.90 1249 - -
1139
-
-
-
-
-
-
-
-
-
-
-
-
-
-
- -
-
-
-
-
-
3.68 1275
3.96 1277
4.45 1287
- -
-
- -
-
-
-
-
-
- -
4.00 1090
4.20 1091
4.96 1099
5.96 1117
7.26 1144
➀
Total static pressure should include external static pressure and accessory / option static pressure from Table 34.1. Unit internal resistance has been included in the unit performance tables.
➁
Brake Horsepower and RPM values are approximate values only. Please consult the AccuSpec selection software for values at other than listed CFM / static pressures.
36
5-594.6
BloWer performance data
table 37.1 - unit performance tables
➀ ➁
unit size
500/600
start 600
500/600
start 600
end 500
500/600
start 500
700/800
start 800
700/800
start 800
700/800
end 700
840/960
end 840
840/960
end 840 digit 16 g or H i, J, K l g or H i, J, K l i, J, K l air total static pressure inches "W.c.
temp 0.25 0.50 0.75 1.00 1.25 1.50 2.00 2.50 3.00
rise cfm BHp rpm BHp rpm BHp rpm BHp rpm BHp rpm BHp rpm BHp rpm BHp rpm BHp rpm
120°F / - 3086 0.62 529 0.82 620 1.03 703 1.26 779 1.50 849 1.75 916 2.28 1038 2.84 1149 3.44 1252
106°F / - 3500 0.84 575 1.06 658 1.30 736 1.54 807 1.80 874 2.07 937 2.63 1054 3.23 1162 3.86 1262
100°F / 120°F 3704 0.97 598 1.20 678 1.45 753 1.70 822 1.97 887 2.25 949 2.83 1064 3.44 1170 4.09 1268
93°F / 111°F 4000 1.18 633 1.43 709 1.69 779 1.96 846 2.24 908 2.53 968 3.14 1080 3.78 1183 4.45 1279
82°F / 99°F 4500 1.61 693 1.88 762 2.17 827 2.46 889 2.77 948 3.09 1001 3.74 1110 4.43 1208 - -
74°F / 89°F 5000 2.13 755 2.43 818 2.75 878 3.07 936 3.40 991 3.74 1044 4.44 1145
67°F / 81°F 5500 2.77 818 3.10 876 3.44 932 3.79 986 4.15 1038 4.51 1088 - -
-
-
-
-
-
- -
-
62°F / 74°F 6000 3.53 882 3.89 936 4.25 988 4.63 1038 -
57°F / 68°F 6500 4.41 946 4.80 996 - - - - -
120°F / - 3086 0.46 401 0.69 496 0.95 580 1.23 657
100°F / 120°F 3704 0.69 443 0.95 527 1.23 604 1.54 675
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
93°F / 111°F 4000 0.82 464 1.09 544 1.39 618 1.71 686 2.05 749 2.42 810 - - - -
74°F / 89°F 5000 1.43 542 1.75 609 2.09 673 2.46 733 2.84 790 3.24 844 4.09 946 5.01 1041
-
-
-
-
62°F / 74°F 6000 2.31 624 2.68 682 3.07 738 3.48 791 3.91 842 4.35 891 5.29 984 6.28 1072 7.33 1155
53°F / 63°F 7000 3.51 709 3.94 760 4.38 809 4.84 857 5.31 903 5.80 947 6.82 1032 7.90 1113 9.03 1191
46°F / 56°F 8000 5.09 797 5.57 842 6.07 886 6.58 928 7.10 970 7.64 1010 8.75 1089 9.92 1163 11.13 1235
41°F / 49°F 9000 7.11 885 7.65 926 8.20 965 8.76 1001 9.33 1042 9.92 1079 11.13 1151 12.38 1220 13.69 1287
- / 44°F
- / 43°F
10000 9.62 975 10.21 1012 10.81 1048 11.43 1083 12.05 1118 12.69 1152 14.00 1218 15.35 1283
10400 10.77 1011 11.38 1046 12.01 1081 12.64 1115 13.29 1149 13.95 1182 15.30 1247 - -
-
- -
-
- / 40°F
- / 40°F
11000 12.66 1065 13.31 1099 13.97 1132 14.64 1164 15.32 1197 16.01 1228 17.42 1290
11111 13.04 1075 13.69 1109 14.36 1141 15.03 1174 15.72 1205 16.41 1237 17.83 1298
62°F / 74°F 6000 1.69 512 1.97 565 2.26 615 2.57 664 2.89 710 3.23 755 - -
53°F / 63°F 7000 2.57 580 2.89 626 3.22 671 3.56 714 3.92 756 4.29 797 5.06 874
-
-
-
-
-
-
-
-
-
-
-
-
46°F / 56°F 8000 3.73 650 4.09 691 4.46 731 4.84 770 5.23 808 5.64 845 6.47 916 7.35 984 - -
41°F / 49°F 9000 5.21 721 5.60 758 6.01 795 6.43 830 6.86 864 7.30 898 8.21 964 9.16 1027 10.14 1088
- / 44°F
- / 43°F
10000 7.04 793 7.48 827 7.93 860 8.39 892 8.85 924 9.33 955 10.31 1016 11.33 1074 12.38 1131
10400 7.88 823 8.34 855 8.80 887 9.28 918 9.76 949 10.25 979 11.26 1038 12.31 1095 13.38 1150
-
-
-
-
- / 40°F
- / 40°F
120°F / -
115°F / -
11000 9.27 866 9.75 897 10.24 927 10.74 957 11.24 986 11.76 1015 12.81 1071 13.90 1126
11111 9.54 874 10.03 905 10.52 935 11.02 964 11.53 993 12.05 1022 13.12 1078 14.21 1132
4321 1.51 685 1.80 760 2.11 830 2.43 896 2.77 958 3.13 1018 3.88 1131 4.69 1236
4500 1.68 708 1.98 780 2.30 847 2.63 912 2.98 973 3.34 1032 4.11 1142 4.94 1245
105°F / 120°F 4938 2.15 763 2.48 89 2.82 893 3.17 953 3.54 1011 3.93 1066 4.74 1172
104°F / 119°F 5000 2.23 770 2.55 836 2.90 899 3.26 959 3.63 1016 4.02 1072 4.83 1176
94°F / 108°F 5500 2.89 834 3.25 895 3.62 953 4.00 1009 4.40 1063 4.81 1116
86°F / 99°F 6000 3.68 900 4.06 956 4.46 1010 4.87 1062 - - - -
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
80°F / 91°F 6500 4.61 965
120°F / - 4321
- - - - - - - -
0.87 443 1.14 421 1.42 591 1.72 657 2.04 717
-
2.37
- -
774 3.08
- - -
879 3.84 974
- -
4.65 1063
104°F / 119°F 5000 1.26 488 1.55 558 1.87 623 2.20 683 2.54 740 2.90 794 3.66 894 4.47 985 5.33 1071
86°F / 99°F 6000 2.02 558 2.36 619 2.73 677 3.10 731 3.49 782 3.89 832 4.73 924 5.62 1010 6.55 1091
65°F / 74°F 8000 4.44 707 4.89 755 5.35 801 5.82 845 6.30 888 6.79 930 7.81 1009 8.87 1085 9.96 1156
58°F / 66°F 9000 6.19 784 6.69 827 7.20 869 7.72 909 8.25 949 8.79 987 9.90 1061 11.04 1131 12.23 1199
52°F / 59°F 10000 8.36 861 8.91 901 9.47 939 10.04 976 10.62 1012 11.21 1048 12.42 1117 13.66 1183 14.93 1246
47°F / 54°F 11000 11.00 940 11.60 976 12.22 1011 12.84 1045 13.47 1079 14.11 1112 15.41 1176 16.74 1238 - -
43°F / 49°F 12000 14.16 1019 14.81 1052 15.48 1085 16.15 1117 16.83 1148 17.52 1179 18.92 1239
40°F / 46°F 13000 17.88 1098 18.59 1129 19.30 1159 - - - - - - - -
-
-
-
-
-
-
-
-
65°F / 74°F 8000 3.26 566 3.60 611 3.95 654 4.31 696 4.67 736 5.05 774 5.84 848 6.66 918 7.51 984
58°F / 66°F 9000 4.54 626 4.92 667 5.30 706 5.70 744 6.10 780 6.52 816 7.37 885 8.25 950 9.17 1012
52°F / 59°F 10000 6.13 687 6.54 724 6.97 760 7.40 794 7.85 828 8.30 861 9.22 925 10.17 987 11.15 1046
47°F / 54°F 11000 8.06 749 8.52 782 8.98 815 9.45 847 9.93 879 10.42 910 11.41 969 12.43 1027 13.48 1083
47°F / 54°F 11050 8.17 752 8.62 785 9.09 818 9.56 850 10.04 881 10.53 912 11.53 972 12.56 1029 13.61 1084
43°F / 49°F 12000 10.37 811 10.86 842 11.37 872 11.88 902 12.40 931 12.92 960 13.99 1016 15.08 1070 16.20 1123
40°F / 46°F 13000 13.09 873 13.63 902 14.17 930 14.72 958 15.27 986 15.83 1013 16.98 1065 18.14 1116 19.33 1166
- / 42°F 14000 16.26 936 16.83 963 17.41 989 18.00 1015 18.59 1041 19.19 1066 - - - - - -
- / 41°F
120°F / -
14500 18.02 968 18.61 994 19.21 1019 19.82 1045 - - - - - - - - - -
6481 2.72 630 3.09 685 3.48 736 3.88 785 4.30 832 4.72 876 5.60 960 6.52 1038 7.48 1112
111°F / - 7000 3.36 672 3.76 723 4.17 772 4.60 818 5.04 863 5.49 905 6.42 986 7.38 1061 8.39 1133
105°F / 120°F 7407 3.93 705 4.35 754 4.79 800 5.23 845 5.69 888 6.16 929 7.13 1007 8.13 1081 9.17 1151
97°F / 111°F 8000 4.87 754 5.33 799 5.90 843 6.27 885 6.76 926 7.26 965 8.28 1040 9.33 1111 10.43 1179
86°F / 99°F 9000 6.80 837 7.31 878 7.83 918 8.36 956 8.90 994 9.44 1030 10.56 1100 11.71 1166 12.90 1230
78°F / 89°F 10000 9.20 921 9.76 958 10.33 995 10.91 1030 11.50 1065 12.10 1099 13.32 1164 14.56 1226
70°F / 80°F 11050 12.28 1010 12.89 1044 13.52 1078 14.16 1110 14.80 1142 15.45 1173 16.77 1234 - -
65°F / 74°F 12000 15.60 1091 16.27 1123 16.95 1154 17.63 1184 18.32 1214 19.02 1243
62°F / 71°F 12500 17.58 1134 18.27 1164 18.97 1194 19.69 1224 - - - -
-
-
-
-
-
-
-
-
-
-
-
-
60°F / 68°F 13000 19.71 1177 - - - - - - - - - - - - - - - -
86°F / 99°F 9000 5.01 675 5.40 715 5.80 753 6.21 789 6.62 825 7.05 859 7.91 925 8.81 988 9.73 1048
78°F / 89°F 10000 6.78 742 7.21 778 7.64 812 8.09 846 8.54 879 9.00 911 9.95 973 10.91 1032 11.91 1088
70°F / 80°F 11050 9.04 812 9.51 845 9.99 877 10.48 908 10.97 939 11.47 968 12.50 1026 13.54 1081 14.61 1135
-
-
-
-
65°F / 74°F 12000 11.48 876 12.00 907 12.51 937 13.04 966 13.57 994 14.11 1022 15.20 1076 16.32 1129 17.46 1179
60°F / 68°F 13000 14.50 945 15.05 973 15.62 1000 16.18 1028 16.75 1054 17.33 1081 18.50 1132 19.70 1181 - -
- / 63°F 14000 18.02 1013 18.61 1039 19.21 1065 19.82 1091 - - - - - - - - - -
➀
Total static pressure should include external static pressure and accessory / option static pressure from Table 34.1. Unit internal resistance has been included in the unit performance tables.
➁
Brake Horsepower and RPM values are approximate values only. Please consult the AccuSpec selection software for values at other than listed CFM / static pressures.
5-594.6
37
BloWer sHeave assemBly data
adjusting the Blower drive setting
Based on the Sheave Arrangement, Tables 38.1 through 39.5 give the Sheave Assembly numbers used on units that include a blower. The Sheave Arrangement is Digit 19 and is found on the unit Model Identification Plate. The Sheave Assembly describes the motor and blower sheave size and bore as well as the belt provided.
To determine how many turns open the motor sheave should be set for:
1. Follow the Selection Procedure found on pages 32 and 33 to determine what blower rpm is required to meet the job specifications.
figure 38.1 - Blower section
EXTENDED
GREASE
LINES
2. Locate the unit Model Identification Plate and note Digit 16 and Digit 19 of the model number. Digit 16 is the Blower
Size and Type and Digit 19 is the Sheave Arrangement.
3. Once the Blower Size and Type (Digit 16) is known, enter the proper Sheave Arrangement table.
4. Use the Sheave Arrangement (Digit 19) to determine the
Sheave Assembly provided.
5. Use Table 40.1 and the Sheave Assembly number to determine the required turns open to achieve the desired blower rpm.
6. Set the motor sheave as described in Blower Adjustments.
ADJUSTABLE
MOTOR
SHEAVE
MOTOR
FILTER
RACK
EXTENDED
GREASE LINE
ZERK FITTINGS
1/4" PERIMETER
GASKETED
BLOWER
CONNECTION
CONVENIENCE
OUTLET
BLOWER DOOR
SAFETY SWITCH
BOTTOM
SUPPORTED
BLOWER AND
MOTOR
DIRECT
DRIVE
DAMPER
ACTUATOR
Blower sheave assembly numbers table 38.1 – digit 16 = a or B (9-7 Blower units)
motor frame size
48
56
143 or 145
656-1001 978-1265 rpm range
1150-1561 1526-1858 1763-2147
Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly
A 3H35125B1 C
3H35125B3
B
3H35125B2
D
3H35125B4
F
3H35125B6
H
3H35125B8
J
3H35125B10
E 3H35125B5 G 3H35125B7 I 3H35125B9 K
3H35125B11
table 38.2 – digit 16 = c or d (9-9 Blower units)
motor frame size
48
56
143 or 145
182 or 184
656-1001 978-1265 rpm range
1150-1561 1526-1858 1763-2147
Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly
A
3H35126B1
C
3H35126B3
B 3H35126B2 D 3H35126B4 F 3H35126B6
E
3H35126B5
G
3H35126B7
H
3H35126B8
I
J
K
3H35126B9 L
3H35126B12
3H35126B10
3H35126B11
M
N
3H35126B13
3H35126B14
38
5-594.6
BloWer sHeave assemBly data
Blower sheave assembly numbers (con’t) table 39.1 - digit 16 = e or f (12-12 Blower units)
motor frame size
48
56
143 to 145
182 or 184
213 or 215
468-715 644-874 863-1078 rpm range
1029-1332 1150-1438 1327-1659
Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly
A 3H35127B1
B
3H35127B2
C
3H35127B3
F
3H35127B6
Q
3H35127B17
D
3H35127B4
G 3H35127B7
E
3H35127B5
H
3H35127B8
I
J
K
3H35127B9
3H35127B10
3H35127B11
L
M
N
3H35127B12
3H35127B13
3H35127B14
O
P
3H35127B15
3H35127B16
table 39.2 - digit 16 = g or H (15-15 Blower units)
motor frame size
48
56
143 to 145
182 or 184
213 or 215
410-625 568-771 rpm range
767-958 934-1136 1136-1380
Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly
A 3H35128B1
B
3H35128B2
C
3H35128B3
D
3H35128B4
G
3H35128B7
O
3H35128B15
E 3H35128B5 H 3H35128B8
F
3H35128B6
I
3H35128B9
J
K
L
3H35128B10
3H35128B11
3H35128B12
M
N
3H35128B13
3H35128B14
table 39.3 - digit 16 = i or J (18-18 Blower units under 15 Hp motor)
motor frame size
56
143 or 145
182 to 184
213 or 215
254
256
491-649 586-744 rpm range
682-821 821-1009 995-1161 1101-1285
Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly
A
3H35129B1
D 3H35129B4
B
3H35129B2
E
3H35129B5
H
3H35129B8
C
3H35129B3
F 3H35129B6 I 3H35129B9 K
3H35129B11
O
3H35129B15
G
3H35129B7
J
3H35129B10
L
3H35129B12
P
3H35129B16
S
3H35129B19
M
3H35129B13
Q
3H35129B17
T
3H35129B20
N
3H35129B14
R
3H35129B18
U
3H35129B21
table 39.4 - digit 16 = K (18-18 Blower units with 15 Hp motor & up)
motor frame size
254
256
284
286
826-1009
rpm range
995-1161 1101-1285 1232-1438
Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly
A
3H35130B1
C
3H35130B3
E
3H35130B5
B
3H35130B2
D
3H35130B4
F
3H35130B6
G
3H35130B13
I 3H35130B15 K 3H35130B17 M
3H35130B19
H
3H35130B14
J
3H35130B16
L
3H35130B18
N
3H35130B20
table 39.5 - digit 16 = l (20-18 Blower units)
motor frame size
143 or 145
182 to 184
213 or 215
254
256
284
286
491-649 626-765 rpm range
765-901 901-1059 995-1161 1101-1285
Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly
A
3H36622B1
B
3H36622B2
C
D
3H36622B3
E
3H36622B5
G
3H36622B7
M
3H36622B13
R
3H36622B18
3H36622B4 F
H
I
3H36622B6
3H36622B8
3H36622B9
L
3H36622B12
N
O
3H36622B14
3H36622B15
S
T
3H36622B19
3H36622B20
W
X
3H36622B23
3H36622B24
J 3H36622B10 P 3H36622B16 U 3H36622B21 Y
3H36622B25
K
3H36622B11
Q
3H36622B17
V
3H36622B22
Z
3H36622B26
5-594.6
39
BloWer sHeave assemBly data
table 40.1 - Blower sheave assembly settings
sheave assembly 0 0.5
1 1.5
turns open
2 2.5
3 3.5
4 4.5
5
Blower rpm
1001 966 932 897 863 828 794 759 725 690 656 3H35125B1-2
3H35125B3-5
3H35125B6-7
1265 1236 1208 1179 1150 1121 1093 1064 1035 1006 978
1561 1520 1479 1438 1396 1355 1314 1273 1232 1191 1150
3H35125B8-9 1858 1825 1791 1758 1725 1692 1659 1625 1592 1559 1526
3H35125B10-11 2147 2108 2070 2032 1993 1955 1917 1878 1840 1802 1763
3H35126B1-2
3H35126B3-5
3H35126B6-8
1001 966 932 897 863 828 794 759 725 690 656
1265 1236 1208 1179 1150 1121 1093 1064 1035 1006 978
1561 1520 1479 1438 1396 1355 1314 1273 1232 1191 1150
3H35126B9-11 1858 1825 1791 1758 1725 1692 1659 1625 1592 1559 1526
3H35126B12-14 2147 2108 2070 2032 1993 1955 1917 1878 1840 1802 1763
3H35127B1-2 715 690 665 641 616 591 567 542 518 493 468
3H35127B3-5
3H35127B6-8
874 851 828 805 782 759 736 713 690 667 644
1078 1057 1035 1013 992 970 949 927 906 884 863
3H35127B9-11 1332 1301 1271 1241 1211 1180 1150 1120 1089 1059 1029
3H35127B12-14 1438 1409 1380 1351 1323 1294 1265 1236 1208 1179 1150
3H35127B15-16 1659 1625 1592 1559 1526 1493 1460 1426 1393 1360 1327
3H35127B17 1332 1301 1271 1241 1211 1180 1150 1120 1089 1059 1029
3H35128B1-3 625 604 582 561 539 518 496 474 453 431 410
3H35128B4-6
3H35128B7-9
771
958
751
939
731
920
710
901
690
882
670
863
649
843
629
824
609
805
589
786
568
767
3H35128B10-12 1136 1116 1096 1076 1055 1035 1015 994 974 954 934
3H35128B13-14 1380 1355 1331 1306 1281 1257 1232 1208 1183 1158 1136
3H35128B15 1136 1116 1096 1076 1055 1035 1015 994 974 954 934
3H35129B1-3
3H35129B4-7
649
744
633
728
617
712
601
696
586
681
570
665
554
649
538
633
522
617
506
601
491
586
3H35129B8-10 821 807 793 779 765 751 737 723 709 696 682
3H35129B11-14 1009 991 973 954 936 918 899 881 863 844 821
3H35129B15-18 1161 1144 1128 1111 1095 1078 1062 1045 1028 1012 995
3H35129B19-21 1285 1266 1248 1230 1211 1193 1174 1156 1138 1119 1101
3H35130B1-2 1009 991 973 954 936 918 899 881 863 844 826
3H35130B3-4 1161 1144 1128 1111 1095 1078 1062 1045 1028 1012 995
3H35130B5-6
3H35130B13-14
1285 1266 1248 1230 1211 1193 1174 1156 1138 1119 1101
974 960 946 932 918 904 890 876 863 849 835
3H35130B15-16 1161 1144 1128 1111 1095 1078 1062 1045 1028 1012 995
3H35130B17-18 1285 1266 1248 1230 1211 1193 1174 1156 1138 1119 1101
3H35130B19-20 1438 1417 1396 1376 1355 1335 1314 1294 1273 1253 1232
3H36622B1-2 649 633 617 601 586 570 554 538 522 506 491
3H36622B3-5 765 751 737 723 709 696 682 668 654 640 626
3H36622B6-11 901 888 875 863 850 837 824 811 798 785 765
3H36622B12-17 1059 1044 1029 1014 999 984 968 953 938 923 901
3H36622B18-22 1161 1144 1128 1111 1095 1078 1062 1045 1028 1012 995
3H36622B23-26 1285 1266 1248 1230 1211 1193 1174 1156 1138 1119 1101
40
5-594.6
BloWer sHeave assemBly data
3H35127B17
3H35128B1
3H35128B2
3H35128B3
3H35128B4
3H35128B5
3H35128B6
3H35128B7
3H35128B8
3H35128B9
3H35128B10
3H35128B11
3H35128B12
3H35128B13
3H35128B14
3H35128B15
3H35127B2
3H35127B3
3H35127B4
3H35127B5
3H35127B6
3H35127B7
3H35127B8
3H35127B9
3H35127B10
3H35127B11
3H35127B12
3H35127B13
3H35127B14
3H35127B15
3H35127B16
3H35125B1
3H35125B2
3H35125B3
3H35125B4
3H35125B5
3H35125B6
3H35125B7
3H35125B8
3H35125B9
3H35125B10
3H35125B11
3H35126B1
3H35126B2
3H35126B3
3H35126B4
3H35126B5
3H35126B6
3H35126B7
3H35126B8
3H35126B9
3H35126B10
3H35126B11
3H35126B12
3H35126B13
3H35126B14
3H35127B1
table 41.1 - Blower sheave assembly settings
sheave assembly
5
5
5.6
5.6
5.2
5.6
5.2
5.6
3.8
3.8
3.8
5
4.4
2.9
2.9
2.9
4.4
5.2
5
5
5.2
5
5.6
5
5
5
4.4
2.9
3.8
3.8
3.8
5.6
5.6
5.6
2.9
3.8
5.6
5.6
5.6
2.9
2.9
4.4
4.4
4.4
3.8
3.8
motor sheave pitch diameter Bore
2.9
0.5
2.9
4.4
4.4
4.4
0.625
0.5
0.625
0.875
3.8
3.8
5.6
5.6
5.6
5.6
0.625
0.875
0.625
0.875
0.625
0.875
1.125
0.625
0.875
1.125
0.625
0.875
1.125
0.5
0.5
0.625
0.5
0.625
0.875
0.625
0.875
0.875
1.125
0.875
1.125
1.375
1.125
1.375
0.625
0.625
0.5
0.625
0.875
0.625
0.875
1.125
0.625
1.125
1.375
0.875
1.125
1.375
1.125
1.375
0.625
0.625
0.875
1.125
0.625
0.875
1.125
0.875
Browning
Belt no.
9
9
8.5
8.5
8
7
6.5
8.5
8.5
8.5
8.5
9
5.7
8
8
8
5.7
6.7
6
6
6.2
5.2
5.7
8
8
8
5.7
7
7.5
7.5
7.5
4.5
4.5
4.5
7
4.2
5.2
5.2
5.2
6
6
4.2
4.2
5
5
6
Blower sheave pitch diameter Bore
5 0.75
6
6
5
6
0.75
0.75
0.75
0.75
4.2
4.2
5.2
5.2
4.5
4.5
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
1
0.75
0.75
0.75
0.75
0.75
0.75
0.75
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
A52
A54
A53
A54
A54
A52
A52
A53
A43
A47
A48
A48
A50
A50
A52
A53
A45
A49
A45
A47
A49
A45
A48
A43
A46
A45
A47
A48
A48
A50
A43
A36
A38
A38
A40
A37
A37
A39
A42
A33
A34
A37
A38
A38
A34
A34
A31
A31
A35
A35
A34
A34
A30
A31
A34
A35
A35
5-594.6
8.9
10.4
11.4
11.4
13.4
13.4
8.4
8.4
10.9
10.9
8.9
8.9
12.4
12.4
12.4
10.4
10.4
9.4
9.4
9.4
9.4
10.4
10.4
9.4
9.4
10.4
10.4
10.4
10.4
10.4
9.4
8.4
9.4
9.4
9.4
11.4
11.4
9.4
9.4
9.4
10.4
10.4
10.4
10.4
9.4
9.4
9.4
12.4
12.4
8.9
9.4
9.4
9.4
Blower sheave pitch diameter Bore
10.9
10.9
1
1
10.9
10.9
10.9
10.9
12.4
12.4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
1.44
4.7
5.5
6
6
7
7
7
7
4.1
4.1
4.1
4.1
5.5
7
7
7
7
7
7
5.5
5.5
7
7
7
7
7
7
7
7
7
7
7
7
7
5.3
5.9
6
6
7
7
7
7
7
7
7
7
7
5.9
5.9
5.3
5.5
5.5
5.5
motor sheave pitch diameter Bore
4.1
4.1
0.625
0.875
4.1
4.7
4.7
4.7
5.5
5.9
1.125
0.625
0.875
1.125
1.375
0.875
1.125
1.375
1.625
1.625
1.375
1.625
1.625
1.125
1.375
1.125
1.375
1.625
1.625
1.375
1.625
1.625
1.875
1.875
1.625
1.125
1.375
1.625
1.625
1.875
1.875
1.625
1.875
1.875
1.125
1.375
1.625
1.625
1.875
1.875
1.875
1.875
0.875
1.125
0.875
1.125
1.375
1.875
1.875
1.875
1.875
1.875
1.875
1.625
1.625
1.625
1.625
1.625
1.625
sheave assembly
3H35130B1
3H35130B2
3H35130B3
3H35130B4
3H35130B5
3H35130B6
3H35130B13
3H35130B14
3H35130B15
3H35130B16
3H35130B17
3H35130B18
3H35130B19
3H35130B20
3H36622B1
3H36622B2
3H36622B3
3H36622B4
3H36622B5
3H36622B6
3H36622B7
3H36622B8
3H36622B9
3H36622B10
3H36622B11
3H36622B12
3H36622B13
3H36622B14
3H36622B15
3H36622B16
3H36622B17
3H36622B18
3H36622B19
3H36622B20
3H36622B21
3H36622B22
3H36622B23
3H36622B24
3H36622B25
3H36622B26
3H35129B1
3H35129B2
3H35129B3
3H35129B4
3H35129B5
3H35129B6
3H35129B7
3H35129B8
3H35129B9
3H35129B10
3H35129B11
3H35129B12
3H35129B13
3H35129B14
3H35129B15
3H35129B16
3H35129B17
3H35129B18
3H35129B19
3H35129B20
3H35129B21
Browning
Belt no.
Qty (2) B74
Qty (2) B74
Qty (2) B78
Qty (2) B78
Qty (2) B77
Qty (2) B77
Qty (2) B82
Qty (2) B82
Qty (2) B79
Qty (2) B79
Qty (2) B77
Qty (2) B77
Qty (2) B75
Qty (2) B75
B75
BX73
B72
B70
BX78
B74
BX75
Qty (2) BX82
Qty (2) BX82
Qty (2) B86
Qty (2) B86
B71
BX74
Qty (2) BX79
Qty (2) BX79
Qty (2) B83
Qty (2) B83
B77
Qty (2) B82
Qty (2) B82
Qty (2) B81
Qty (2) B81
Qty (2) B80
Qty (2) B80
Qty (2) B80
Qty (2) B80
B73
B72
B78
B78
B70
B77
B77
BX75
BX75
BX68
BX68
BX75
BX75
B71
B71
B70
BX71
BX71
BX71
BX71
BX77
41
electrical data
total unit amp draw
The total unit amp draw is a combination of the motor, the control step down transformer, and the power exhauster motor (or step down transformer for 460V/3Ph or 575V/3Ph units). The control step down transformer includes damper actuators, ignition controllers, gas valves, control relays, amplifiers, and motor starters.
Motor Amp Draw (Tables 42.1 to 46.1) =
Control Step Down Transformer Amp Draw (Table 42.1) =
Power Exhauster Motor Amp Draw (Table 42.1) =
Total Amp Draw + _________
table 42.1 - control step down transformer amp draws
digit 14 control step down transformer amp draw
power exhauster amp draw ➀
supply voltage
0 digit 15 - transformer
1 2 3 4 75-175 200-400 model size
500-800 840-960 a
115/60/1
0 0.35 0.65
1.3
2.17
1.4
2.00/2.40
4.00/4.80
6.00/7.20
B 208/60/1
0 0.19 0.36 0.72
1.2
0.7
1.10/1.40
2.20/2.80
3.30/4.20
c 230/60/1
0 0.17 0.33 0.65 1.09 0.66/0.60
0.95/1.30
1.90/2.60
2.85/3.90
d g
208/60/3
0 0.19 0.36 0.72
1.2
0.7
1.10/1.40
2.20/2.80
3.30/4.20
e 230/60/3
0 0.17 0.33 0.65 1.09 0.66/0.60
0.95/1.3
1.90/2.60
2.85/3.90
f
460/60/3 ➅
0 0.09 0.16 0.33 0.54
0.30➁ 0.54②/0.65➂ 1.08③/1.3➃ 1.63④/2.0➄
575/60/3 ➅
0 0.07 0.13 0.26 0.43
0.24➁ 0.43②/0.52➂ 0.87③/1.1➃ 1.30④/1.6➄
➀
When 2 amp draws are listed, the first is for Outdoor units and the second is for Indoor Power Vented & Separated Combustion units.
➁
Amp draw is for a 250 VA transformer.
➂
Amp draw is for a 500 VA transformer.
➃
Amp draw is for a 750 VA transformer.
➄
Amp draw is for a 1000 VA transformer.
➅
Only include amp draw for gravity vented models. For power vented models, the step down transformer amp draw is included in the
Power Exhauster Motor Amp Draw. Amp draw is for 250 VA step down transformer.
table 42.2 - motor data for digit 14 = a - 115v/60Hz/1ph table 42.3 - motor data for digit 14 = B - 208v/60Hz/1ph
digits motor motor frame amp. service Weight efficiency
17&18
size (Hp) type ➀ size draw factor (lbs) (%) ➁
digits motor motor frame amp. service Weight efficiency
17&18
size (Hp) type ➀ size draw factor (lbs) (%) ➁
a1
a5
B1
B5
c1
c5
d1
d5
e1
e5
f1 or r1
f5 or r5
g1 or s1
g5 or s5
1/3 ➂ ODP 56 6.6 1.35
1/3 ➂ TENV 48 5.0 1.00
1/2 ➂ ODP 56 9.0 1.25
1/2 ➂ TEFC 56 8.0 1.15
3/4 ➂ ODP 56 11.0 1.25
3/4 ➂ TE 56 11.0 1.15
1 ➂ ODP 56 13.4 1.15
1 ➂ TE 56 13.4 1.15
1 1/2 ➂ ODP 56 18.0 1.15
1 1/2 ➂ TE 56 15.2 1.15
2 ODP 145T 21.0 1.15
2 TE 182T 20.0 1.15
3 ODP 184T 34.0 1.15
3 TE 184T 32.0 1.00
37
40
45
49
54
81
83
25
25
23
28
25
30
32
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
a1
B1
B5
c1
c5
d1
d5
e1
e5
f1 or r1
f5 or r5
H1 or t1
H5 or t5
1/3 ➂ ODP 56 3.0 1.35
1/2 ➂ ODP 56 4.1 1.25
1/2 ➂ TEFC 56 4.0 1.15
3/4 ➂ ODP 56 5.5 1.25
3/4 ➂
1 1/2 ➂
2
2
5
5
TE
1 ➂ ODP 56 6.8 1.15
1 ➂ TE
1 1/2 ➂ ODP 56 9.3 1.15
TE
ODP 145T 11.3
TE
ODP 184T 23.0
TE
56 5.4 1.15
56 6.8 1.15
56 8.2
182T 10.8
184T 22.8
1.15
1.15
1.15
1.15
1.00
➀
Refer to page 46 for Motor Type abbreviations.
➁
Motors manufacturers do not rate single-phase motors for efficiency.
Single phase motors, 1-1/2HP and smaller, feature integral thermal overload protection. 2HP and larger require external protection. The optional motor starter for those sizes provides overcurrent protection.
25
23
28
25
30
32
37
40
45
49
54
87
86
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
42
5-594.6
motor data
table 43.1 - motor data for digit 14 = c - 230v/60Hz/1ph
digits
17&18
a1
a5
B1
B5
c1
c5
d1
d5
e1
e5
f1 or r1
f5 or r5
g1 or s1
g5 or s5
H1 or t1
H5 or t5
motor size (Hp)
1/3 ➂
1/3 ➂
1/2 ➂
1/2 ➂
3/4 ➂
3/4 ➂
1 ➂
1 ➂
1 1/2 ➂
1 1/2 ➂
2
2
3
3
5
5
motor
type ➀
ODP
TENV
ODP
TEFC
ODP
TE
ODP
TE
ODP
TE
ODP
TE
ODP
TE
ODP
TE
frame size
56
56
56
56
56
145T
182T
184T
56
48
56
56
56
184T
184T
184T
amp. draw
3.3
2.5
4.5
4.0
5.5
5.5
6.7
6.7
9.0
7.6
10.5
10.0
17.0
16.0
22.0
20.2
service factor
1.35
1.00
1.25
1.15
1.25
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.00
1.15
1.00
Weight
(lbs)
45
49
54
81
30
32
37
40
25
25
23
28
25
83
87
86
efficiency
➁
(%)
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
➀
Refer to page 46 for Motor Type abbreviations.
➁
Motors manufacturers do not rate single-phase motors for efficiency.
Single phase motors, 1-1/2HP and smaller, feature integral thermal overload protection. 2HP and larger require external protection. The optional motor starter for those sizes provides overcurrent protection.
table 43.2 - motor data for digit 14 = d - 208v/60Hz/3ph ➀
motor
digits size motor frame amp. service Weight efficiency
17&18 (Hp)
type ➁
size draw factor (lbs) ( %) motor
digits size motor frame amp. service Weight efficiency
17&18 (Hp) type ➁
size draw factor (lbs) (%)
a1 or l1 1/3
a5 or l5 1/3
B1 or m1 1/2
B5 or m5 1/2
c1 or n1 3/4
c5 or n5 3/4
d1 or p1
d2 or p2
1
1
ODP
TE
ODP
TEFC
ODP
TEFC
ODP
56
48
56
56
56
1.5
1.2
2.1
2.1
2.7
56 2.7
143T 3.1
ODP HE 143T 3.2
1.35
1.00
1.25
1.15
1.25
1.15
1.15
1.15
d3 or p3
1 ODP 18/9 143T 3.5/1.5 1.15
d4 or p4
1 ODP 18/12 145T 3.4/2.0 1.15
d5 or p5
1
d6 or p6
1
TEFC 56 3.5
TE HE 143T 3.5
1.15
1.15
d7 or p7
1 TEFC 18/9 143T 3.5/1.5 1.00
17
15
18
18
21
N/A
N/A
N/A
N/A
N/A
d8 or p8
1 TEFC 18/12 145T 3.2/1.8 1.00
e1 or Q1 1 1/2
e2 or Q2 1 1/2
ODP
ODP
145T 5.9
145T 4.8
1.15
1.00
e3 or Q3 1 1/2 ODP 18/9 145T 5.0/2.1
1.15
e4 or Q4 1 1/2 ODP 18/12 145T 5.0/2.9 1.15
e5 or Q5 1 1/2 TEFC 56 4.8
e6 or Q6 1 1/2 TE HE 145T 4.9
1.15
1.15
e7 or Q7 1 1/2 TEFC 18/9 145T 4.3/1.9 1.00
e8 or Q8 1 1/2 TEFC 18/12 145T 5.0/2.9 1.00
f1 or r1 2
f2 or r2 2
ODP
ODP
145T 7.2
145T 5.8
1.15
1.00
f3 or r3 2 ODP 18/9 145T 6.2/2.6 1.15
f4 or r4 2 ODP 18/12 182T 6.5/3.5 1.15
f5 or r5 2
f6 or r6 2
f8 or r8 2
TE 145T 7.0
TE HE 145T 6.5
1.15
1.15
f7 or r7 2 TEFC 18/9 145T 6.4/2.5 1.00
TE 18/12 182T 6.4/3.9 1.15
ODP 182T 10.0 1.15
ODP HE 182T 8.9
g1 or s1 3
g2 or s2 3 1.15
g3 or s3 3 ODP 18/9 182T 10.1/4.1 1.15
g4 or s4 3 ODP 18/12 184T 9.3/4.9 1.15
g5 or s5 3
g6 or s6 3
g7 or s7 3
g8 or s8 3
H1 or t1
5
H2 or t2
5
TE
TE HE
TE 18/9
ODP
ODP HE
182T 10.0 1.15
182T 9.4-9.1
182T 9.3/3.5
TE 18/12 184T 9.2/5.4
1.15
1.00
1.15
184T 16.0 1.15
182T 15.7 1.15
H3 or t3
5 ODP 18/9 184T 16.0/6.2 1.15
H4 or t4
5 ODP 18/12 215T 16.0/9.7 1.15 117 86.0 / 78.0%
H5 or t5
5
H6 or t6
5
H7 or t7
5
H8 or t8
5
i1 or W1 7 1/2
TE
TE HE
TE 18/9
ODP
184T 14.2
184T 15.0
184T 15.0/5.3 1.00
TE 18/12 213T 15.0/8.5 1.15
213T 26.9
1.15
1.15
1.15
76
94
81 85.0 / 77.0%
90
99
85
84.0%
89.5%
107 85.0 / 80.0%
106
87.5%
88.5%
85.0 / 85.0%
81.5%
30
40
N/A
82.5%
30 84.0%
26 76.0 / 59.0%
42 74.0 / 60.0%
28 N/A
84.5% 68
29 76.0 / 58.0%
31 74.0 / 60.0%
43
35
80.0%
89.5%
29 80.0 / 65.0%
49 80.0 / 71.0%
33
62
N/A
84.0%
38 83.0 / 71.0%
38 80.0 / 72.0%
43
74
82.0%
89.5%
33 81.0 / 67.0%
78 81.0 / NA%
52 84.0%
86.5% 66
41 84.0 / 70.0%
65 84.0 / 77.0%
78
83
81.5%
89.5%
66 82.0 / 72.0%
79 81.0 / 75.0%
83
92
87.5%
88.5%
64 84.0 / 70.0%
84 84.0 / 82.0%
i2 or W2 7 1/2 ODP HE 213T
22.3 1.15
i3 or W3 7 1/2 ODP 18/9 213T 23.0/9.3
1.15
i4 or W4 7 1/2 ODP 18/12 215T 22.0/12.3 1.15
i5 or W5 7 1/2
TE 213T 24.0
i6 or W6 7 1/2
TE HE 213T 22.0
1.15
1.15
i7 or W7 7 1/2 TE 18/9
213T 21.0/8.8 1.15
i8 or W8 7 1/2 TE 18/12 215T 21.8/12.0 1.15
J1 or X1 10
ODP 215T 32.6
J2 or X2 10
ODP HE 215T 29.0
1.15
1.15
J3 or X3 10
ODP 18/9 215T 27.7/11.2 1.15
J4 or X4 10 ODP 18/12 256T 27.0/14.5 1.15
J5 or X5 10
J6 or X6 10
TE 215T 29.0
TE HE 215T 27.6
1.15
1.15
126
118 88.0 / 77.0%
J7 or X7 10 TE 18/9 215T 29.0/11.5 1.15 118 87.0 / 77.0%
J8 or X8 10 TE 18/12 254T 30.0/17.0 1.15 212 88.0 / 80.0%
K1 or y1 15 ODP 254T 45.6
K2 or y2 15 ODP HE 254T 43.4
K3 or y3 15 ODP 18/9 256T 42.5/16.5 1.15
K5 or y5 15
1.15
1.15
1.15
1.15
141 91.7%
108 85.0 / 72.0%
167 89.0 / 85.0%
126
158
89.5%
90.2%
106 87.0 / 75.0%
124 86.0 / 80.0%
120 84.0%
91.7%
196 88.0 / 80.0%
130
200
87.5%
90.2%
K6 or y6 15
K7 or y7 15 TE 18/9 256T 44.0/16.0 1.15 218 88.0 / 82.0%
K8 or y8 15 TE 18/12 256T 42.0/23.0 1.15 219 88.0 / 84.0%
v1 or Z1 20
v2 or Z2 20 ODP HE 256T 57.0
v3 or Z3 20
TE
TE HE
ODP
254T 42.0
254T 40.3
256T 61.6 1.15
1.15
ODP 18/9 284T 56.0/21.0 1.15
v4 or Z4 20 ODP 18/12 286T 54.0/28.0 1.15
147
220
244 90.2 / 84.0%
250
259
200
250
87.5%
93.0%
91.0%
91.7%
87.5%
93.6%
221 90.2 / 82.5%
270 89.0 / 86.0%
v6 or Z6 20 TE HE 256T 54.0 1.15 290 91.7%
v7 or Z7 20 TE 18/9 284T 59.0/20.0 1.15 346 89.0 / 88.0%
➀
Motors have no thermal overload protection.
➁
Refer to page 46 for Motor Type abbreviations
.
5-594.6
43
motor data
table 44.1 - motor data for digit 14 = e - 230v/60Hz/3ph ➀
motor
digits size motor frame amp. service Weight efficiency
17&18 (Hp)
type ➁
size draw factor (lbs) (%)
a1 or l1 1/3
a5 or l5 1/3
B1 or m1 1/2
B5 or m5 1/2
ODP
TE
ODP
TEFC
56
48
56
56
1.6
1.2
2.2
2.2
c1 or n1 3/4
c5 or n5 3/4
ODP
TEFC
56
56
2.8
2.8
d1 or p1 1 ODP 143T 3.1
d2 or p2 1 ODP HE 143T 3.2
1.35 17
1.00 15
1.25 18
1.15 18
1.25 21
1.15 30
1.15 36
1.15 30
N/A
N/A
N/A
N/A
N/A
N/A
82.5%
84.0%
d3 or p3 1 ODP 18/9 143T 3.4/1.6 1.15 26 76.0 / 59.0%
d4 or p4 1 ODP 18/12 145T 3.4/2.2 1.15 42 74.0 / 60.0%
d5 or p5
d6 or p6
1
1
TEFC 56 3.6
TE HE 143T 3.0
1.15 28
1.15 68
N/A
85.5%
d7 or p7 1 TEFC 18/9 143T 3.4/1.6 1.00 29 76.0 / 58.0%
d8 or p8 1 TEFC 18/12 145T 3.4/2.2 1.00 31 74.0 / 60.0%
e1 or Q1 1 1/2 ODP
e2 or Q2 1 1/2 ODP
145T 4.4
145T 5.6
1.15 42
1.00 35
e3 or Q3 1 1/2 ODP 18/9 145T 4.8/2.7 1.15
e4 or Q4 1 1/2 ODP 18/12 145T 4.9/2.8 1.15
84.0%
89.5%
29 80.0 / 65.0%
49 80.0 / 71.0%
e5 or Q5 1 1/2 TEFC 56 4.8
e6 or Q6 1 1/2 TE HE 145T 5.0
1.15 33
1.15 62
N/A
86.5%
e7 or Q7 1 1/2 TEFC 18/9 145T 4.0/1.7 1.00 38 83.0 / 71.0%
e8 or Q8 1 1/2 TEFC 18/12 145T 4.9/2.8 1.00 38 80.0 / 72.0%
f1 or r1 2
f2 or r2 2
ODP
ODP
145T 5.8
145T 5.8
1.15 43
1.00 74
84.0%
89.5%
f3 or r3 2 ODP 18/9 145T 6.4/2.7 1.15 33 81.0 / 67.0%
f4 or r4 2 ODP 18/12 182T 6.3/3.5 1.15 78 81.0 / NA%
f5 or r5 2
f6 or r6 2
TE 145T 5.8
TE HE 145T 6.0
1.15 52
1.15 64
84.0%
85.5%
f7 or r7 2 TEFC 18/9 145T 6.4/2.6 1.00 41 84.0 / 70.0%
f8 or r8 2 TE 18/12 182T 6.4/4.2 1.15 65 84.0 / 77.0%
g1 or s1 3 ODP 182T 9.4
g2 or s2 3 ODP HE 182T 8.6
1.15 81
1.15 74
86.5%
89.5%
g3 or s3 3 ODP 18/9 182T 11.6/4.4 1.15 66 82.0 / 72.0%
g4 or s4 3 ODP 18/12 184T 8.5/4.6 1.15 79 81.0 / 75.0%
g5 or s5 3
g6 or s6 3
TE 182T 8.2
TE HE 182T 8.0
1.15 83
1.15 110
87.5%
89.5%
g7 or s7 3 TE 18/9 182T 10.0/3.6 1.00 64 84.0 / 70.0%
g8 or s8 3 TE 18/12 184T 8.8/5.5 1.15 84 84.0 / 82.0%
H1 or t1 5 ODP 184T 14.0 1.15 87
H2 or t2 5 ODP HE 184T 13.6 1.15 94
87.5%
89.5%
H3 or t3 5 ODP 18/9 184T 17.7/6.2 1.15 81 85.0 / 77.0%
H4 or t4 5 ODP 18/12 215T 15.5/10.2 1.15 117 86.0 / 78.0%
H5 or t5 5
H6 or t6 5
TE 184T 13.0 1.15 90
TE HE 184T 13.0 1.15 117
87.5%
90.2%
H7 or t7 5 TE 18/9 184T 16.0/5.3 1.00 85 85.0 / 85.0%
H8 or t8 5 TE 18/12 213T 14.0/8.8 1.15 107 85.0 / 80.0%
➀
Motors have no thermal overload protection.
➁
Refer to page 46 for Motor Type abbreviations.
motor
digits size motor frame amp. service Weight efficiency
17&18 (Hp) type ➁
size draw factor (lbs) (%)
i1 or W1 7 1/2 ODP 213T 19.6 1.15 121
i2 or W2 7 1/2 ODP HE 213T 19.4 1.15 160
88.5%
91.7%
i3 or W3 7 1/2 ODP 18/9 213T 22.5/8.2 1.15 108 85.0 / 72.0%
i4 or W4 7 1/2 ODP 18/12 215T 19.5/12.3 1.15 167 89.0 / 85.0%
i5 or W5 7 1/2 TE 213T 20.0 1.15 126
i6 or W6 7 1/2 TE HE 213T 19.2 1.15 194
89.5%
91.7%
i7 or W7 7 1/2 TE 18/9 213T 21.0/8.8 1.15 106 87.0 / 75.0%
i8 or W8 7 1/2 TE 18/12 215T 20.0/12.4 1.15 124 86.0 / 80.0%
J1 or X1 10 ODP 215T 26.8 1.15 138
J2 or X2 10 ODP HE 215T 25.2 1.15 220
89.5%
91.7%
J3 or X3 10 ODP 18/9 215T 32.4/11.6 1.15 118 88.0 / 77.0%
J4 or X4 10 ODP 18/12 256T 24.0/13.0 1.15 196 88.0 / 80.0%
J5 or X5 10 TE 215T 26.0 1.00 138
J6 or X6 10 TE HE 215T 25.0 1.15 213
89.5%
90.2%
J7 or X7 10 TE 18/9 215T 29.0/11.5 1.15 118 87.0 / 77.0%
J8 or X8 10 TE 18/12 254T 28.0/17.5 1.15 212 88.0 / 80.0%
K1 or y1 15 ODP 254T 38.6 1.15 215
K2 or y2 15 ODP HE 254T 37.8 1.15 217
91.0%
93.0%
K3 or y3 15 ODP 18/9 256T 40.0/17.0 1.15 244 90.2 / 84.0%
K5 or y5 15 TE 254T 40.0 1.15 250
K6 or y6 15 TE HE 254T 38.0 1.15 322
91.0%
92.4%
K7 or y7 15 TE 18/9 256T 39.0/15.0 1.15 218 88.0 / 82.0%
K8 or y8 15 TE 18/12 256T 38.0/22.0 1.15 219 88.0 / 84.0%
v1 or Z1 20 ODP 256T 50.0 1.15 233
v2 or Z2 20 ODP HE 256T 49.0 1.15 250
91.0%
93.6%
v3 or Z3 20 ODP 18/9 284T 51.0/21.5 1.15 221 90.2 / 82.5%
v4 or Z4 20 ODP 18/12 286T 48.0/26.0 1.15 270 89.0 / 86.0%
v5 or Z5 20
v6 or Z6 20
TEFC
TE HE
256T
256T
51.0
48.2
1.15
1.15
287
368
91.0%
93.0%
v7 or Z7 20 TE 18/9 284T 52.0/18.0 1.15 346 89.0 / 88.0%
44
5-594.6
motor data
table 45.1 - motor data for digit 14 = f - 460v/60Hz/3ph ➀
motor
digits size motor frame amp. service Weight efficiency
17&18 (Hp)
type ➁
size draw factor (lbs) (% )
a1 or l1 1/3
a3 or l3 1/3
B1 or m1 1/2
B5 or m5 1/2
ODP
TE
ODP
TEFC
56 0.8 1.35 17
48 0.6 1.00 15
56 1.1 1.25 18
56 1.1 1.15 18
c1 or n1 3/4
c5 or n5 3/4
ODP
TEFC
56 1.4 1.25 21
56 1.4 1.15 30
d1 or p1 1 ODP 143T 1.6 1.15 36
d2 or p2 1 ODP HE 143T 1.5 1.15 30
N/A
N/A
N/A
N/A
N/A
N/A
82.5%
84.0%
d3 or p3 1 ODP 18/9 143T 1.8/0.8 1.15 26 76.0 / 59.0%
d4 or p4 1 ODP 18/12 145T 1.7/1.1 1.15 39 74.0 / 60.0%
d5 or p5 1
d6 or p6 1
TEFC
TE HE
56
143T
1.8
1.5
1.15
1.15
28
68
N/A
85.5%
d7 or p7 1 TEFC 18/9 143T 1.8/0.8 1.00 28 73.0 / 58.0%
d8 or p8 1 TEFC 18/12 145T 1.7/1.1 1.00 31 74.0 / 60.0%
e1 or Q1 1 1/2 ODP
e2 or Q2 1 1/2 ODP
145T
145T
2.2
2.4
1.15
1.00
42
35
84.0%
89.5%
e3 or Q3 1 1/2 ODP 18/9 145T 2.3/1.0 1.15 29 80.0 / 65.0%
e4 or Q4 1 1/2 ODP 18/12 145T 2.4/1.4 1.15 32 75.0 / 71.0%
e5 or Q5 1 1/2 TEFC 56 2.4 1.15 33
e6 or Q6 1 1/2 TE HE 145T 2.5 1.15 62
N/A
86.5%
e7 or Q7 1 1/2 TEFC 18/9 145T 2.0/0.9 1.00 39 83.0 / 71.0%
e8 or Q8 1 1/2 TEFC 18/12 145T 2.5/1.4 1.00 37 80.0 / 72.0%
f1 or r1 2
f2 or r2 2
ODP
ODP
145T
145T
2.9
2.9
1.15
1.00
43
74
84.0%
89.5%
f3 or r3 2 ODP 18/9 145T 3.0/1.3 1.15 33 79.0 / 62.0%
f4 or r4 2 ODP 18/12 182T 3.0/2.0 1.15 61 80.0 / 70.0%
f5 or r5 2
f6 or r6 2
TE
TE HE
145T
145T
2.9
3.0
1.15
1.15
52
64
84.0%
85.5%
f7 or r7 2 TEFC 18/9 145T 3.2/1.3 1.00
f8 or r8 2 TE 18/12 182T 3.1/1.9 1.15
42 84.0 / 70.0%
68 81.0 / 77.0%
g1 or s1 3 ODP 182T 4.5 1.15 81
g2 or s2 3 ODP HE 182T 4.3 1.15 74
86.5%
89.5%
g3 or s3 3 ODP 18/9 182T 4.5/1.8 1.15 60 80.0 / 66.0%
g4 or s4 3 ODP 18/12 184T 4.6/2.7 1.15 71 82.5 / NA%
g5 or s5 3
g6 or s6 3
TE
TE HE
182T
182T
4.1
4.0
1.15
1.15
83
110
87.5%
89.5%
g7 or s7 3 TE 18/9 182T 4.6/1.7 1.15 65 84.0 / 70.0%
g8 or s8 3 TE 18/12 184T 4.3/2.6 1.15 73 82.5 / 75.5%
H1 or t1 5 ODP 184T 7.0 1.15 87
H2 or t2 5 ODP HE 184T 6.8 1.15 94
87.5%
89.5%
H3 or t3 5 ODP 18/9 184T 9.1/3.2 1.15 94 84.0 / 73.0%
H4 or t4 5 ODP 18/12 215T 7.1/4.8 1.15 117 78.0 / 71.0%
H5 or t5 5 TE 184T 6.5 1.15 90 87.5%
motor
digits size motor frame amp. service Weight efficiency
17&18 (Hp) type ➁
size draw factor (lbs) (%)
H6 or t6 5 TE HE 184T 6.5 1.15 117
H7 or t7 5 TE 18/9 184T 7.0/2.5 1.15
90.2%
83 86.0 / 83.0%
H8 or t8 5 TE 18/12 213T 6.9/4.1 1.15 107 85.0 / 75.5%
i1 or W1 7 1/2 ODP 213T 9.8 1.15 121 88.5%
i2 or W2 7 1/2 ODP HE 213T 9.7 1.15 160 91.7%
i3 or W3 7 1/2 ODP 18/9 213T 11.8/4.2 1.15 125 85.0 / 72.0%
i4 or W4 7 1/2 ODP 18/12 215T 10.0/6.0 1.15 131 87.0 / 80.0%
i5 or W5 7 1/2 TE 213T 10.0 1.15 126 89.5%
i6 or W6 7 1/2 TE HE 213T 9.6 1.15 194
i7 or W7 7 1/2 TE 18/9 213T 10.0/4.1 1.15
91.7%
83 84.0 / 74.0%
i8 or W8 7 1/2 TE 18/12 215T 10.3/5.6 1.15 128 85.0 / 80.0%
J1 or X1 10 ODP 215T 13.4 1.15 138 89.5%
J2 or X2 10 ODP HE 215T 12.6 1.15 220 91.7%
J3 or X3 10 ODP 18/9 215T 15.0/5.3 1.15 116 83.0 / 71.0%
J4 or X4 10 ODP 18/12 256T 12.0/6.3 1.15 192 87.0 / 82.0%
J5 or X5 10 TE 215T 13.0 1.00 138 89.5%
J6 or X6 10 TE HE 215T 12.5 1.15 213 90.2%
J7 or X7 10 TE 18/9 215T 13.0/5.4 1.15 107 86.5 / 77.0%
J8 or X8 10 TE 18/12 254T 13.5/7.5 1.15 222 87.0 / 82.0%
K1 or y1 15 ODP 254T 19.3 1.15 215 91.0%
K2 or y2 15 ODP HE 254T 18.9 1.15 217 93.0%
K3 or y3 15 ODP 18/9 256T 19.3/7.8 1.15 203 88.5 / 81.5%
K4 or y4 15 ODP 18/12 256T 18.0/9.5 1.15 298 86.0 / 81.0%
K5 or y5 15 TE 254T 20.0 1.15 250 91.0%
K6 or y6 15 TE HE 254T 19.0 1.15 322 92.4%
K7 or y7 15 TE 18/9 256T 19.5/7.5 1.15 218 88.0 / 82.0%
K8 or y8 15 TE 18/12 256T 19.5/11.0 1.15 223 88.0 / 84.0%
v1 or Z1 20 ODP 256T 25.0 1.15 233 91.0%
v2 or Z2 20 ODP HE 256T 24.5 1.15 250 93.6%
v3 or Z3 20 ODP 18/9 256T 25.2/10.0 1.15 208 89.5 / 82.5%
v4 or Z4 20 ODP 18/12 286T 24.0/13.0 1.15 270 90.0 / 84.0%
v5 or Z5 20 TEFC 256T 25.5 1.15 287 91.0%
v6 or Z6 20 TE HE 256T 24.1 1.15 368 93.0%
v7 or Z7 20 TE 18/9 284T 26.0/8.7 1.15 331 89.0 / 88.0%
v8 or Z8 20 TE 18/12 284T 24.7/14.0 1.15 361 90.0 / 86.0%
➀
Motors have no thermal overload protection.
➁
Refer to page 46 for Motor Type abbreviations.
5-594.6
45
motor data
table 46.1 - motor data for digit 14 = g - 575v/60Hz/3ph ➀
digits
17&18
g6 or s6
H1 or t1
H5 or t5
H6 or t6
i1 or W1
i5 or W5
i6 or W6
J1 or X1
J5 or X5
J6 or X6
K1 or y1
K5 or y5
K6 or y6
v1 or Z1
v5 or Z5
v6 or Z6
a5 or l5
B1 or m1
B5 or m5
c1 or n1
c5 or n5
d1 or p1
d5 or p5
d6 or p6
e1 or Q1
e5 or Q5
e6 or Q6
f1 or r1
f5 or r5
f6 or r6
g1 or s1
g5 or s5
motor size (Hp)
15
20
20
20
10
10
15
15
3
5
5
5
7 1/2
7 1/2
7 1/2
10
1 1/2
1 1/2
1/12
2
2
2
3
3
1/3
1/2
1/2
3/4
3/4
1
1
1
➀
Motors have no thermal overload protection.
➁
Motor Type Abbreviations
ODP Open Drip Proof
ODP HE
ODP 18/9
Open Drip Proof, High Efficiency
Open Drip Proof, 2-speed 1800/900 RPM
ODP 18/12 Open Drip Proof, 2-speed 1800/1200 RPM
TE Totally Enclosed
TEFC
TE HE
Totally Enclosed, Fan Cooled
Totally Enclosed, High Efficiency
TE 18/9
TE 18/12
TENV
Totally Enclosed, 2-speed 1800/900 RPM
Totally Enclosed, 2-speed 1800/1200 RPM
Totally Enclosed, Non-Ventilating
motor
type ➁
TE HE
ODP
TEFC
TE HE
ODP
TEFC
TE HE
ODP
TE
TE HE
ODP
TE
TE HE
ODP
TEFC
TE HE
TEFC
ODP
TEFC
ODP
TEFC
ODP
TEFC
TE HE
ODP
TEFC
TE HE
ODP
TEFC
TE HE
ODP
TEFC
frame size
215T
215T
254T
254T
254T
256T
256T
256T
182T
184T
184T
184T
213T
213T
213T
215T
145T
145T
145T
145T
145T
145T
182T
182T
56
56
56
56
56
143T
56
143T
amp. draw
10.4
9.6
15.4
16.0
15.2
20.8
20.4
19.5
3.2
5.2
5.2
5.2
7.8
8.0
7.6
10.3
1.8
2.0
1.7
2.3
2.3
2.4
3.4
3.4
0.6
0.9
0.9
0.9
1.1
1.1
1.5
1.2
service factor
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.25
1.15
1.25
1.15
1.15
1.15
1.15
efficiency
(%)
89.5%
90.2%
91.0%
91.0%
92.4%
91.0%
91.0%
93.0%
89.5%
87.5%
87.5%
89.5%
88.5%
89.0%
90.2%
89.5%
84.0%
84.0%
85.5%
84.0%
84.0%
86.5%
86.5%
87.5%
N/A
N/A
N/A
N/A
N/A
82.5%
77.0%
85.5%
Weight
(lbs)
154
200
184
250
326
255
287
368
100
91
89
117
113
142
192
123
65
66
72
98
48
72
66
50
33
41
28
68
16
25
24
28
46
5-594.6
page intentionally left BlanK
5-594.6
47
dimensions - unit
figure 48.1 - dBs separated combustion Blower package unit dimensions
Qty (4) Drill Locator
Dimples for Field
Drilled Electrical
Conduit Entry Holes
(spaced 2.0" apart)
500 - 800 model shown figure 48.2 - dcs separated combustion cooling package unit dimensions
Qty (4) Drill Locator
Dimples for Field
Drilled Electrical
Conduit Entry Holes
(spaced 2.0" apart)
Ø N
Exhaust
Ø P Combustion
Air Inlet
table 48.1 - indoor separated combustion unit dimensions (all dimensions in inches)
model Blower type Qty. of
size (digit 16) furnaces a
75
100/125
150/175
200/225
All
All
All
All
250/300 E, F, G, or H
350/400 E, F, G, or H
500/600
G or H
700/800
G or H
1
1
1
1
1
1
2
2
B c d e f g dimensions
H J K l m
n ➄ p ➄
s gas y conn.
33.75 18.90 15.18 28.75 18.00 25.00 20.02 39.23 32.06 10.26 23.08 18.19 3.86 4.17 87.77 85.69 1/2
33.75 18.90 17.67 28.75 21.00 25.00 20.02 39.23 34.56 10.26 23.08 18.19 3.86 4.17 87.77 85.69 1/2
33.75 18.90 21.95 28.75 24.00 25.00 23.99 39.23 38.82 10.26 23.08 18.19 3.86 4.17 87.77 85.69 1/2
37.75 22.90 24.05 32.75 27.00 28.00 23.99 43.23 40.94 9.60 26.43 19.21 5.86 6.18 87.77 85.69 1/2
37.75 22.90 27.05 32.75 30.00 28.00 29.96 43.23 44.05 9.60 26.43 19.21 5.86 6.18 87.77 85.69 3/4
37.75 22.90 38.60 32.75 42.00 28.00 41.90 43.23 55.57 9.60 26.43 19.21 5.86 6.18 87.77 85.69 3/4
37.75 22.90 27.05 32.75 n/a n/a 29.96 43.23 44.05 9.60 26.43 19.21 5.86 6.18 128.77 126.78 3/4
37.75 22.90 38.60 32.75 n/a n/a 41.90 43.23 55.57 9.60 26.43 19.21 5.86 6.18 128.77 126.78 3/4
➀
For Right Hand Access Units - Location of drill locator dimples for field drilled gas connection entry holes - one side of unit and one on bottom.
➁
For Left Hand Access Units - Location of drill locator dimples for field drilled gas connection entry holes - one side of unit and one on bottom.
➂
For Right Hand Access Units - Location of drill locator dimples for field drilled electrical connection entry holes - identical sizes as side electrical connections.
➃
For Left Hand Access Units - Location of drill locator dimples for field drilled electrical connection entry holes - identical sizes as side electrical connections.
➄
Nominal vent pipe size is 4" (Models 75-175) and 6" (Models 200-800). Exhaust pipe installed over collar. Combustion air pipe installed collar.
48
5-594.6
dimensions - unit
figure 49.1 - dBs separated combustion Blower package unit dimensions with Blower type i, J, K, or l
22.90
(Height)
X
C (Width)
(Inside)
10.26
9.05
1 2 1
34.49
20.00
2
4.50
Y
2.00
W
50.37
U
Qty (4) Drill Locator
Dimples for Field
Drilled Electrical
Conduit Entry Holes
(spaced 2.0" apart)
34.00
36.68
4.24
7.30
9.60
24.92
2.03
S
500 - 800 model shown
Return Air
Duct Connection
74.50
24.00
(Inside)
4.35
1.90
34.00
37.84
2.32
Ø 5.86
5
Exhaust
9.21
Ø 6.18
5
Combustion
Air Inlet
Fresh Air
26.43
Duct Connection
19.21
6.38
5.29
1.50
3
1
J Over Roof
X
G INSIDE
2
4
24.00
(Inside)
43.23
6.38
5.29
9.21
3.00
figure 49.2 - dcs separated combustion cooling package unit dimensions with Blower type i, J, or K
10.26
7.65
23.95
Outlet Air
Duct
Connection
30.5
X
E (Width)
32.75
19.23
1
4.24
7.30
9.60
33.84
20.00
2.00
4.50
24.92
2
2.03
144.84
50.37
Qty (4) Drill Locator
Dimples for Field
Drilled Electrical
Conduit Entry Holes
(spaced 2.0" apart)
34.00
147.26
36.68
34.00
2.32
37.85
24.00
(Inside)
Ø
5.386
Exhaust
1.90
Ø
6.18
Combustion
Air Inlet
9.21
26.43
19.21
6.38
5.29
Return Air
Duct Connection
24.00
(Inside)
4.35
1.50
3
1
J Over Roof
G INSIDE
2
4
24.00
(Inside)
43.23
6.38
5.29
9.21
3.00
table 49.1 - indoor separated combustion unit dimensions with Blower i, J, K, or l (all dimensions in inches)
model Blower type Qty. of
size (digit 16) furnaces c
250/300
I, J, or K
350/400
I, J, or K
500/600 I, J, K, or L
700/800 I, J, K, or L
840/960 I, J, K, or L
1
1
2
2
3
e g J dimensions s
u ➅ W ➅ X ➅
27.05 30.00 29.96 44.05 123.63 n/a
38.60 42.00 41.90 55.57 123.63 n/a n/a n/a
y gas conn.
n/a 121.53 3/4 n/a 121.53 3/4
27.05 n/a 29.96 44.05 164.63 29.74 6.50 41.62 162.63 3/4
38.60 n/a 41.90 55.57 164.63 29.74 6.50 41.62 162.63 3/4
38.60 n/a 41.90 55.57 205.77 29.74 6.50 41.62 203.72 3/4
➀
For Right Hand Access Units - Location of drill locator dimples for field drilled gas connection entry holes - one side of unit and one on bottom.
➁
For Left Hand Access Units - Location of drill locator dimples for field drilled gas connection entry holes - one side of unit and one on bottom.
➂
For Right Hand Access Units - Location of drill locator dimples for field drilled electrical connection entry holes - identical sizes as side electrical connections.
➃
For Left Hand Access Units - Location of drill locator dimples for field drilled electrical connection entry holes - identical sizes as side electrical connections.
➄
Nominal vent pipe size is 4" (Models 75-175) and 6" (Models 200-800). Exhaust pipe installed over collar. Combustion air pipe installed collar.
➅
Applies to units with Digit 16 = L only.
5-594.6
49
dimensions - unit
figure 50.1 - unit Base dimensions
A
C To end of unit
0.63
M
B
J
2.36
0.75" Suspension
Hanging Locations
(Typical 4 Corners)
E Inside
D
Suspension
Point
Lifting
Point
K
Suspension
Point
24.00 Inside
Lifting
Point
M
Return Air
Opening
4.35
1.45
L
N
model size
75
100/125
150/175
200/225
250/300
250/300
350/400
350/400
500/600
500/600
700/800
700/800
840/960
table 50.1 - indoor separated combustion Blower package units (all dimensions in inches)
Blower type
(digit 16) a B c d e
dimensions f g n K l J
All
All
All
All
87.77 34.85 84.73
87.77 37.36 84.73
87.77 41.61 84.73
87.77 43.71 84.73
E,F,G, or H 87.77 46.75 84.73
I, J, or K 123.62 46.75 120.57
E,F,G, or H 87.77 58.27 84.73
I, J, or K 123.62 58.27 120.57
19.52
19.52
23.49
23.49
29.46
81.88
81.88
81.88
81.88
81.88
56.96
56.96
56.96
56.96
56.96
29.46 117.73 92.81
41.40 81.88 56.96
41.40 117.73 92.81
G, or H 128.77 46.75 119.54 42.00 29.46 81.88 56.96 97.03 42.00
I, J, K, or L 164.63 46.75 155.41 42.00 29.46 117.73 92.81 125.70 90.15
G, or H 128.77 58.27 119.54 42.00 41.40 81.88 56.96 97.03 42.00
I, J, K, or L 164.63 58.27 155.41 42.00 41.40 117.73 92.81 125.70 90.15
43.89
43.89
55.41
55.41
I, J, K, or L 205.77 58.27 196.52 48.58 41.40 117.73 92.81 166.84 82.94 166.84 55.41
32.00
34.50
38.75
40.85
43.89
43.89
55.41
55.41
m
6.23
7.49
7.63
8.69
7.21
7.21
7.00
7.00
7.21
7.21
7.00
7.00
7.00
table 50.2 - indoor separated combustion cooling package units (all dimensions in inches)
model size
75
100/125
150/175
200/225
250/300
250/300
350/400
350/400
Blower type
(digit 16) a
All
All
All
All
111.75
111.75
111.75
111.75
E, F, G, or H 111.75
I, J, or K 147.60
E, F, G, or H 111.75
I, J, or K 147.60
B
34.85
37.36
41.61
43.71
46.75
46.75
58.27
58.27
c
108.75
108.75
108.75
108.75
108.75
144.60
108.75
144.60
dimensions e f g J
19.52
19.52
23.49
23.49
81.88 56.96 32.00
81.88 56.96 34.50
81.88 56.96 38.75
81.88 56.96 40.85
29.46 81.88 56.96 43.89
29.46 117.73 92.81 43.89
41.40 81.88 56.96 55.41
41.40 117.73 92.81 55.41
➀
Gas connection for 1st furnace. For Models 500-800 add 41.09" for second furnace gas connection.
For Model 840-960 add 41.09" and 82.19" for second and third furnace gas connections.
m
6.23
7.49
7.63
8.69
7.21
7.21
7.00
7.00
50
5-594.6
dimensions - cooling coils
figure 51.1 - dX coil drawing -
(All dimensions in inches)
Airflow Direction
rows 2 3 4
6
W 7.5 6 7.5 10
TOP VIEW
L
1.5
1.5
W
Coil for Right Hand Units
(Digit 9 = R)
Headers on opposite side for Left Hand Units
H
S
FRONT VIEW
1.5
FL
FH
Distributor Inlet (Liquid
Line) Connection(s)
(Second Inlet on Dual
Circuit Coils)
SIDE VIEW
Airflow
Direction
Suction Line Connections in direction of airflow
(Second Inlet on Dual Circuit Coils)
I
table 51.1 - dX coil dimensions
model cooling size mBH
75
100/125
All
All
dX - single circuit
dX - dual circuit
fH H s fl i l suction liquid line (Qty) line (Qty) fl i l suction liquid
line (Qty) line (Qty)
27.5 30.5 1.5 18 25 21 (1) 1.625 (1) 1.375 16.25 26.5 19.25 (2) 1.625 (2) 0.875
27.5 30.5 1.5 21 28 24 (1) 1.625 (1) 1.375 19.5 29.75 22.5 (2) 1.625 (2) 0.875
150/175
200/225
250/300
350/400
All
Below 185
MBH
185 MBH
& Up
Below 185
MBH
185 MBH
& Up
Below 185
MBH
185 MBH
& Up
27.5 30.5 1.5 24 31 27 (1) 1.625 (1) 1.375 23 33.25 26.0 (2) 1.625 (2) 0.875
32.5 34.5 0.5 27 34 30 (1) 1.625 (1) 1.375
32.5 34.5 0.5 27 34.5 30 (1) 2.125 (1) 1.375
32.5 34.5 0.5 30 37 33 (1) 1.625 (1) 1.375
32.5 34.5 0.5 30 37.5 33 (1) 2.125 (1) 1.375
32.5 34.5 0.5 42 49 45 (1) 1.625 (1) 1.375
32.5 34.5 0.5 42 49.5 45 (1) 2.125 (1) 1.375
25.5 35.75 28.5 (2) 1.625 (2) 0.875
28.5 38.75 31.5 (2) 1.625 (2) 0.875
40.25 50.5 43.25 (2) 1.625 (2) 0.875
figure 51.2 - chilled Water coil drawing
(All dimensions in inches)
Airflow Direction
rows 4 6
W 7.5 10
TOP VIEW
L
1.5
1.5
1.8
W
Coil for Right Hand Units (Digit
9 = R)
Headers on opposite side for
Left Hand Units
H
S
FRONT VIEW
FL
FH
2.25
Return Water Line
Connection turned 90˚ in direction of airflow
Airflow
Direction
SIDE VIEW
V
2.25
Supply Water Line
Connection turned 90˚ in direction of airflow
I
1.8
table 51.2 - chilled Water coil dimensions
model size fH
75
100/125
150/175
200/225
250/300
350/400
27
27
27
33
33
33
H
30
30
30
34.5
34.5
34.5
s
1.5
1.5
1.5
0.5
0.5
0.5
v
1.5
1.5
1.5
1
1
1
fl i l supply line return line
16.25 25.50 19.25 1.50 MPT
19.50 28.75 22.50 1.50 MPT
23.00 32.25 26.00 1.50 MPT
25.50 34.75 28.50 1.50 MPT
28.50 37.75 31.50 1.50 MPT
40.25 49.50 43.25 1.50 MPT
1.50 MPT
1.50 MPT
1.50 MPT
1.50 MPT
1.50 MPT
1.50 MPT
5-594.6
51
dimensions/WeigHts / maintenance
figure 52.1 - remote panel dimensions
5.57
3.53
C
A
3.53
notes:
1. Holes visable on right side are also on left side in the same location.
2. Holes on top are also on the back in the same location horizontally,
1" down vertically.
1.50
B
2.56
3.38
2.13
maintenance
All heating equipment should be serviced before each heating season to assure proper operations. The following items may be required to have more frequent service schedule based on the environment in which the unit is installed, and the frequency of the equipment operation.
Blower assembly
The blower assembly includes the bearings, drive sheaves and belts.
Blower bearings should be checked and lubricated based on the blower manufacturer’s recommendations. Bearings should also be checked for any unusual wear and replaced if needed.
Drive sheaves should be checked at the same time the bearings are inspected. Check to make sure the sheaves are in alignment and are securely fastened to the blower and motor shafts.
Belt tension should be rechecked shortly after the unit has been installed to check for belt stretching. After the initial start-up, monthly checks are recommended.
filters
If the unit is supplied with a dirty filter switch and light, clean or replace the filters any time the dirty filter light comes on.
Units which do not have a dirty filter warning light should have the filters checked monthly. Clean or replace if necessary. In dirty atmospheres, filter maintenance may be required more often.
table 52.1 - remote panel dimensions
(All dimensions in inches)
remote panel type
Light and Switch Panels Only
Light and Switch Panels with Single Stage
Thermostat or Electronic Set Point Adjustor
Light and Switch Panels with
Two Stage Thermostat
a
7.06
B
-
c
2.81
10.60 3.53 4.58
13.09 6.03 5.82
figure 52.2 - filter replacement arrangement for Blower size
(digit 16) a, B, c, d, e, f, g and H
FILTER SPACE
table 52.2 - Blower package unit operating Weights ➀
model Blower type
size (digit 16) unit
75
100/125
All
All
373
409
150/175
200/225
All
All
441
515
250/300 E,F,G, or H
568
250/300
I, J, or K 817
350/400 E,F,G, or H
652
350/400
I, J, or K
500/600
G or H
933
843
500/600 I, J, K, or L
1092
700/800
G or H 981
700/800 I, J, K, or L
1262
840/960 I, J, K, or L
1591
motor filters dampers dampers insulation double Wall fresh air f & ra (all sections)
8
15
12
17
6
6
6
6
8
15
12
17
17
26
26
29
29
33
33
38
38
33
33
38
38
38
46
46
52
52
60
60
70
70
60
60
70
70
70
5
5
5
7
7
14
7
14
7
14
7
14
14
46
93
53
96
38
38
43
46
46
93
53
96
96
B
B
C
C
75
B
B
B
B
B
B
A
A
100/125
150/175
FILTER SPACE
A
A
A
A
A
C
A A A A
A A C
A
220/225 250/300
500/600 350/400
700/800
A = 20" X 25" FILTER
B = 16" X 25" FILTER
C = 15" X 25" FILTER
Filter Spacer to be inserted on non-access side of unit
table 52.3 - cooling package unit operating Weights ➀
model Blower type
size (digit 16) unit motor
75
100/125
All
All
480
519
150/175
200/225
All
All
556
641
250/300 E,F,G, or H 698
250/300
I, J, or K 947
350/400 E,F,G, or H 801
350/400
I, J, or K 1082
filters dampers dampers insulation double Wall fresh air f & ra (indoor only) (all sections)
6
6
6
6
8
15
12
17
26
26
29
29
33
33
38
38
46
46
52
52
60
60
70
70
10
10
10
12
12
19
12
19
72
72
77
85
87
134
101
144
All weights in inches.
52
5-594.6
maintenance
figure 53.1 - filter replacement arrangement for
Blower size (digit 16) i, J, K, and l
a a
NON-ACCESS
SIDE
FILTER
SPACER
a d a a
NON-ACCESS
SIDE
FILTER
SPACER
a
figure 53.2 - manifold assembly removal
ELECTRICAL
JUNCTION
BOX
SERIAL PLATE ON
OUTSIDE OF DOOR
(NOT SHOWN)
a a a c
250/300
500/600
c a c
A = 20'' x 25''
B = 16'' x 25''
C = 20'' x 16''
D = 15'' X 25''
a
B d
350/400
700/800
840/960
B
duct furnace
When providing annual maintenance for the duct furnace, keep the unit free from dust, dirt, grease and foreign matter. Pay particular attention to:
1. The combustion air and exhaust vent piping.
2. The burner ports and pilot burner orifices (avoid the use of hard, sharp instruments capable of damaging surfaces for cleaning these ports). To check the burner port and pilot burner orifice, see Burner and Pilot Assembly Removal.
3. The air shutters and main burner orifices (avoid the use of hard, sharp instruments capable of damaging surfaces for cleaning these orifices). To check the air shutters and main burner orifices, see for Manifold Assembly Removal.
electrical Wiring
The electrical wiring should be checked annually for loose connections or deteriorated insulation.
gas piping & controls
The gas valves and piping should be checked annually for general cleanliness and tightness.
The gas control should be checked to insure that the unit is operating properly.
manifold assembly removal to remove the manifold
1. Shut off gas and electric supply.
2. Remove the burner side access panel.
3. Disconnect gas manifold at ground union joint.
4. Remove the two screws holding the manifold to the heat exchanger support.
5. Slide the manifold through the manifold bracket.
6. Clean the orifices and adjust the air shutters as necessary.
7. Follow steps 3-6 in reverse order to install the manifold assembly.
8. Turn on the electric and gas supply.
9. Check the ground union joint for leaks with a soap solution.
Tighten if necessary.
10. Install the burner side access panel.
GROUND
UNION
JOINT
BURNER SIDE
ACCESS PANEL
HEAT EXCHANGER
SUPPORT
MANIFOLD
Burner and pilot assembly removal to remove the burner
1. Shut off gas and electric supply.
2. Remove the burner side access panel.
3. Disconnect the pilot supply line from the gas valve.
4. Disconnect the ignition cable from the ignition controller
(located in the electrical junction box). Feed the cable through the bushing in the bottom of the electrical junction box.
5. Remove the screws holding the burner side access panel.
Attached to the panel are the burner retaining pins that align the burner.
6. Slide the burner assembly out. The pilot is attached to the burner assembly.
7. Examine the burner and pilot assembly for cleanliness and/ or obstructions as necessary (see Duct Furnace for cleaning instructions).
8. Replace the burner assembly in reverse order. In replacing the burner, be certain that the rear burner slots are located properly on the burner retaining pins. Do not force the burner side access panel, it will not fit if the burner is not properly aligned.
9. Reconnect the ignition cable and pilot gas supply line.
10. Install the burner side access panel.
11. Turn on the electric and gas supply.
figure 53.3 - Burner and pilot assembly removal
5-594.6
PILOT
ASSEMBLY
IGNITION
CABLE
PILOT
SUPPLY
LINE
HEAT
EXCHANGER
SUPPORT
AIR SHUTTERS
(NOT SHOWN)
ARE LOCATED
ON THE
MANIFOLD
53
service & trouBlesHooting
WARNING
When servicing or repairing this equipment, use only
Modine-approved service replacement parts. A complete replacement parts list may be obtained by contacting Modine
Manufacturing Company. Refer to the rating plate on the appliance for complete appliance model number, serial number, and company address. Any substitution of parts or controls not approved by Modine will be at the owner’s risk.
table 54.1 - troubleshooting
trouble power exhauster motor will not start
pilot does not light
main burners do not light (pilot is lit) lifting flames (see figure 55.1)
1. Defective valve.
2. Loose wiring.
3. Defective pilot sensor
4. Defective ignition controller.
5. Improper thermostat wiring.
1. Too much primary air.
2. Main pressure set too high.
3. Orifice too large.
yellow tipping
(With propane gas, some yellow tipping is always present.)
flashback
1. Insufficient primary air.
2. Dirty orifice.
3. Misaligned orifice.
1. Too much primary air.
2. Main pressure set too high.
3. Orifice too large.
CAUTION
Do not attempt to reuse ignition controllers which have been wet. Replace defective controller.
IMPORTANT
To check most of the Possible Remedies in the troubleshooting guide listed in Table 54.1, refer to the applicable sections of the manual.
possible cause
1. Power supply is off.
2. No 24V power to thermostat.
3. Thermostat malfunction.
4. Defective power exhauster relay.
5. Defective power exhauster motor.
1. Main gas is off.
2. Power supply is off.
3. Air in gas line.
4. Dirt in pilot orifice.
5. Gas pressure out of proper range.
6. Pilot valve does not open.
a. Defective ignition controller.
b. Defective gas valve.
7. No Spark at ignitor.
a. Loose wire connections.
b. Pilot sensor is grounded.
c. Defective ignition controller.
8. Safety device has cut power.
possible remedy
1. Turn on main power.
2. Check control transformer.
3. Check/replace thermostat.
4. Replace power exhauster relay.
5. Replace power exhauster motor.
1. Open manual gas valve.
2. Turn on main power.
3. Purge gas line.
4. Check for plugged pilot orifice and clean with compressed air if necessary.
5. Adjust to a maximum of 14" W.C.
Minimum for Natural Gas - 6" W.C.
Minimum for Propane Gas - 11" W.C.
6. Check wiring for 24 volts to valve. a. Replace ignition controller. b. Replace gas valve.
7.
a. Check all ignition controller wiring.
b. Replace sensor if cracked or worn c. Replace ignition controller.
8. Check all safety devices (High limit, air flow proving switch, differential pressure switch, gas pressure switches, etc.)
Determine and correct problem. Reset if necessary.
1. Replace valve.
2. Check wiring to gas valve.
3. Replace pilot sensor.
4. Replace ignition controller.
5. Verify wiring compared to wiring diagram.
1. Reduce primary air.
2. Adjust to a maximum of 14" W.C.
3. Check orifice size with those listed on the serial plate.
1. Increase primary air.
2. Check orifices and clean with compressed air if necessary.
3. Check manifold, replace if necessary.
1. Reduce primary air.
2. Adjust to a maximum of 14" W.C.
3. Check orifice size with those listed on the serial plate.
54
5-594.6
service & trouBlesHooting
table 55.1 - troubleshooting (continued)
trouble floating flames (see figure 55.2) possible cause
1. Insufficient primary air.
2. Main pressure set too high.
3. Orifice too large.
flame rollout (see figure 55.3) not enough Heat
4. Blocked vent.
1. Main pressure set too high.
2. Orifice too large.
3. Blocked vent.
1. Unit cycling on high limit. ➀ a. Obstructions/leaks in duct system.
b. Main pressure set too high.
c. Blower motor not energized.
too much Heat
d. Loose belt e. Blower speed too low.
f. Blocked/damaged venting system.
g. Air distribution baffle removed (high
temperature rise units only).
h. Defective high limit switch.
2. Main pressure set too low.
3. Too much outside air.
4. Thermostat malfunction.
5. Gas controls wired incorrectly.
6. Unit undersized.
1. Thermostat malfunction.
2. Gas controls do not shut-off. a. Gas controls wired incorrectly.
b. Short circuit.
3. Main gas pressure set too high.
4. Defective gas valve.
possible remedy
1. Increase primary air.
2. Adjust to a maximum of 14" W.C.
3. Check orifice size with those listed on the serial plate.
4. Clean/correct venting system.
1. Adjust to a maximum of 14" W.C.
2. Check orifice size with those listed on the serial plate.
3. Clean/correct venting system.
1. a. Clean/correct duct system.
b. Adjust to a maximum of 14" W.C. c. Check/correct to insure blower motor
operates within 45 seconds of when
- gas controls are energized.
d. Adjust belt tension.
e. Check/correct blower drive settings for
proper rpm.
f. Check/correct venting system.
g. Replace air distribution baffle.
h. Replace high limit switch.
2. Adjust main gas pressure.
Minimum for Natural Gas — 6" W.C.
Minimum for Propane Gas — 11" W.C.
3. Adjust outside air damper to decrease outside air percentage (if possible).
4. Check/replace thermostat.
5. Check unit wiring against the wiring diagram.
6. Check design conditions. If unit is undersized, an additional unit(s) or other heat source must be added.
1. Check/replace thermostat.
2.
a. Check unit wiring against the wiring
diagram.
b. Check for loose or worn wires.
3. Adjust to a maximum of 14" W.C.
4. Replace gas valve.
➀
automatic reset High limit
The duct furnace comes standard with an automatic reset high limit switch that will shut-off the gas should the discharge air temperature become excessive. See Figure 21.1, indicator
46 for the location of either the standard automatic or optional manual reset high limit switch. The switch should operate only when something is seriously wrong with the unit operation.
Anytime the switch operates, correct the difficulty immediately or serious damage may result. If the switch cuts off the gas supply during normal operation, refer to the “Not Enough Heat” section of Service & Troubleshooting.
figure 55.1 - lifting flame condition figure 55.2 floating flame condition figure 55.3 flame rollout appearance
5-594.6
55
model designations
model identification
Indoor duct furnace/make-up air units contain CSA and
ETL/ETL Canada certified indoor separated combustion duct furnace(s). This duct furnace is combined with either a blower section or a blower and cooling section to make a complete make-up air or heating/ventilating/ cooling unit that is ETL/ETL
Canada certified. For this reason, two identification plates are used on these models. The serial plate is used to identify the duct furnace and its components. The
model identification
plate is used to identify the complete model, including blower and cooling sections.
ordering
When servicing, repairing or replacing parts on these units, locate the model identification plate of the unit and always give the complete Model Number and Serial Number from the model identification plate. The model identification plate is located on the door of the electrical control box (See Figure
56.1). The part numbers for some common replacement parts are listed on the serial plate (See Figure 56.2) and the model identification plate (See Figure 57.1). For a complete description of the model number, see Model Identification.
figure 56.2 - serial plate
Modine Manufacturing Company
1500 DeKoven Ave., Racine, WI 53403
Phone: 800.828.4328
D
figure 56.1 - serial plate and model identification plate locations
SERIAL
PLATE
MODEL
IDENTIFICATION
PLATE
3.5
56
5-594.6
model designations
figure 57.1 - model identification plate
DBS 75AFRHN10A1AA1AAA1A 01101010199-0002
115/208-230
115 60 1
60 1
8.47
6.6/3.0-3.3
9F20218
5H71790-
10.00
Modine Manufacturing Company
1500 DeKoven Ave., Racine, WI 53403
Phone: 800.828.4328
5H63081-20
5H58064-3
5H76183-31
figure 57.2 - dfs serial number designations ➀
s 09 17 09 36
serial numBer prefiX
<blank> if standard
"S" if Special Product Order
series identity numBer control supplier
01-Robertshaw 09-White Rodgers
05-Honeywell 17-United Technologies
08-Fenwal
gas valve supplier
01-Robertshaw 09-White Rodgers
05-Honeywell
10 0123 10000
spo numBer
<blank> if standard
##### if Special Product Order
seQuential numBer
Varies - 0000 TO 9999
Each unit in a week has a unique number
year produced
WeeK produced
figure 57.3 - dBs/dcs serial number designations ➀
serial number designations
motor vendor code
01 – Century
15 – Marathon etc.
fan or BloWer vendor code
10 – Lau
20 – Morrison etc.
series identity numBer
Identifies which series of controls were furnished on the unit.
01 10 201 01 02-1000
seQuence numBer year of manufacture
01 – 2001
02 – 2002 etc.
WeeK of manufacture
01 – 1st week of year
26 – 26th week of year
➀
Serial number format subject to change. When contacting the factory for replacement parts, always have the actual serial number ready from the unit(s).
5-594.6
57
start-up cHecKlist indirect gas-fired Heating eQuipment
Job Name:
Address:
Date:
Model No.:
City & State: Order No.:
Start-Up Check List “ALL ITEMS MUST BE CHECKED” Serial No.:
1. All shipping straps, braces, tie downs removed?
2. Unit installed level and secure?
3. Gas burner properly located and aligned?
4. Blower and motor alignment okay?
5. Bearings aligned and tight on shaft/bearing supports?
6. Electrical connections checked and secure?
7. Gas piping checked and tightened if necessary?
8. Any visible damage to unit?
Describe: ______________________________________________
If damaged, was the damage repaired?
9. Air inlet and discharge checked for obstructions?
10. Bearings checked for proper lubrication?
11. Filters in place and correct to direction of air flow?
____ Yes
____ Yes
____ Yes
____ Yes
____ Yes
____ Yes
___ No
___ No
____ Yes ___ No
____ Yes ___ No
___ No
___ No
___ No
___ No
____ Yes ___ No
____ Yes ___ No
____ Yes ___ No
____ Yes ___ No
____ Yes ___ No 12. Belt tension checked?
13. Electric supply to unit: ______ Volts, ______ Hz, ______ Phase
14. Gas supply to unit: ______ Natural, ______ Propane
15. Gas supply pressure to unit: ______ " W.C., ______ PSIG
16. Inlet and/or discharge dampers operating correctly?
17. Blower rotation correct?
18. Blower speed: Hi Speed ______ RPM, Lo Speed ______ RPM
19. Motor speed: Hi Speed ______ RPM, Lo Speed ______ RPM
____ Yes
____ Yes
___ No
___ No
20. Is unit noisy? Excessive vibration?
21. Motor voltage: L1 ______ V, L2 ______ V, L3 ______ V
22. Motor amps: L1 ______ Amp, L2 ______ Amp, L3 ______ Amp
23. High temperature limit control continuity checked?
24. Burner light off
____ Yes
____ Yes
___ No
___ No
Low Fire: Does entire burner light off?
Hi Fire: Burner pressure reading? ______ " W.C.
Is flame clean and stable?
Does flame modulate in response to temperature control(s)?
25. Gas input checked?
Input at maximum firing rate: __________ Btu/Hr
Input at minimum firing rate: -__________ Btu/Hr
26. Gas piping checked for and free of leaks?
____ Yes ___ No
____ Yes ___ No
____ Yes
____ Yes
___ No
___ No
____ Yes ___ No
27. Has wiring been verified to match the unit wiring diagram? ____ Yes ___ No
28. Have all the modes of the sequence of operation been verified and tested? ____ Yes ___ No
29. What optional and/or accessory control devices have been set?
Device: _______________ Setting: ___________ (°F/psi/Inches W.C./etc.) ____ Yes ___ No
Device: _______________ Setting: ___________ (°F/psi/Inches W.C./etc.) ____ Yes ___ No
Device: _______________ Setting: ___________ (°F/psi/Inches W.C./etc.) ____ Yes ___ No
Customer/Owner instructed in operation and maintenance of unit? ____ Yes ___ No
Name of Person(s) Instructed: ______________________________________________________________
Comments: ____________________________________________________________________________
____________________________________________________________________________
Start-Up Company Name: _______________________________ Phone: __________________________
Signature: _______________________________________________________ Date: ________________
58
5-594.6
model nomenclature for system units
Weatherproof model nomenclature
1
PT
2
UC
3
V
1 - product type (pt)
D - Indoor HVAC Unit
4 5 6
MBH
7
HE
2 - unit configuration (uc)
B - Blower Package - Furnace & Blower
8 9 10 11 12 13 14 15
DS AS ATR GT GV SS SV TR
C - Cooling Package - Furnace, Blower, & Cooling Cabinet
16
BB
17
HP
18
MT
19 20 21 22 23
SA AC EC CC
16 - Blower size & Bearing type (BB)
A - 9-7 Spider Bearings G - 15-15 Spider Bearings
B - 9-7 Pillow Block Bearings H - 15-15 Pillow Block Bearings
C - 9-9 Spider Bearings I - 18-18 Spider Bearings under 15 Hp
D - 9-9 Pillow Block Bearings J - 18-18 Pillow Block Bearings under 15 Hp
E - 12-12 Spider Bearings K - 18-18 Pillow Block Bearings for 15 Hp & up
F - 12-12 Pillow Block Bearings L - 20-18 Pillow Block Bearings
3 - venting (v)
S - Separated Combustion
4,5,6 - furnace input rating (mBH) (output on 840 & 960)
100 - 100,000 Btu/Hr Input
175 - 175,000 Btu/Hr Input
250 - 250,000 Btu/Hr Input
400 - 400,000 Btu/Hr Input
A - Aluminized Steel
500 - 500,000 Btu/Hr Input
600 - 600,000 Btu/Hr Input
840 - 1,050,000 Btu/Hr Input
960 - 1,200,000 Btu/Hr Input
7 - Heat exchanger/Burner/drip pan material (He)
S - 409 Stainless Steel Heat Exchanger/Burner
T - 409 Stainless Steel Heat Exchanger/Burner/Drip Pan
17 - motor Horsepower (Hp)
A - 1/3 Hp
B - 1/2 Hp
C - 3/4 Hp
D - 1 Hp
E - 1-1/2 Hp
F - 2 Hp
G - 3 Hp
H - 5 Hp
I - 7-1/2 Hp
J - 10 Hp
K - 15 Hp
V - 20 Hp
L - 1/3 Hp with Motor Starter
M - 1/2 Hp with Motor Starter
N - 3/4 Hp with Motor Starter
P - 1 Hp with Motor Starter
Q - 1-1/2 Hp with Motor Starter
R - 2 Hp Hp with Motor Starter
S - 3 Hp with Motor Starter
T - 5 Hp with Motor Starter
W - 7-1/2 Hp with Motor Starter
X - 10 Hp with Motor Starter
Y - 15 Hp with Motor Starter
Z - 20 Hp with Motor Starter
8 - development sequence designation (ds)
F - Single Stage M - 2-stage or Modulating
9 - access side (as)
R - Right Hand L - Left hand
18 - motor type (mt)
1 - ODP
2 - ODP - High Eff.
3 - ODP, 1800/900 RPM
4 - ODP, 1800/1200 RPM
5 - TE
6 - TE - High Eff.
7 - TE, 1800/900 RPM
8 - TE, 1800/1200 RPM
10 - air temperature rise (atr)
H - High 60°-100°F
L - Low 20°-60°F
11 - gas type (gt)
N - Natural with ignition controller
P - Propane with ignition controller
12 - gas valve (gv)
1 - Single Stage
2 - Two Stage
4 - Electronic Modulation
6 - Electronic Modulation Slave
7 - Electronic Modulation 0-10 Vdc
External Input
5 - Electronic Modulation Master 8 - Electronic Modulation 4-20 mA
External Input
13 - additional safety switches (ss)
0 - No Switches (Standard)
1 - Low Gas Pressure Switch (Premium)
2 - High Gas Pressure Switch (Premium)
3 - High and Low Gas Pressure Switch (Premium)
14 - supply voltage (sv)
A - 115/60/1
B - 208/60/1
C - 230/60/1
D - 208/60/3
15 - transformer (tr)
1 - 40 VA
2 - 75 VA
3 - 150 VA
E - 230/60/3
F - 460/60/3
G - 575/60/3
4 - 250 VA
0 - None
19 - sheave arrangement (sa)
A - (See Sheave Tables)
20,21 - air control (ac)
AA - RA Opening
BA - FA Opening
CA - FA & RA Openings
DA - FA Dampers w/ 2 pos motor (No RA)
EA - FA & RA Dampers w/ 2 pos motor
EQ - ASHRAE Cycle I - (“EA” with Warm-up Stat)
FA - FA Damper & RA Opening w/ 2 pos motor
GA - FA & RA Mod motor w/ 0-10 Vdc External Input
GB - FA & RA Mod motor w/ 4-20 mA External Input
GC - FA & RA Mod motor w/ Minimum Position
GD - FA & RA Mod motor w/ Remote Position (On Remote Panel)
GE - FA & RA Mod motor w/ 3 pos. damper (100% RA, Variable, 100% OA)
GF - FA & RA Mod motor w/ A350P Proportional Temp Controller
GG - FA & RA Mod motor w/ Minimum Position & Prop. Temp Controller
GH - FA & RA Mod motor w/ Remote Position & Prop. Temp Controller
GJ - FA & RA Mod motor w/ FA Enthalpy Controller
GK - ASHRAE Cycle II - (“GG” with Warm-up Stat)
GM - ASHRAE Cycle II - (“GH” with Warm-up Stat)
GN - ASHRAE Cycle III - (“GF” with Warm-up Stat)
HP - FA & RA Floating motor w/ Space Pressure Controller
JA - Manual FA & RA Dampers
KA - Manual FA Damper with Return Air Opening
22 - evaporative cooling (ec)
0 - None
23 - cooling coil (cc)
0 - None 1 - Factory Installed Coil
59
commercial Warranty
Seller warrants its products to be free from defects in material and workmanship, EXCLUSIVE, HOWEVER, of failures attributable to the use of materials substituted under emergency conditions for materials normally employed. This warranty covers replacement of any parts furnished from the factory of Seller, but does not cover labor of any kind and materials not furnished by Seller, or any charges for any such labor or materials, whether such labor, materials or charges thereon are due to replacement of parts, adjustments, repairs, or any other work done. This warranty does not apply to any equipment which shall have been repaired or altered outside the factory of
Seller in any way so as, in the judgment of Seller, to affect its stability, nor which has been subjected to misuse, negligence, or operating conditions in excess of those for which such equipment was designed. This warranty does not cover the effects of physical or chemical properties of water or steam or other liquids or gases used in the equipment.
BUYER AGREES THAT SELLER’S WARRANTY OF ITS PRODUCTS TO
BE FREE FROM DEFECT IN MATERIAL AND WORKMANSHIP, AS LIMITED
HEREIN, SHALL BE IN LIEU OF AND EXCLUSIVE OF ALL OTHER
WARRANTIES, EITHER EXPRESS OR IMPLIED, WHETHER ARISING
FROM LAW, COURSE OF DEALING, USAGE OF TRADE, OR OTHERWISE,
tHere are no otHer Warranties, including Warranty of mercHantaBility or fitness for purpose, WHicH eXtend
Beyond tHe product description confirmed By Buyer and seller as of tHe date of final agreement.
This warranty is void if the input to the product exceeds the rated input as indicated on the product serial plate by more than 5% on gas-fired and oil-fired units, or if the product in the judgment of SELLER has been installed in a corrosive atmosphere, or subjected to corrosive fluids or gases, been subjected to misuse, negligence, accident, excessive thermal shock, excessive humidity, physical damage, impact, abrasion, unauthorized alterations, or operation contrary to SELLER’S printed instructions, or if the serial number has been altered, defaced or removed.
BUYER’S REMEDY FOR BREACH OF WARRANTY, EXCLUSIVE OF ALL
OTHER REMEDIES PROVIDED BY LAW, IS LIMITED TO REPAIR OR
REPLACEMENT AT THE FACTORY OF SELLER, ANY COMPONENT WHICH
component
Applicable Models
SHALL, WITHIN THE APPLICABLE WARRANTY PERIOD DEFINED HEREIN
AND UPON PRIOR WRITTEN APPROVAL, BE RETURNED TO SELLER
WITH TRANSPORTATION CHARGES PREPAID AND WHICH THE
EXAMINATION OF SELLER SHALL DISCLOSE TO HAVE BEEN DEFECTIVE;
EXCEPT THAT WHEN THE PRODUCT IS TO BE USED BY BUYER AS A
COMPONENT PART OF EQUIPMENT MANUFACTURED BY BUYER,
BUYER’S REMEDY FOR BREACH, AS LIMITED HEREIN, SHALL BE
LIMITED TO ONE YEAR FROM DATE OF SHIPMENT FROM SELLER. FOR
GAS-FIRED PRODUCTS INSTALLED IN HIGH HUMIDITY APPLICATIONS
AND UTILIZING STAINLESS STEEL HEAT EXCHANGERS, BUYER’S
REMEDY FOR BREACH, AS LIMITED HEREIN, SHALL BE LIMITED TO TEN
YEARS FROM DATE OF SHIPMENT FROM SELLER.
These warranties are issued only to the original owner-user and cannot be transferred or assigned. No provision is made in these warranties for any labor allowance or field labor participation. Seller will not honor any expenses incurred in its behalf with regard to repairs to any of Seller’s products. No credit shall be issued for any defective part returned without proper written authorization (including, but not limited to, model number, serial number, date of failure, etc.) and freight prepaid.
OPTIONAL SUPPLEMENTAL WARRANTY
Provided a supplemental warranty has been purchased, Seller extends the warranty herein for an additional four (4) years on certain compressors.
Provided a supplemental warranty has been purchased, Seller extends the warranty herein for an additional four (4) years or nine (9) years on certain heat exchangers.
EXCLUSION OF CONSUMABLES & CONDITIONS BEYOND
SELLER’S CONTROL
The above referenced warranty shall not be applicable to any of the following items: refrigerant gas, belts, filters, fuses and other items consumed or worn out by normal wear and tear or conditions beyond Seller’s control, including
(without limitation as to generality) polluted or contaminated or foreign matter contained in the air or water utilized for heat exchanger (condenser) cooling or if the failure of the part is caused by improper air or water supply, or improper or incorrect sizing of power supply.
“applicaBle Warranty period”
Heat exchangers
Gas-Fired Units except PSH/BSH
TEN YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER, WITHIN
TEN YEARS FROM DATE OF RESALE BY BUYER OR ANY OTHER USER, WITHIN TEN YEARS
FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION, OR WITHIN ONE
HUNDRED TWENTY-SIX MONTHS FROM DATE OF SHIPMENT FROM SELLER, WHICHEVER
OCCURS FIRST
Heat exchangers
Low Intensity Infrared Units
compressors
Condensing Units for Cassettes
Burners
Low Intensity Infrared Units
other
Components excluding Heat Exchangers,
Coils, Condensers, Burners, Sheet Metal
FIVE YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER, WITHIN
FIVE YEARS FROM DATE OF RESALE BY BUYER OR ANY OTHER USER, WITHIN FIVE YEARS
FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION, OR WITHIN SIXTY-SIX
MONTHS FROM DATE OF SHIPMENT FROM SELLER, WHICHEVER OCCURS FIRST
TWO YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER, WITHIN
TWO YEARS FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION, OR WITHIN
THIRTY MONTHS FROM DATE OF SHIPMENT FROM SELLER, WHICHEVER OCCURS FIRST
Heat exchangers/coils
Indoor and Outdoor Duct Furnaces and
System Units, PSH/BSH, Steam/Hot Water Units,
Oil-Fired Units, Electric Units, Cassettes,
Vertical Unit Ventilators
compressors
Vertical Unit Ventilators
Burners
High Intensity Infrared Units
sheet metal parts
All Products
ONE YEAR FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER, WITHIN
ONE YEAR FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION, OR WITHIN
EIGHTEEN MONTHS FROM DATE OF SHIPMENT FROM SELLER, WHICHEVER OCCURS FIRST
As Modine Manufacturing Company has a continuous product improvement program, it reserves the right to change design and specifications without notice.
© Modine Manufacturing Company 2010
commercial products group
Modine Manufacturing Company
1500 DeKoven Avenue
Racine, WI 53403
Phone: 1.800.828.4328 (HEAT) www.modine.com
Litho in USA

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Key features
- separated combustion
- gas-fired
- indoor
- make-up air units
- built-in power exhauster
- various sizes