Modine DBG, DCG gas-fired indoor gravity vented duct furnace Installation and service manual

Below you will find brief information for DBG, DCG. This manual outlines installation and service procedures for Modine's gas-fired indoor gravity vented duct furnaces. It includes instructions on unit location, duct installation, venting, gas connections, electrical connections, start-up procedures, and more.

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5-562.8

5H77937a1

April, 2010

installation and service manual gas-fired indoor gravity vented duct furnaces/make-up air units models dBG/dcG

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.

9900100

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.

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.

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 draft diverter is provided - additional external diverters are not required or permitted.

3. Gas-fired heating equipment which has been improperly vented, or which experiences a blocked vent condition may have flue gases accidentally spilled into the heated space. See page 25 for specific information about the blocked vent safety switch supplied on the unit.

4. 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.

5. Gas pressure to appliance controls must never exceed 14"

W.C. (1/2 psi).

6. Disconnect power supply before making wiring connections to prevent electrical shock and equipment damage.

7. 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.

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

11. When servicing or repairing this equipment, use only factoryapproved service replacement parts. A complete replacement parts list may be obtained by contacting Modine Manufacturing

Company. Refer to the rating plate on the appliance for complete appliance model number, serial number, and company address. Any substitution of parts or controls not approved by the factory will be at the owners risk.

CAUTION

1. Purging of air from gas supply line should be performed as described in ANSI Z223.1 - latest edition “National Fuel

Gas Code”, or in Canada in CAN/CGA-B149 codes.

2. Do not attempt to reuse any mechanical or electronic ignition controllers which has been wet. Replace defective controller.

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

5-562.8

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 15 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 Table 50.1, refer to the applicable sections of the manual.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Gas Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

Cooling Coil Specifications and Installation. . . . . . . . . . . 10

Start-Up Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Pilot Burner and Main Burner Adjustment . . . . . . . . . . . . . 13

Blower Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Lubrication Recommendations . . . . . . . . . . . . . . . . . . . . 15

Damper Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . 15

Control Operating Sequence. . . . . . . . . . . . . . . . . . . . . . 15

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

General Performance Data. . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Unit Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Blower Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Blower Sheave Assembly Data . . . . . . . . . . . . . . . . . . . . . . . 34

Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Motor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Dimensions Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Service & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Model Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Start-Up Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Model Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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

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 m mm meters

3 /min

to convert multiply By to obtain

CFH 1.699 m 3 /min

Btu/ft3

pound

0.0374

0.453 mJ/m kg

Btu/hr

gallons psig

0.000293

3.785

27.7 kW/hr liters

"W.C.

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.

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 Tables 3.2 and 3.3.

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 exhaust vent piping must be connected to the outside atmosphere.

8. In garages or other sections of aircraft hangars such as offices and shops that communicate with areas used for servicing or storage, keep the bottom of the unit at least

7' above the floor unless the unit is properly guarded to provide user protection from moving parts. In parking garages, the unit must be installed in accordance with the standard for parking structures ANSI/NFPA 88A, and in repair garages the standard for repair garages NFPA #88B.

In Canada, installation of 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.

figure 3.1 - combustible material and service clearances

3'' minimum clearance to combustible material is required from the vent collar

Access

Side

➀

A 3'' minimum clearance to combustible material is required from the vent collar.

table 3.2 - combustible material clearances

model size

75-175

200-960

access side

(a)

non- access side

(B)

top

(c)

table 3.3 - recommended service clearances

model size

access side

(a) non-access side

(B) top

(c)

100/125

150/175

200/225

250/300

350/400

500/600

700/800

840/960

18"

20"

25"

27"

30"

41"

30"

41"

10"

combustion air requirements

Units installed in tightly sealed buildings or confined spaces must be provided with two permanent openings, one near the top of the confined space and one near the bottom. Each opening should have a free area of not less than one square inch per 1,000 BTU per hour of the total input rating off all units in the enclosure, freely communicating with interior areas having, in turn adequate infiltration from the outside.

For further details on supplying combustion air to a confined

(tightly sealed) space or unconfined space, see the National

Fuel Gas Code ANSI Z223.1 of CAN/CGA B149.1 or .2

Installation Code, latest edition.

sound and vibration levels

All standard blower 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.

5-562.8

unit location/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

45 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

3/4" diameter suspension hanging locations are provided in the base rail assembly of the unit. Refer to Figure 45.1 for

Suspension Hanging Locations and Figure 4.1 demonstrates how the unit should be suspended and the suspension rods fastened to the unit base rail. If required, vibration isolators may be added.

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 5/8inch anchor bolts spaced according to Figure 4.2, 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 4.1 - unit suspension method

BLOWER

SECTION

DOOR

ELECTRICAL

SECTION

DOOR

DUCT

FURNACE

Standard blower cabinet shown

figure 4.2 - floor mounted units

3/4" Suspension Rods

(by others)

(1) 3/4" NUT &

LOCKWASHER

(2) 3/4" NUTS &

LOCKWASHER

5/8 Dia. (4)

model Blower type dBG units dcG units all units dBG units

size (digit 16) (a) (a) (B) (c)

100/25

150/175

200/225

All

86.27

86.37

115.48 33.85

115.48 36.36

115.48 40.61

115.48 42.71

250/300 E,F,G, or H 86.37

250/300 I,J, or K 112.12

115.48

151.34

45.75

350/400 E,F,G or H 86.37

350/400 I,J, or K 122.2

115.48

151.34

57.27

500/600 G or H

500/600 I,J, or K

119.52

155.38

700/800 G or H 119.52

700/800 I,J,K, or L 155.37

840/960 I,J,K, or L 184.61

45.75

57.27

33.5

62.73

5-562.8

duct installation

duct installation

furnace discharge duct connection

1. The furnace discharge is designed to accept straight ductwork. (See Figure 5.1.) 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 5.2).

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 5.1 - furnace discharge duct connection

DUCT FURNA

figure 5.2 - recommended field installed discharge duct configurations for Blower package units

Dimension "B" should never be less than 1/2 of dimension "A".

Provide leak tight access panels in discharge duct for heat exchanger

Turning

Vanes

3" Max.

3" Min.

Air

Flow

SIDE VIEW

12" Min.

3" Min.

Dimension "B" should never be less than 1/2 of dimension "A".

Turning

Vanes

3" Max.

Provide leak tight access panels in discharge duct for heat exchanger inspection.

DUCTW

ORK A

ACCESS

PANEL

STRAIGFIT

DUCTWORK

Air

Flow

TOP VIEW

12" Min.

Blower section and cooling cabinet discharge duct connections

The blower section back and bottom and cooling cabinet section discharge are designed to accept 90° flanged ductwork.

(See Figure 5.3.) Provide an airtight seal between the ductwork and the unit. 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.

figure 5.3 - Blower section and cooling cabinet discharge duct connections

1/2"

DUCT FURNACE

DUCTWORK

90°

FLANGED

DUCTWORK

5-562.8

installation

venting

WARNING

1. Gas fired heating equipment must be vented - do not

operate unvented.

2. A built-in draft diverter is provided - additional external

draft diverters are not required or permitted.

3. Gas-fired heating equipment which has been improperly

vented, or which experiences a blocked vent condition may

have flue gasses accidentally spilled into the heated space.

See page 25 for specific information about the blocked vent

safety switch supplied on the unit.

4. Modine Manufacturing Company offers power exhausters

as an accessory. Power exhausters not supplied by Modine

Manufacturing Company are not permitted.

table 6.1 - ansi venting requirements

appliance

category

iii

description

Negative vent pressure

Non-condensing

Negative vent pressure

Condensing

Positive vent pressure

Non-condensing

Positive vent pressure

Condensing

venting requirements

Follow standard venting requirements.

Condensate must be drained.

Vent must be gastight.

Vent must be liquid and gastight. Condensate must be drained.

General venting air instructions

1. Installation of venting 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. All units with single-stage controls are Category I. All units with two-stage or modulating controls are Category II.

The installation of a Catagory II unit must conform to the requirements from Table 6.1 in addition to those listed below.

3. From Table 43.1 or 44.1, select the size of vent pipe that fits the flue outlet for the unit. Do not use a vent pipe smaller than the size of the outlet on the appliance. The pipe should be suitable corrosion resistant material. Follow the National

Fuel Gas Code for minimum thickness and composition of vent material. The minimum thickness for connectors varies depending on the pipe diameter.

4. Limit length of horizontal runs to 75% of vertical height.

Install with a minimum upward slope from unit of 1/4 inch per foot and suspend securely from overhead structure at points no greater than 3 feet apart. For best venting, put as much vertical vent as close to the unit as possible.

Fasten individual lengths of vent together with at least three corrosion-resistant sheet-metal screws.

5. Vent 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 vent pipe from entering the unit. The drip leg should be inspected and cleaned out periodically during the heating season.

6. The National Fuel Gas Code requires at least 6 inches from combustible materials for single wall vent pipe. 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 inches if heat damage other than fire (such as material distortion or discoloration) could result.

7. Avoid venting through unheated space . When venting does pass through an unheated space, insulate runs greater than

5 feet to minimize condensation. Inspect for leakage prior to insulating and use insulation that is noncombustible with a rating of not less than 350°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 7.1.

8. When the vent passes through an interior wall or floor, a metal thimble 4 inches greater than the vent diameter is necessary. If there is 6 feet 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

5-562.8

be 2 inches greater than the diameter of the vent pipe. If a thimble is not used, all combustible material must be cut away to provide 6 inches of clearance. Any material used to close the opening must be noncombustible.

9. Do NOT use dampers or other devices in the vent or combustion air pipes.

10. Precautions must be taken to prevent degradation of building materials by flue products.

11. The outlet of the vent should extend as shown in Figure 7.1 and Table 7.1 if the following conditions are met:

Vent diameter is less than 12 inches, vent is of double wall construction and is a listed product, and the vent does not terminate within 10 feet of a vertical wall or similar obstruction.

For vents that have a diameter of 12 inches or larger, constructed of single wall, or terminate within 10 feet of a vertical wall or similar obstruction, the vent pipe shall extend at least 2 feet higher than any portion of a building within a horizontal distance of 10 feet (refer to Figure 7.2).

12. Use a vent terminal to reduce downdrafts and moisture in vent. A vent terminal that is very open will avoid spillage at unit’s diverter relief opening and tripping of the blocked vent safety switch.

13. Check vent system to see that combustion products are being vented properly. Operate unit for several minutes and then pass a lighted match around the edge of the diverter relief opening. If the flame is drawn into the opening, the vent system is drawing properly. If not, make adjustments to provide adequate draft (see Figure 49.1).

14. For instructions on common venting refer to the National

Gas Code.

15. The vent must terminate no less than 5 feet above the vent connector.

16. A unit located within an unoccupied attic or concealed space shall not be vented with single wall vent pipe.

17. Single wall vent pipe must not pass through any attic, inside wall, consealed space, or floor.

installation

table 7.1 - minimum Height from roof to lowest discharge opening

Rise

X (in)

Roof Pitch

0-6

6-7

7-8

8-9

Flat to 6/12

6/12 to 7/12

7/12 to 8/12

8/12 to 9/12

9-10 9/12 to 10/12

10-11 10/12 to 11/12

11-12 11/12 to 12/12

12-14 12/12 to 14/12

14-16 14/12 to 16/12

16-18 16/12 to 18/12

18-20 18/12 to 20/12

20-21 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 7.1 - Gravity vented duct furnace venting

(pitched roof)

ADDITIONAL VENTING REqUIREMENTS FOR CATEGORY II

UNITS

Vent system must provide for drainage of condensate. At the low point of the vent system, install a tee fitting with a connector and attach flexible tubing, minimum 3/8 inch I.D., and run to a drain.

Tee fitting and associated condensate disposal system must be periodically cleaned.

ADDITIONAL VENTING REqUIREMENTS FOR VENTING

INTO AN EXISTING MASONRY CHIMNEY OR COMMON VENT

(CATEGORY III OR IV UNITS ONLY).

1. Do not vent a Category l or ll unit into a common vent with mechanical draft systems operating under positive pressure

(Category lll or lV units.)

2. When connecting vent to an existing chimney, do not push vent pipe beyond internal surface of chimney.

3. When venting into a common vent, the area of the common vent should be equal to or greater than the area of the largest vent plus 50 percent of the area of all additional vents.

4. When venting into a common vent, the individual vents should enter at different levels.

figure 7.2 - Gravity vented duct furnace venting

(obstructed)

5-562.8

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 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.

CAUTION

Purging of air from gas supply line should be performed as described in ANSI Z223.1 - latest edition “National Fuel Gas

Code”, or in Canada in CAN/CGA-B149 codes.

IMPORTANT

To prevent premature heat exchanger failure, the input to the appliance, as indicated on the serial plate, must not exceed the rated input by more than 5%.

1. Installation of piping must conform with local building codes, or in the absence of local codes, with the National Fuel Gas

Code, ANSI Z223.1 (NFPA 54) - Latest Edition. In Canada, installation must be in accordance with CAN/CGA-B149.1 for natural gas units and CAN/CGA-B149.2 for propane units.

2. Piping to units should conform with local and national requirements for type and volume of gas handled, and pressure drop allowed in the line. Refer to Table 14.1 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 8.1. 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 8.1 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

(See Figure 8.1). Verify the manual shut-off valve is gas tight on an annual basis.

4. Provide a sediment trap before each unit in the line where low spots cannot be avoided. (See Figure 8.1).

5. When Pressure/Leak testing, pressures above 14" W.C.

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

figure 8.1 - recommended sediment trap/manual shut-off valve installation - side or Bottom Gas connection

GAS

SUPPLY LINE

➀

SHUT-OFF VALVE

GROUND

JOINT

UNION

W/ BRASS

SEAT

GAS

SUPPLY LINE

MIN.

PLUGGED

1/8" NPT TEST

GAGE CONNECTION

CONTROLS

SEDIMENT

TRAP

➀

Manual shut-off valve is in the “OFF” position when handle is perpendicular to pipe.

100

125

150

table 8.1 - Gas pipe capacities

Gas pipe capacities (up to 14” W.c. Gas pressure through schedule 40 pipe) cubic feet per Hour with pressure drop of 0.3” W.c.

natural Gas - specific Gravity - 0.60

propane Gas - specific Gravity - 1.50

length

of pipe 1/2" 3/4" pipe diameter

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

(feet) natural propane natural propane natural propane natural propane natural propane natural propane

132

278

190

152

130

115

105

175

120

520

350

285

245

215

195

180

170

160

150

130

120

328

221

180

154

135

123

113

107

101

1050

730

590

500

440

400

370

350

320

305

275

250

662

460

372

315

277

252

233

221

202

192

173

158

1600

1100

890

760

670

610

560

530

490

460

410

380

1008

693

561

479

422

384

353

334

309

290

258

239

3050

2100

1650

1450

1270

1150

1050

990

930

870

780

710

1922

1323

1040

914

800

725

662

624

586

548

491

447

5-562.8

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% greater than rated voltage.

1. Installation of wiring must conform with local building codes, or in the absence of local codes, with the National Electric

Code ANSI/NFPA 70 - Latest Edition. Unit must be electrically grounded in conformance to this code. In Canada, wiring must comply with CSA C22.1, Part 1, Electrical Code.

2. Two copies of the job specific wiring diagram are provided with each unit, one 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 Table 9.1 for maximum wire lengths. Once the wire gauge has been determined, refer to Table 9.2 for the number of wires for which the low voltage terminal blocks in the unit are rated.

table 9.1 - low voltage (24v) maximum Wire length

(feet)

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 of CSA code.

Wire Gauge

model no. trans.

digit 15 va

150

250

18 Ga 16Ga 14 Ga 12 Ga 10 Ga

162 216 315 360 495

115

168

192

264

132

table 9.2 - number of Wires per terminal

Wire Gauge

#10 AWG

#12 AWG

#14 AWG

#16 AWG

#18 AWG

#22 AWG

number of Wires per terminal

1 to 2

1 to 3

1 to 4

1 to 5

2 to 5

4. Make sure all multi-voltage components (motors, transformers, etc.) are wired in accordance with the power supply voltage.

5-562.8

figure 9.1 - recommended accessory field installed disconnect switch mounting locations

BLOWER

SERVICE

DOOR

DISCONNECT

SWITCH WIRING,

AND CONNECTOR

ELECTRIC

SUPPLY

ELECTRICAL

SECTION DOOR

LEFT HAND ACCESS

UNIT SHOWN

ELECTRIC SUPPLY

COMPONENTS MUST BE

CLEAR OF SERVICE DOORS

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 18.1) 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 9.1. For fusible disconnect switches, refer to the Model Identification plate for the fuse size and type.

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. Refer to the unit dimensional drawings on Figures 43.1 through 44.1 for the electrical knock-out locations.

9. 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.

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, 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.

figure 10.1 - cooling section

Optional double wall construction

DX single circuit (shown) and dual circuit coils available

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 10.2 - General dX piping

Liquid Line

Suction Header

Distributor

Equalizer Line

Nozzle

Expansion Valve

(By Others)

Coil

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

Right or left hand coil header access to match gas controls

Full coverage

3-way sloping

409 stainless steel drain pan

1” stubbed drain connection

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.

10 5-562.8

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 of 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 factory representative.

unit installation

table 11.1 - cooling coil performance limits

model size dX - single circuit dX - dual circuit chilled Water 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

② ③

dX chilled coils Water coils

100

125

150

175

200

225

250

300

350

400

1891

2206

2521

3352

3724

5214

3.44

4.01

4.58

6.09

6.77

9.48

1707

2048

2416

3165

3538

4996

3.10

3.72

4.39

5.76

6.43

9.08

1676

2011

2372

3214

3592

5073

3.05

3.66

4.31

5.84

6.53

9.22

609 ④ 9.38

741 ⑤ 11.43

926

1111

1296

1481

1667

1852

2222

2593

2963

11.43

13.42

18.12

20.24

27.26

10.56

12.62

14.77

19.28

21.33

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.

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.

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 11.1 - General chilled fluid piping

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.

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.

5-562.8

unit installation / start-up procedure

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.

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 15 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 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.

5-562.8

unit installation / start-up procedure

19. Recheck the gas supply pressure at the field installed manual shut-off valve. The minumum 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 for intermitent pilot ignition. 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 54 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 installation. 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 combination 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 13.1).

4. Replace the cap from the pilot adjustment screw.

figure 13.1 - correct pilot flame

3/4" to 1"

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 or at the pressure tap of the gas valve for standard gas string. (See Figure 14.1).

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 or gas valve 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 14.2 for item number locations, this is accomplished as follows: a. Disconnect power.

b. Remove all wires from Maxitrol Amplifier terminal “3” or

duct furnace terminal “43” (if available).

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.

h. Disconnect power.

i. Replace cover plate (2) and re-install all wires from

Maxitrol amplifier terminal “3” or 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.

5-562.8

start-up procedure

figure 14.1 - checking manifold pressure with

“u” tube manometer

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.

figure 14.2 - 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 gas valve in Figure 14.1. The larger models may require the removal of the manifold (see Manifold Assembly

Removal).

natural Gas flame control

Control of burner flames on duct furnaces utilizing natural gas is achieved by resetting the primary air shutters (See Figure

48.4) 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 48.4 for air shutter and

14 5-562.8

table 14.1 - manifold pressure and Gas consumption

model size type of Gas

Btu/cu. ft.

specific Gravity

High fire manifold pressure

inches of Water column natural

1040

0.60

3.5

propane

2500

1.53

100

125

150

175

200

225

250

300

350

400

500 ➀

600 ➀

700 ➀

800 ➀

840 ➁

960 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

➀

Model contains 2 furnaces. Values shown are per furnace.

➁

Model contains 3 furnaces. Values shown are per furnace.

72.1

96.1

120.2

240.4

288.7

336.5

384.6

144.2

168.3

192.3

216.3

240.4 ➀

288.7 ➀

336.5 ➀

384.6 ➀

336.5 ➁

384.6 ➁

30.0

40.0

50.0

100.0

120.0

140.0

160.0

60.0

70.0

80.0

90.0

100.0 ➀

120.0 ➀

140.0 ➀

160.0 ➀

140.0 ➁

160.0 ➁

no. of orifices

➀

➁

start- up procedure

Blower adjustments

If blower fan speed changes are required, adjust motor sheave as follows:

1. Refer to page 34 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 15.1 - motor sheave adjustment

Toward Motor

Set Screw

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 15.3.

4. Tighten the 5/16" hex head screw on the ball joint.

figure 15.3 - damper linkage adjustment

CONNECTING

ROD

BALL

JOINT

BLADE ARM

Adjustable Half of Sheave

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 15.2 - Belt tension adjustment

DAMPER BLADE

control operating sequence

IMPORTANT

To prevent premature heat exchanger failure, with all control systems, a blower starting mechanism must be provided so that the blower is running or energized within 45 seconds of the gas control operation.

➪

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.

5-562.8

Indoor gravity vented duct furnaces are supplied with intermittent pilot systems with continuous retry as standard. For intermittent pilot systems, both the main burner and pilot burner are turned off 100% when the thermostat is satisfied. 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 approximately 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.

note: Gas Control Options (see page 16) could change the listed sequence of operation based on their function.

The descriptions given are for the basic duct furnace.

start-up procedure

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 pilot valve opens and the spark ignitor sparks in an attempt to light the pilot. (If the unit was not provided with a time delay relay, the blower starts at this time.)

3. Once the pilot is lit, the flame sensor proves the pilot and stops the spark ignitor from sparking.

4. The main gas valve is opened and the main burner is lit to

100% full fire.

5. If the unit was provided with a time delay relay, the blower starts after 30 to 45 seconds.

6. The unit continues to operate until the thermostat is satisfied, at which time both the main and pilot valves close

100%. (If the unit was not provided with a time delay relay, the blower stops at this time).

7. If the unit was provided with a time delay relay, the blower stops after 30 to 45 seconds.

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 pilot valve opens and the spark ignitor sparks in an attempt to light the pilot. (If the unit was not provided with a time delay relay, the blower starts at this time.)

3. Once the pilot is lit, the flame sensor proves the pilot and stops the spark ignitor from sparking.

4. The main gas valve is opened and the main burner is lit to

50% fire.

5. If the unit was provided with a time delay relay, the blower starts after 30 to 45 seconds.

6. If the temperature at the thermostat continues to fall, the thermostat will call for high stage heat.

7. The main gas valve is opened completely and the main burner is lit to 100% full fire.

8. The unit continues to operate until the high stage of the thermostat is satisfied, at which time the main valve closes to 50% fire.

9. The unit continues to operate until the low stage thermostat is satisfied, at which time both the main and pilot valves close 100%. (If the unit was not provided with a time delay relay, the blower stops at this time.)

10. If the unit was provided with a time delay relay, the blower stops after 30 to 45 seconds.

Electronic Modulating Gas

Controls

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 thermostat 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 pilot valve opens and the spark ignitor sparks in an attempt to light the pilot. (If the unit was not provided with a time delay relay, the blower starts at this time.)

16 5-562.8

3. Once the pilot is lit, the flame sensor proves the pilot and stops the spark ignitor from sparking.

4. The main gas valve is opened and the main burner is lit to

100% full fire.

5. If the unit was provided with a time delay relay, the blower starts after 30 to 45 seconds.

6. The modulating gas valve can be controlled by either an electronic modulating room or duct thermostat. The thermostat 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 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.

7. The unit continues to operate in this manner until the thermostat is satisfied, at which time both the main and pilot valves close 100%. (If the unit was not provided with a time delay relay, the blower stops at this time.)

8. If the unit was provided with a time delay relay, the blower stops after 30 to 45 seconds.

electronic modulating Gas controls two & three furnaces - model sizes 500-960

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 adjuster.

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.

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 & Three Furnaces is the same as Electronic

Modulating Gas Controls - Single Furnace.

start-up procedure

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 pilot valve opens and the spark ignitor sparks in an attempt to light the pilot. (If the unit was not provided with a time delay relay, the blower starts at this time.)

3. Once the pilot is lit, the flame sensor proves the pilot and stops the spark ignitor from sparking.

4. The main gas valve is opened and the main burner is lit to

100% full fire.

5. If the unit was provided with a time delay relay, the blower starts after 30 to 45 seconds.

6. 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.

7. 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.)

8. If the unit was provided with a time delay relay, the blower stops after 30 to 45 seconds.

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 the 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 the space.

3. Building management control which allows for an external signal of 0-10VDC of 4-20mA to adjust the unit airflow.

Additionally, when the air mover supplied by others can provide variable air movement (i.e. 2-speed or variable frequency drive units), the allowable minimum CFM of the duct furnace can be 66% of the minimum listed CFM in Table 26.1 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.

5-562.8

options

options - factory installed figure 18.1 - factory mounted option locations

1. Discharge Thermostat

2. Low Gas Pressure Switch

3. High Gas Pressure Switch

5. Timed Freeze Protection

6. Ignition Controller

8. Control Relay

9. Time Delay Relay

10. 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

50 58

48 45 43

38 36

42 39 37

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

30. Direct Drive Damper Actuator

31. Enthalpy Controller

32. Damper to Damper Linkage

33. Return Air Damper

34. Proportional Temp Controller Sensor

35. Motor and Blower Vibration Isolation

36. Blower Support

37. Convenience Outlet

34 32

33 31

38. Blower Door Switch

39. Dirty Filter Switch

40. Motor Starter/VFD Control

42. Proportional Temp Controller

43. Warm-Up Stat

44. Blower Supply Power Terminal Strip

45. Service Switches

46. Electronic Modulating Amplifier

47. Electronic Modulating Gas Valve

48. Air Flow Proving Switch

49. High Limit Switch

50. Supply Air Fire Stat

51. Main Gas Valve

52. Burner Box

56. Blocked Vent Safety Switch

58. Energy Cut off Switch

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. 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 for cooling package units below the unit junction box. For blower package units the thermostat is factory wired and capillary is to be field installed in duct work. The thermostat body contains the discharge air set point adjuster that must be field set.

figure 18.2 - two-stage capillary type thermostat

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Right

Setpoint

Adjuster

R B

Left

Duct Furnace

Electrical

Duct

Furnace

Electrical

Control

Box

Thermostat body

(Shown with cover removed)

options

b) Two-stage Electronic Type 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 latest revision.

figure 19.1 - two-stage electronic type thermostat sensor figure 19.4 - low or High Gas pressure switch

Reset Switch

Duct

Furnace

Electrical

Control

Box

Sensor c)

Electronic Modulating Discharge Air Thermostat –

Includes a factory installed mixing tube and discharge air sensor for cooling package units. For blower package units, the air sensor is factory wired but field installed in duct work. The set point adjuster is field installed remotely and must be field set. Refer to Literature 5-578 latest revision.

figure 19.3 - electronic modulating discharge air thermostat

Air flow

Mixing Tube

Discharge air

Sensor Terminals

Duct

Furnace

Electrical

Control

Box

(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).

(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 19.5 - 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).

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options

(6) ignition controller – (opt)

The ignition controller is factory installed in the duct furnace electrical junction box with the spark ignitor and sensor located on the burner.

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.

(8) control relay – (opt)

The control relay is factory installed in the duct furnace electrical junction box. The relay has a 24V coil with doublepole, 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.

(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) 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.

See description of Option 8 for additional details.

(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)

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 20.1 - dead front disconnect switch assembly

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 20.1). When in the “OFF” position, power is disconnected to all unit wiring electrically following the switch (See Warning). To open, see Figure 20.1.

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 20.1). 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.

(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.

(18) step down transformer – (opt)

The step down transformer is factory installed in the eletrical section. The transformer is required for power exhausted units with a supply voltage of 460V/3Ph and 575V/3Ph.

(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 20.2 - minimum positioner

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Handle opening instruction table

Pinch handle latch

(A) & handle (B) together when opening and closing door

Belimo

Supply Power Terminals

(See Warning)

To override turn shaft 90° C.W.

(with door open)

Blower Electrical Section

Stand-off Panel

options

(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.

(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.

(

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. For single phase units 1-1/2 HP and less, the fire stat de-energizes a relay that controls blower motor operation. For three phase units and single phase units 2 HP and greater, the fire stat de-energizes the motor starter that controls blower motor operation.

(

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) pillow Block Bearings – (opt)

The blower bearings are factory installed in the blower section.

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 MERV 7 or

2" FARR® 30/30 MERV 8 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/ft2 at 1" W.C.) dampers with self-compensating stainless steel side seals and santoprene and galvanized steel blade seals are used.

(30) 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

5-562.8

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 accom plished by the following:

1. Determine the amount of damper rotation required

(Percentage of outside air).

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 21.1 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.

figure 21.1 - two-position damper actuator and limiter

Lock down with screw as shown.

Adjustable end switch set to angle of rotation

Actuator clamp at

50% rotation limit

options

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.

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.

(

31) 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.

An enthalpy sensor is provided with Air Control option GJ 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.

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:

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 temperature air 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.

22 5-562.8

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 22.1 - enthalpy controller

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 22.2 - enthalpy changeover set point control points

options

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 24.2 for the corresponding control point. The factory installed 620ohm jumper placed across terminals S

and + is required for proper operation and should not be removed. Refer to suppliers literature supplied with the unit for additional information.

(32) 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.

(

33) 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/ft2 at 1" W.C.) dampers with selfcompensating stainless steel side seals and santoprene blade seals are used.

(34) 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.

(

35) 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.

(36) 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.

(37) 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.

(38) Blower door switch – (opt)

The blower door switch is factory installed inside the blower

5-562.8

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. For servicing, the switch is equipped with an override position that can be manually pulled out to override the switch.

See Figure 23.1

figure 23.1 - Blower door switch with manual override

COM

NC NO

Operating Point

Rest position

Override Position

(blower may start)

(

39) 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 23.2

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 approximately 0.25" W.C.) This will allow for the increase in static pressure due to dirty filters.

figure 23.2 - dirty filter pressure switch and air flow proving switch

Positive pressure connector

Negative pressure connector

Pressure adjustment set screw

options

(40) 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.

(40) 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.

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.

If the factory installed motor starter option was not ordered with a unit that has a three phase motor or single phase motor 2 Hp or greater, a motor starter must be field supplied and installed.

figure 24.1 - motor starter

1 L1 3 L2 5 L3

13 NO

CONTACTOR

MODULE

TRIP

INDICATOR

WINDOW

CURRENT

SET POINT

DIAL

RESET

OVERLOAD

MODULE

figure 24.2 - proportional temperature controller

A350 P

VOLTS

2 4 6 8 10

4 8 12 16 25

MILLIAMPS

JOHNSON

CONTROLS

SET POINT

DIAL

(44) 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.

(45) 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 24.3 - service switches

(42) 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).

(43) 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).

(46) electronic modulation amplifier – (opt)

An electronic modulation amplifier is provided factory installed in the duct furnace electrical junction box when the unit is equip ped 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.

24 5-562.8

options

(47) 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.

(48) 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 start the blower and burner ignition sequence.

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.

(49) 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.

(50) 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. For single phase units 1-1/2 HP and less, the fire stat de-energizes a relay that controls blower motor operation. For three phase units and single phase units 2 HP and greater, the fire stat de-energizes the motor starter that controls blower motor operation.

(51) 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.

(52) 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.

(56) Blocked vent safety switch

A manual reset BVSS is supplied on all gravity vented duct furnaces and is designed to prevent operation of the main burner in the event there is spillage of flue producs into the space. This spillage may occur due to a restricted vent, inadequate vent draw, uninsulated vent pipe in cold ambient or long vent runs, excessive vent diameter, restricitve vent terminal, negative pressure within space, etc. After the cause of the spillage has been corrected, depressing the button of the

BVSS found on top of the unit may reset the BVSS. See trouble shooting section for more information.

(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 25.1 - circuit analyzer

Circuit analyzer tagging will vary based on the unit ordered.

Circuit analyzer shown is for reference only.

5-562.8

General performance data

table 26.1 - 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

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

75,000

60,000

A or B C or D

100 100

28 20

1980 2778

556 556

100 125 150

10,0000

80,000

125,000

100,000

150,000

120,000

C or D E or F C or D E or F C or D E or F

100 85 100 100 100 100

21 20

3450 3704

741 875

3450

926

4630

926

3350

1111

5556

1111

200

200,000

160,000

C or D E or F

100 85

44 28

3400 5250

1481 1750

225 250

225,000

180,000

250,000

200,000

G or H C or D E or F G or H E or F G or H I, J, or K

85 100 95 95 100 100 96

23 49

6500 3400

1750 1667

5250

1750

6500

1750

6000

1852

7250

1852

9259

1925

300 350 400

300,000 350,000 400,000

240,000 280,000 320,000

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

11111 5700

2222 2593

100

7000 12000

2593 2593

100

5700 7000

2963 2963

100

12000

2963

175

175,000

140,000

C or D E or F

100 100

39 23

3350 5556

1296 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

500

500,000

400,000

G or H I, J, or K

120 120

53 40

7000 9259

3086 3086

120 120

40 63

9259 7000

3086 3704

600

600,000

480,000

G or H I, J, or K

120

11111 11111

3704 3704

700

700,000

560,000

G or H I, J, or K

120 120

76 40

6850 12963

4321 4321

120

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

800,000

640,000

G or H I, J, or K

120

6850

4938

120

13000

4938

840

1,050,000

840,000

I, J, or K L

120

14500 13000

4938 6481

120

13000

6481

960

1,200,000

960,000

I, J, or K L

120

13000 14000

7407 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 17.

26 5-562.8

General performance data

table 27.1 - air temperature rise

Btu/Hr

➀

input output 20 max

25 30 35 air temperature rise through unit (°f)

40 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

Btu/Hr

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 17.

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.

5-562.8

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.

28 5-562.8

selection example conditions

Select an indirect-fired, 100% make-up air unit to meet the following conditions:

1. CFM at sea level = 5,000 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 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 55, 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

(gravity vented) that are obtained from item #5. Using the

Model Nomenclature on page 55, the Model Configuration and Venting = DBG.

2. determine the furnace input rating (mBH):

Using the Heating output capacity, the Furnace Input

Rating is determined from Table 26.1. 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 DBG400 @ 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 baffle must remain in place.

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.

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 DBG/DCG models, a 75VA Transformer is required.

Thus, the Transformer = 2.

12. determine the Blower size and Bearing type:

Using Table 26.1, the Model Size 400 has three available blowers for which the performance tables are shown on pages 30-33. Since all of the blower performance curves can provide the required 5000 cfm, the total static pressure must be determined.

A) The Pressure Drop of an option or accessory is determined by entering the right of the table at the desired cfm and reading up the table until the cfm intersects the desired item. For this example, in table

30.1 the 2'' Permanent Filter line is used. At the point of intersection, read across the table to the left and read 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:

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 30, for the Model Size 400 with Digit 16 = I, J, or K:

2'' Permanent Filters:

Internal Static Pressure Drop

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 (Table 32.1).

Using Table 32.1, enter the table at the required 5000 cfm for E, F blowers, and follow the cfm line up 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 this 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 0.89'' W.C. T.S.P), the horsepower is 5 hp and

920 rpm. Following this procedure for I,J,H blowers

(Using 5000 cfm and 0.87'' W.C. T.S.P), the horsepower is 3hp and 700 rpm. Although I,J,H blowers results in a

3 hp motor, this blower requires the use of the extended cabinet length. As a result, for purposes of this selection example G,H will be used.

Since the Bearing Type was not specified, the standard spider bearings will be used. Thus, using Table 32.1 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 38 to

42 contain the motor frame size.

A) Using the Supply Voltage (460V/60Hz/3Ph), enter the correct Motor Data table (Table 41.1). 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 35.2). 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

35.2, 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 21. 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:

DBG400SMRLN40F2GG1IDA00

Once the basic model has been determined, the additional options and accessories outlined on page 18 to 25 can be added to the unit.

5-562.8

option & accessory pressure drop data

table 30.1 - option & accessory pressure drop tables (in ''W.c.)

➀

all units Weatherproof unit only

unit size digit 16 cfm

4000 0.05

4500 0.06

5000 0.07

5500 0.09

6000 0.11

6500 0.13

1852 0.03

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

4500 0.17

4630 0.17

1111 0.01

1500 0.02

2000 0.03

2500 0.05

3000 0.06

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

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

4000 0.05

5000 0.08

6000 0.11

7000 0.15

8000 0.19

9000 0.24

10400 0.32

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

100/125

150/175

200/225

250/300

500/600

350/400

700/800

840/960 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

0.09

0.11

0.15

0.18

0.22

0.31

0.42

0.51

0.03

0.05

0.12

0.15

0.18

0.21

0.25

0.28

0.05

0.06

0.23

0.27

0.32

0.34

0.38

0.03

0.04

0.06

0.08

0.10

0.37

0.39

0.04

0.05

0.08

0.11

0.15

0.18

0.03

0.13

0.16

0.02

0.04

0.07

0.10

0.14

0.19

0.24

0.30

0.03

0.04

0.05

0.06

0.07

0.09

0.10

0.11

0.02

0.03

0.04

0.06

0.08

0.11

0.13

0.16

0.19

0.23

0.27

0.31

0.04

0.05

0.06

0.08

0.10

0.12

0.14

0.17

0.19

0.22

0.09

0.12

0.16

0.21

0.27

0.33

0.42

0.47

0.04

0.06

0.08

0.10

0.13

0.19

0.26

0.32

0.01

0.03

0.08

0.10

0.11

0.14

0.16

0.18

0.02

0.03

0.13

0.16

0.19

0.21

0.23

0.02

0.04

0.05

0.06

0.20

0.21

0.02

0.03

0.04

0.06

0.08

0.11

0.01

0.07

0.09

0.02

0.04

0.06

0.08

0.11

0.13

0.16

0.01

0.02

0.03

0.04

0.05

0.01

0.02

0.03

0.04

0.05

0.07

0.09

0.12

0.14

0.17

0.20

0.24

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0.10

0.11

0.05

0.08

0.11

0.15

0.20

0.25

0.33

0.38

0.07

0.10

0.12

0.15

0.18

0.25

0.34

0.41

0.03

0.05

0.11

0.13

0.16

0.19

0.22

0.25

0.05

0.18

0.21

0.25

0.27

0.30

0.03

0.04

0.05

0.07

0.09

0.25

0.26

0.03

0.04

0.06

0.09

0.11

0.14

0.02

0.11

0.15

0.02

0.03

0.05

0.07

0.10

0.13

0.16

0.20

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0.10

0.02

0.04

0.05

0.07

0.10

0.12

0.15

0.18

0.22

0.26

0.30

0.04

0.05

0.06

0.07

0.09

0.10

0.12

0.14

0.16

0.18

0.08

0.11

0.15

0.19

0.24

0.30

0.38

0.43

0.01

0.16

0.23

0.01

0.02

0.04

0.08

0.12

0.17

0.23

0.30

0.01

0.02

0.03

0.04

0.06

0.08

0.10

0.12

0.05

0.37

0.51

0.06

0.08

0.14

0.21

0.30

0.40

0.51

0.63

0.05

0.08

0.11

0.14

0.17

0.21

0.25

0.30

0.01

0.03

0.04

0.07

0.10

0.14

0.18

0.07

0.10

0.15

0.20

0.27

0.34

0.41

0.03

0.05

0.09

0.14

0.20

0.27

0.35

0.23

0.28

0.50

0.59

0.45

0.55

0.30 0.63 0.60

5200 Max CFM for Evap

0.02

0.03

0.05

0.08

0.10

0.08

0.12

0.17

0.22

0.27

0.04

0.07

0.10

0.15

0.20

0.13

0.17

0.21

0.25

0.33

0.40

0.47

0.55

0.27

0.34

0.42

0.50

0.30 0.63 0.60

6000 Max CFM for Evap

0.02

0.03

0.10

0.11

0.05

0.06

0.04

0.06

0.09

0.11

0.15

0.19

0.24

0.29

0.09

0.13

0.17

0.23

0.15

0.22

0.35

0.48

0.29

0.43

0.30 0.63 0.60

6500 Max CFM for Evap

0.01

0.03

0.05

0.10

0.02

0.05

0.03

0.04

0.05

0.06

0.08

0.10

0.12

0.15

0.17

0.20

0.04

0.07

0.10

0.14

0.15

0.20

0.26

0.34

0.09

0.14

0.20

0.27

0.18

0.23

0.41

0.50

0.35

0.45

0.30 0.64 0.60

10400 Max CFM for Evap

0.10

0.13

0.16

0.19

0.23

0.27

0.31

0.36

0.40

0.45

0.05

0.07

0.10

0.13

0.16

0.20

0.24

0.29

0.34

0.39

0.02

0.04

0.06

0.09

0.12

0.16

0.20

0.08

0.09

0.14

0.19

0.25

0.31

0.38

0.46

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

0.11

0.14

0.22

0.31

0.42

0.55

0.70

0.86

0.16

0.20

0.25

0.32

0.39

0.47

0.55

0.64

0.74

0.85

0.23

0.34

0.46

0.61

0.77

0.95

1.23

0.24

0.32

0.41

0.52

0.64

0.91

1.23

0.08

0.15

0.60

0.73

0.89

1.05

1.23

0.15

0.17

0.77

0.95

1.15

1.23

0.12

0.19

0.27

0.36

0.47

0.09

0.15

0.24

0.34

0.46

0.61

0.07

0.68

0.96

0.08

0.12

0.23

0.36

0.53

0.73

0.97

1.23

0.07

0.12

0.17

0.22

0.29

0.36

0.44

0.53

0.02

0.31

0.45

0.02

0.04

0.08

0.15

0.23

0.34

0.46

0.60

0.02

0.04

0.06

0.08

0.11

0.15

0.19

0.23

➀

Accesssory / Option static pressure losses are approximate values only. Please consult the Accuspec selection software for static pressure losses at other than listed CFM.

0.03

0.04

0.06

0.08

0.10

0.15

0.21

0.27

0.02

0.04

0.11

0.14

0.18

0.21

0.26

0.30

0.02

0.13

0.17

0.21

0.23

0.26

0.02

0.03

0.04

0.06

0.09

0.25

0.26

0.02

0.04

0.05

0.07

0.10

0.00

0.08

0.12

0.00

0.01

0.02

0.04

0.07

0.11

0.15

0.19

0.00

0.01

0.02

0.03

0.04

0.05

0.06

0.02

0.03

0.05

0.07

0.10

0.14

0.19

0.24

0.30

0.36

0.43

0.51

0.02

0.03

0.04

0.05

0.06

0.07

0.09

0.10

0.12

0.14

0.08

0.12

0.18

0.25

0.33

0.42

0.57

0.66

0.09

0.12

0.14

0.16

0.19

0.25

0.31

0.37

0.07

0.12

0.18

0.22

0.27

0.32

0.38

0.45

0.07

0.08

0.18

0.22

0.27

0.29

0.33

0.03

0.05

0.08

0.10

0.14

0.25

0.26

0.02

0.03

0.05

0.08

0.10

0.14

0.01

0.11

0.15

0.03

0.05

0.07

0.10

0.13

0.16

0.19

0.22

0.01

0.02

0.03

0.04

0.06

0.07

0.08

0.03

0.04

0.07

0.11

0.17

0.23

0.30

0.38

0.48

0.58

0.69

0.81

0.03

0.04

0.05

0.07

0.09

0.11

0.14

0.17

0.20

0.23

0.16

0.22

0.28

0.35

0.42

0.51

0.64

0.71

0.03

0.04

0.06

0.07

0.09

0.13

0.18

0.23

0.02

0.04

0.06

0.08

0.10

0.12

0.14

0.16

0.02

0.06

0.08

0.10

0.11

0.13

0.01

0.02

0.04

0.05

0.11

0.01

0.02

0.04

0.05

0.00

0.04

0.06

0.01

0.02

0.03

0.04

0.05

0.07

0.09

0.01

0.02

0.03

0.01

0.02

0.04

0.05

0.08

0.10

0.14

0.17

0.21

0.26

0.01

0.02

0.03

0.04

0.05

0.07

0.11

0.16

0.21

0.28

0.35

0.47

0.53

30 5-562.8

BloWer performance data

table 31.1 - unit performance tables

➀ ➁

air digit temp. unit size 16 rise cfm

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

end 100 c,d

100/125 c,d

start 125

100/125 e,f

150/175 c,d

start 175

150/175 e,f

200/225 c,d

start 225

200/225 e,f

200/225 G,H

56°F / -

46°F / -

40°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 - -

- -

35°F / -

31°F / -

1600 0.93 1308 1.09 1412 1.25 1509 1.42 1601

1800 1.28 1445 1.46 1539 - - - -

800 - - 0.15 795 0.21 960 - -

69°F / -

56°F / -

46°F / -

40°F / -

35°F / -

1000 - - 0.20 822 0.28 975 0.36 1112 - - - -

1200 0.19 705 0.27 862 0.35 1003 0.44 1131 0.54 1250 0.65 1361

- -

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 31°F / -

28°F / -

24°F / -

20°F / -

100°F / -

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 80°F/100°F

62°F/77°F

53°F/66°F

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

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

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 - - - 28°F/36°F

25°F/31°F

41°F/51°F

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

2200 0.43 553 0.58 662 0.75 762 0.93 855 1.12

2600 0.63 614 0.81 710 1.00 800 1.20 885 1.41

3000 0.91 680 1.11 766 1.32 847 1.54 1731 1.77

942 1.33 1025

965 1.63 1042

997 2.01 1068 2.51 1202 3.04 1328 3.60 1446 25°F/31°F

22°F/27°F

20°F/25°F

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

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 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

86°F/100°F

79°F/93°F

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

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

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 - - - 43°F/50°F

37°F/43°F

86°F/100°F

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

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

2200 0.44 588 0.59 697 0.75 796 0.91 887 1.09

952

972 1.27 1052 1.67 1201

51°F/59°F

43°F/50°F

37°F/43°F

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

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

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 - 26°F/31°F

24°F/28°F

21°F/25°F

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

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 - - - - - -

49°F/56°F

85°F/95°F

74°F/83°F

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

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

59°F/67°F

49°F/56°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 - 42°F/48°F

37°F/42°F

33°F/37°F

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

49°F/56°F

42°F/48°F

37°F/42°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

3000 0.65 571 0.83 654

3500 0.97 639 1.17 713

4000 1.38 710 1.60 776

0.75 692

1.02 732

1.38 782

1.83 839

0.94

1.23

1.60

2.08

774

807

850

899

1.16

1.45

1.84

2.34

851 1.38 925 - -

877 1.69 944 2.21 1071

914 2.10 975 2.64 1093 3.23 1202 3.86 1307

958 2.60 1014 3.18 1123 3.80 1226 4.46 1324

- -

33°F/37°F

30°F/33°F

27°F/30°F

25°F/28°F

4500 1.90 783 2.14 842

5500 3.32 933 3.61 982

2.40 899

6000 4.25 1009 4.57 1054 4.89 1099

2.66

955

2.94

3.91 1030 4.22 1077 4.54

1008

1123

3.23 1061

4.87 1168

- -

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

➀

Total static pressure should include external static pressure and accessory / option static pressure from Table 30.1. 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.

5-562.8

BloWer performance data

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

31°F / 37°F

26°F / 32°F

23°F / 28°F

20°F / 24°F

- / 22°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

47°F / 54°F

100°F / -

table 32.1 - unit performance tables

➀ ➁

digit unit size 16

250/300 start 300 e,f air temp. rise cfm

100°F / 120°F

83°F / 100°F

74°F / 89°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 m

0.54 782 0.69 887 0.85 985 1.03 1074 1.39 1239 1.79 1387 2.21 1523

2222 0.39 582 0.54 703 0.70 810 0.87 909 1.05 1000 1.24 1085 1.64 1242 2.06 1385 2.52 1517

2500 0.51 625 0.68 736 0.85 836 1.04 930 1.23 1016 1.43 1099 1.85 1250 2.30 1389 2.78 1517

250/300

350/400 start 40 start 300

end 250

350/400 start 400

G,H e,f

G,H i,J,K

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

250/300 i, J, K

28°F / 34°F

46°F / 56°F

37°F / 44°F

3000 0.80 706 0.99 803 1.19 893 1.40 978 1.62 1058 1.84 1133 2.31 1275 2.81 1406 3.33 1529

3500 1.19 793 1.41 878 1.64 959 1.87 1036 2.12 1109 2.36 1179 2.88 1312 3.42 1435 3.99 1552

4000 1.69 882 1.94 958 2.20 1032 2.46 1102 2.73 1170 3.01 1234 3.58 1358 4.17 1474 4.78 1584

4500 2.34 974 2.62 1043 2.90 1109 3.19 1174 3.49 1236 3.79 1296 4.41 1412 - - - -

5000 3.14 1067 3.44 1130 3.76 1191 4.08 1250 4.40 1308 4.73 1364

5500 4.11 1161 4.44 1219 4.78 1275 - - - - - -

- -

1852 - - 0.34 519 0.49 623 0.66 713 0.85 795 1.05

2222 0.28 424 0.43 537 0.61 634 0.79 721 0.99 800 1.20

2500 0.35 447 0.52 553 0.71 646 0.90 730 1.11 806 1.33

3000 0.53 492 0.72 588 0.93 674 1.15 752 1.38 824 1.62

870

872

877

892

1.47 1005

1.65 1005

1.81 1006

2.13 1016

1.94 1126

2.14 1123

2.32 1123

2.68 1129

2.44 1237

2.67 1231

2.87 1230

3.27 1232

3500 0.76 542 0.98 878 1.21 707 1.45 780 1.71 848 1.97

4000 1.07 594 1.31 673 1.57 746 1.83 814 2.11 878 2.39

912

939

2.52 1031

2.99 1052

3.11 1140

3.62 1156

3.74 1240

4.28 1253

4500 1.45 649 1.72 721 2.00 789 2.29 852 2.59 912 2.90 969 3.54 1077 4.22 1177 4.92 1270

5000 1.92 706 2.22 771 2.52 834 2.84 894 3.16 950 3.50 1004 4.18 1107 4.90 1202 - -

5500 2.50 767 2.81 824 3.14 882 3.49 938 3.83 991 4.19 1042 4.93 1140

6000 3.16 822 3.52 878 3.87 933 4.24 984 4.61 1035 5.00 1084 - -

6500 3.96 881 4.34 934 4.72 984

4000 - - 0.97 507 1.25 583

1.56

654

1.89

719

2.24

781

5000 - - 1.51 560 1.84 626 2.19 688 2.56 748 2.95

6000 1.94 559 2.29 620 2.66 679 3.06 734 3.46 787 3.89

7000 2.93 632 3.33 686 3.75 738 4.19 788 4.64 836 5.11

8000 4.24 707 4.69 755 5.16 802 5.64 847 6.14 891 6.65

804 3.77 908

838 4.79 935

4.67 1005

5.75 1025

- -

6.77 1110

882 6.09 971 7.13 1055 8.22 1134

933 7.72 1015 8.83 1093 10.00 1167

9259 6.40 804 6.91 846 7.45 887 7.99 927 8.55 966 9.12 1004 10.30 1079 11.52 1150 12.79 1218

10000 7.97 862 8.52 901 9.09 939 9.67 977 10.27 1014 10.87 1050 12.12 1120 13.41 1187 14.74 1252

11111 10.79 949 11.40 985 12.03 1020 12.66 1054 13.31 1087 13.97 1121 - - - - - -

2593 0.61 668 0.80 781 1.01 882 1.22 975 1.45 1061 1.69 1142 2.19 1290 2.73 1425 3.30 1550

2700 0.67 686 0.87 796 1.08 895 1.30 986 1.53 1071 1.78 1151 2.29 1297 2.84 1431 3.42 1555

2963 0.85 730 1.06 834 1.28 928 1.52 1015 1.76 1097 2.02 1174 2.56 1316 3.13 1446 3.74 1568

3500 1.30 826 1.54 917 1.80 1002 2.07 1081 2.34 1157 2.62 1228 3.22 1362 3.84 1486 4.50 1602

4000 1.86 918 2.13 1000 2.42 1078 2.71 1151 3.01 1221 3.32 1288 3.97 1414 4.65 1531 - -

4500 2.57 1012 2.87 1087 3.18 1158 3.51 1226 3.84 1291 4.18 1353 4.88 1472

5000 3.44 1109 3.78 1177 4.12 1242 4.47 1305 4.84 1366 - - - -

5500 4.50 1206 4.87 1269 - - - - - - - - - - - - - -

2593 0.43 479 0.62 585 0.84 679 1.09 764 1.35 841 1.64 1142 2.26 1046 2.94 1165 3.68 1275

2963 0.57 516 0.79 614 1.02 702 1.28 782 1.56 856 1.86

3500 0.85 574 1.09 662 1.35 742 1.63 815 1.93 885 2.25

926

951

2.50 1053

2.93 1072

3.20 1170

3.66 1183

4000 1.19 631 1.45 710 1.74 784 2.04 853 2.36 918 2.70 980 3.41 1096 4.19 1202

4500 1.61 690 1.91 762 2.22 830 2.55 895 2.89 956 3.25 1014 4.00 1124 4.81 1226

3.96 1277

4.45 1287

5000 2.22 767 2.46 817 2.80 880 3.15 940 3.52 998 3.90 1053 4.70 1157

5500 2.77 813 3.12 874 3.49 933 3.87 989 4.25 1042 4.66 1095 - -

6000 3.53 876 3.91 933 4.30 987 4.70 1040

6500 4.42 939 4.82 992 - - - -

2593

2963

0.77

0.89

561

571

1.04

1.18

639

646

1.34

1.49

709

715

1.66

1.81

4000 - - 1.07 533 1.37 609 1.69 679 2.03 742 2.40

5000 1.37 515 1.69 590 2.04 658 2.41 721 2.79 779 3.19

774 2.36 891

779 2.54 894

802 3.18 910

835 4.05 937

3.14 995

3.34 997

4.00 1090

4.20 1091

4.04 1009 4.96 1099

4.98 1030 5.96 1117

6000 2.20 588 2.58 654 2.97 715 3.39 772 3.82 826 4.26

7000 3.34 665 3.77 723 4.22 778 4.68 830 5.16 879 5.65

877

927

5.20 973

6.68 1016

6.21 1061

7.77 1099

7.26 1144

8.90 1178

8000 4.84 744 5.33 796 5.83 845 6.34 893 6.87 938 7.41 982 8.53 1066 9.70 1144 10.92 1219

9000 6.75 824 7.29 871 7.85 917 8.41 960 8.99 1002 9.58 1043 10.80 1121 12.07 1194 13.37 1265

10000 9.13 906 9.72 948 10.33 990 10.95 1030 11.58 1069 12.22 1107 13.54 1180 14.90 1249

11000 12.01 988 12.66 1027 13.32 1065 14.00 1103 14.68 1139 - - - - - -

11500 13.66 12.09 14.34 1067 - - - - - - - - - - - -

➀

Total static pressure should include external static pressure and accessory / option static pressure from Table 30.1. 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.

32 5-562.8

BloWer performance data

table 33.1 - 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

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

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

4500

1.51 685 1.80 760 2.11 830 2.43 896 2.77 958

1.68 708 1.98 780 2.30 847 2.63 912 2.98 973

3.13 1018 3.88 1131 4.69 1236

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 30.1. 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.

5-562.8

BloWer sHeave assemBly data

adjusting the Blower drive setting

Based on the Sheave Arrangement, Tables 34.1 through 35.5 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 28 and 29 to determine what blower rpm is required to meet the job specifications.

figure 34.1 - 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 36.1 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

5 HP

TWO-SPEED

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 34.1 - digit 16 = a or B (9-7 Blower units)

motor frame size

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

3H35125B2

3H35125B4

3H35125B6

3H35125B8

3H35125B10

E 3H35125B5 G 3H35125B7 I 3H35125B9 K

3H35125B11

table 34.2 - digit 16 = c or d (9-9 Blower units)

motor frame size

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

3H35126B2

3H35126B4

3H35126B6

E 3H35126B5 G 3H35126B7

3H35126B9

3H35126B12

3H35126B10 M

3H35126B13

3H35126B8

3H35126B11

3H35126B14

34 5-562.8

BloWer sHeave assemBly data

Blower sheave assembly numbers (con’t) table 35.1 - digit 16 = e or f (12-12 Blower units)

motor frame size

143 to 145

182 or 184

213 or 215

468-715 644-874 rpm range

863-1078 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

3H35127B17

3H35127B4

G 3H35127B7 I 3H35127B9 L

3H35127B12

E 3H35127B5 H 3H35127B8 J

3H35127B10

3H35127B11

3H35127B13

3H35127B14

3H35127B15

3H35127B16

table 35.2 - digit 16 = G or H (15-15 Blower units)

motor frame size

143 to 145

182 or 184

213 or 215

410-625

rpm range

568-771 767-958 934-1136 1136-1380

Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly

A 3H35128B1

3H35128B2

3H35128B4

3H35128B7

3H35128B15

3H35128B3

E 3H35128B5

3H35128B6

3H35128B8

3H35128B9

3H35128B10

3H35128B11

3H35128B13

3H35128B12

3H35128B14

table 35.3 - digit 16 = i or J (18-18 Blower units under 15 Hp motor)

motor frame size

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

3H35129B1

3H35129B4

B 3H35129B2

3H35129B3

3H35129B5

3H35129B6

3H35129B8

3H35129B9

3H35129B11

3H35129B15

G 3H35129B7 J 3H35129B10 L

3H35129B12

3H35129B16

3H35129B19

3H35129B13

3H35129B17

3H35129B20

3H35129B14

3H35129B18

3H35129B21

table 35.4 - 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

Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly

A 3H35130B1 C 3H35130B3 E

3H35130B5

3H35130B2

3H35130B13

3H35130B14

3H35130B4

3H35130B15

3H35130B16

3H35130B6

3H35130B17

3H35130B18

1232-1438

3H35130B19

3H35130B20

table 35.5 - 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 C 3H36622B3

3H36622B2

D 3H36622B4 F 3H36622B6

E 3H36622B5 G 3H36622B7 M

3H36622B13

3H36622B18

3H36622B8

3H36622B9

3H36622B10

3H36622B11

3H36622B12

P q

3H36622B14

3H36622B15

3H36622B16

3H36622B17

3H36622B19

3H36622B20

3H36622B21

3H36622B22

3H36622B23

3H36622B24

3H36622B25

3H36622B26

5-562.8

BloWer sHeave assemBly data

table 36.1 - Blower sheave assembly settings

turns open sheave assembly 0 0.5

1 1.5

2 2.5

Blower rpm

3 3.5

4 4.5

3H35125B1-2

3H35125B3-5

3H35125B6-7

3H35125B8-9

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

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

1001 966 932 897 863 828 794 759 725 690 656

1265 1236 1208 1179 1150 1121 1093 1064 1035 1006 978

3H35126B6-8

3H35126B9-11

1561 1520 1479 1438 1396 1355 1314 1273 1232 1191 1150

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

3H35127B3-5

3H35127B6-8

3H35127B9-11

715 690 665 641 616 591 567 542 518 493 468

874 851 828 805 782 759 736 713 690 667 644

1078 1057 1035 1013 992 970 949 927 906 884 863

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

3H35128B4-6

3H35128B7-9

625 604 582 561 539 518 496 474 453 431 410

771 751 731 710 690 670 649 629 609 589 568

958 939 920 901 882 863 843 824 805 786 767

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

3H35129B8-10

649 633 617 601 586 570 554 538 522 506 491

744 728 712 696 681 665 649 633 617 601 586

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

3H35130B3-4

3H35130B5-6

3H35130B13-14

1009 991 973 954 936 918 899 881 863 844 826

1161 1144 1128 1111 1095 1078 1062 1045 1028 1012 995

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

3H36622B3-5

3H36622B6-11

649 633 617 601 586 570 554 538 522 506 491

765 751 737 723 709 696 682 668 654 640 626

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

36 5-562.8

BloWer sHeave assemBly data

3H35127B2

3H35127B3

3H35127B4

3H35127B5

3H35127B6

3H35127B7

3H35127B8

3H35127B9

3H35127B10

3H35127B11

3H35127B12

3H35127B13

3H35127B14

3H35127B15

3H35127B16

3H35127B17

3H35128B1

3H35128B2

3H35128B3

3H35128B4

3H35128B5

3H35128B6

3H35128B7

3H35128B8

3H35128B9

3H35128B10

3H35128B11

3H35128B12

3H35128B13

3H35128B14

3H35128B15

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 37.1 - Blower sheave assembly numbers and size

sheave assembly

3.8

5.6

5.2

5.6

5.2

5.6

4.4

2.9

3.8

4.4

5.2

2.9

3.8

5.6

2.9

4.4

5.6

4.4

3.8

motor sheave pitch diameter Bore

2.9

4.4

0.5

0.625

0.5

4.4

3.8

0.625

0.875

0.625

0.875

0.625

0.875

0.625

0.875

0.5

0.625

0.5

0.625

0.875

0.625

0.875

0.5

0.625

0.875

1.125

0.625

0.875

1.125

0.625

0.875

1.125

0.625

0.875

1.125

0.875

1.125

0.625

0.875

1.125

0.875

1.125

1.375

1.125

1.375

0.625

1.125

1.375

0.625

0.5

0.625

0.875

0.625

1.125

0.875

1.125

1.375

0.875

1.125

1.375

Browning

Belt no.

8.5

6.5

8.5

5.2

5.7

8.5

5.7

6.7

6.2

7.5

4.2

5.2

4.5

5.2

4.5

4.2

Blower sheave pitch diameter

Bore

0.75

4.2

0.75

A50

A52

A53

A52

A54

A53

A54

A52

A53

A45

A48

A43

A47

A48

A50

A43

A45

A49

A45

A47

A49

A42

A43

A46

A45

A47

A48

A36

A38

A40

A37

A39

A33

A34

A37

A38

A35

A34

A38

A34

A30

A31

A34

A35

A31

5-562.8

11.4

13.4

8.4

9.4

10.9

8.9

12.4

8.9

10.4

9.4

8.4

10.4

9.4

12.4

10.4

9.4

11.4

10.4

9.4

8.9

9.4

10.4

Blower sheave pitch diameter Bore

10.9

12.4

1.44

5.3

5.9

4.1

5.5

4.7

5.5

5.3

5.5

motor sheave pitch diameter Bore

4.1

0.625

4.1

4.7

0.875

1.125

0.625

4.7

5.5

5.9

0.875

1.125

1.375

0.875

1.125

1.375

1.625

1.375

1.625

1.125

1.375

1.625

1.125

1.375

1.625

1.875

1.625

1.875

1.625

1.875

1.375

1.625

1.875

1.125

1.375

0.875

1.125

0.875

1.125

1.375

1.125

1.375

1.875

1.625

1.875

sheave assembly

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

3H35129B1

3H35129B2

3H35129B3

3H35129B4

3H35129B5

3H35129B6

3H35129B7

3H35129B8

3H35129B9

3H35129B10

3H35129B11

3H35129B12

3H35129B13

3H35129B14

3H35129B15

3H35129B16

3H35129B17

3H35129B18

3H35129B19

3H35129B20

3H35129B21

3H35130B1

3H35130B2

3H35130B3

3H36622B15

3H36622B16

3H36622B17

3H36622B18

3H36622B19

3H36622B20

3H36622B21

3H36622B22

3H36622B23

3H36622B24

3H36622B25

3H36622B26

Browning

Belt no.

B75

BX73

B72

B70

BX78

B74

BX75 qty (2) BX82 qty (2) BX82 qty (2) B86 qty (2) B86

B71

BX74 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 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

BX68

BX75

B73

B72

B78

B70

B77

B77 qty (2) B74 qty (2) B74

B71

B70

BX71

BX77

BX75

electrical data / motor data

total unit amp draw

The total unit amp draw is a combination of the motor, and the control step down transformer. The control step down transformer includes damper actuators, ignition controllers, gas valves, control relays, amplifiers, and motor starters.

Motor Amp Draw (Tables 38.2 to 42.1) =

Control Step Down Transformer Amp Draw (Table 38.1) =

Total Amp Draw =

table 38.1 - control step down transformer amp draws

digit 15

(transformer)

(115/60/1)

0.35

0.65

1.30

2.17

(208/60/1)

0.19

0.36

0.72

1.2

(230/60/1) digit 14 (supply voltage) d

(208/60/3) e

(230/60/3)

0.17

0.33

0.65

1.09

0.19

0.36

0.72

1.20

0.17

0.33

0.65

1.09

(460/60/3)

0.09

0.16

0.33

0.54

(575/60/3)

0.07

0.13

0.26

0.43

table 38.2 - motor data for digit 14 = a - 115v/60Hz/1ph

digits

17&18

f1 or r1

f5 or r5

G1 or s1

G5 or s5

motor size (Hp)

1-1/2

1/3

1/2

3/4

motor

type ➀

ODP

TEFC

ODP

TEFC

ODP

TEFC

ODP

TEFC

ODP

TEFC

ODP

TEFC

frame size

145T

182T

184T

amp. draw

13.4

18.0

15.2

21.0

20.0

34.0

32.0

6.6

5.0

9.0

8.0

11.0

13.4

service factor

1.15

1.00

1.35

1.00

1.20

1.15

1.25

1.00

1.15

table 38.3 - motor data for digit 14 = B - 208v/60Hz/1ph

digits

17&18

f1 or r1

f5 or r5

H1 or t1

H5 or t5

motor size (Hp)

1/3

1/2

3/4

1-1/2

motor

type ➀

ODP

TEFC

ODP

TEFC

ODP

TEFC

ODP

TEFC

ODP

TEFC

frame size

145T

182T

184T

amp. draw

3.0

4.1

4.0

5.5

5.4

6.8

9.3

8.2

11.3

10.8

23.0

22.8

service factor

1.35

1.20

1.15

1.25

1.00

1.15

1.00

thermal overload

Yes

thermal overload

Yes

Weight

(lbs)

Weight

(lbs)

efficiency

➁

(%)

N/A

efficiency

➁

(%)

N/A

38 5-562.8

motor data

table 39.1 - motor data for digit 14 = c - 230v/60Hz/1ph

digits

17&18

f1 or r1

f5 or r5

G1 or s1

G5 or s5

H1 or t1

H5 or t5

motor size (Hp)

1-1/2

1/3

1/2

3/4

motor

type ➀

ODP

TENV

ODP

TEFC

ODP

TEFC

ODP

➀

Refer to page 42 for Motor Type abbreviations.

➁

Motors manufacturers do not rate single-phase motors for efficiency.

frame size

145T

182T

184T

amp. draw

6.7

9.0

7.6

10.5

10.0

17.0

16.0

22.0

20.2

3.3

2.5

4.5

4.0

5.5

6.7

service factor

1.15

1.00

1.15

1.00

1.35

1.00

1.20

1.15

1.25

1.00

1.15

thermal overload

Yes

Weight

(lbs)

efficiency

➁

(%)

N/A

table 39.2 - motor data for digit 14 = d - 208v/60Hz/3ph ①

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

ODP

TEFC

ODP

TEFC

ODP

1.5

1.2

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

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

d7 or p7 1 TEFC 18/9 143T 3.5/1.5 1.00

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

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

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

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

f7 or r7

2 TEFC 18/9 145T 6.4/2.5 1.00

f8 or r8 2

G1 or s1

G2 or s2

TE 145T 7.0

TE HE 145T 6.5

ODP 182T 10.0

ODP HE 182T 8.9

1.15

TE 18/12 182T 6.4/3.9 1.15

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

TE 182T 10.0 1.15

TE HE 182T 9.4-9.1 1.15

N/A

82.5%

84.0%

76.0 / 59.0%

42 74.0 / 60.0%

N/A

84.5%

29 76.0 / 58.0%

29 80.0 / 65.0%

38 83.0 / 71.0%

38 80.0 / 72.0%

74.0 / 60.0%

80.0%

89.5%

80.0 / 71.0%

N/A

84.0%

82.0%

89.5%

33 81.0 / 67.0%

78 81.0 / NA%

84.0%

86.5%

41 84.0 / 70.0%

65 84.0 / 77.0%

81.5%

89.5%

G5 or s5 3

G6 or s6 3

G7 or s7

G8 or s8 3

H1 or t1 5

H2 or t2 5

TE 18/9 182T 9.3/3.5 1.00

TE 18/12 184T 9.2/5.4 1.15

ODP

ODP HE

184T

182T

16.0

15.7

184T 14.2

1.15

66 82.0 / 72.0%

79 81.0 / 75.0%

H3 or t3

5 ODP 18/9 184T 16.0/6.2 1.15 81 85.0 / 77.0%

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

H7 or t7

H8 or t8 5

i1 or W1 7 1/2

87.5%

88.5%

84.0 / 70.0%

84.0 / 82.0%

84.0%

89.5%

87.5%

TE HE 184T 15.0 1.15

TE 18/9 184T 15.0/5.3 1.00

99 88.5%

85 85.0 / 85.0%

TE 18/12 213T 15.0/8.5 1.15 107 85.0 / 80.0%

ODP 213T 26.9 1.15 106 81.5%

motor

digits size motor frame amp. service Weight efficiency

17&18 (Hp) type ➁

size draw factor (lbs) (%)

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 1.15

i6 or W6 7 1/2

TE HE

213T 24.0

213T 22.0 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 1.15

J2 or X2 10

ODP

ODP HE

215T 32.6

215T 29.0 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 TE 215T 29.0 1.15

J6 or X6 10

TE HE 215T 27.6 1.15

J7 or X7 10 TE 18/9 215T 29.0/11.5 1.15

J8 or X8 10 TE 18/12 254T 30.0/17.0 1.15

K1 or y1 15 1.15

K2 or y2 15

ODP

ODP HE

254T 45.6

254T 43.4 1.15

K3 or y3 15 ODP 18/9 256T 42.5/16.5 1.15

K5 or y5 15

K6 or y6 15

TE 254T 42.0

TE HE 254T 40.3

1.15

K7 or y7 15

TE 18/9 256T 44.0/16.0 1.15

K8 or y8 15 TE 18/12 256T 42.0/23.0 1.15

v1 or Z1 20 ODP 256T 61.6

v2 or Z2 20 ODP HE 256T 57.0

v3 or Z3 20

ODP 18/9 284T 56.0/21.0 1.15

v4 or Z4 20 ODP 18/12 286T 54.0/28.0 1.15

v6 or Z6 20

v7 or Z7 20

TE HE 256T 54.0

TE 18/9

1.15

284T 59.0/20.0 1.15

①

Motors have no thermal overload.

②

Refer to page 42 for Motor Type abbreviations.

141 91.7%

108 85.0 / 72.0%

167 89.0 / 85.0%

126 89.5%

158 90.2%

106 87.0 / 75.0%

124 86.0 / 80.0%

120 84.0%

126 91.7%

118 88.0 / 77.0%

196 88.0 / 80.0%

130 87.5%

200 90.2%

118 87.0 / 77.0%

212 88.0 / 80.0%

147 87.5%

220 93.0%

244 90.2 / 84.0%

250

259

91.0%

91.7%

218 88.0 / 82.0%

219 88.0 / 84.0%

200

250

87.5%

93.6%

221 90.2 / 82.5%

270 89.0 / 86.0%

290 91.7%

346 89.0 / 88.0%

5-562.8

motor data

table 40.1 - motor data for digit 14 = e - 230v/60Hz/3ph ①

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

1.6

1.2

2.2

1.35

1.00

1.25

c1 or n1 3/4

c5 or n5 3/4

d1 or p1 1

d2 or p2

d3 or p3 1

TEFC

ODP

TEFC

ODP

143T

ODP HE 143T

2.2

2.8

3.1

3.2

ODP 18/9 143T 3.4/1.6

1.15

1.25

1.15

d4 or p4

1 ODP 18/12 145T 3.4/2.2 1.15

TEFC 56 3.6

1.15

1.15 d5 or p5 1

d6 or p6

1 TE HE 143T 3.0 1.15

d7 or p7 1 TEFC 18/9 143T 3.4/1.6 1.00

d8 or p8

1 TEFC 18/12 145T 3.4/2.2 1.00

e1 or Q1 1 1/2 ODP 145T 4.4 1.15

e2 or Q2 1 1/2

ODP 145T 5.6 1.00

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

e5 or Q5 1 1/2 4.8 1.15

e6 or Q6 1 1/2

TEFC

TE HE

145T 5.0 1.15

e7 or Q7 1 1/2 TEFC 18/9 145T 4.0/1.7 1.00

e8 or Q8 1 1/2 TEFC 18/12 145T 4.9/2.8

1.00

f1 or r1 2 ODP 145T 5.8

N/A

82.5%

84.0%

76.0 / 59.0%

74.0 / 60.0%

N/A

85.5%

76.0 / 58.0%

74.0 / 60.0%

84.0%

89.5%

80.0 / 65.0%

80.0 / 71.0%

N/A

86.5%

83.0 / 71.0%

f2 or r2

f3 or r3 2

f5 or r5 2

ODP 145T 5.8 1.00

ODP 18/9 145T 6.4/2.7 1.15

f4 or r4

2 ODP 18/12 182T 6.3/3.5 1.15

TE 145T 5.8

1.15

f6 or r6

2 TE HE 145T 6.0 1.15

f7 or r7 2 TEFC 18/9 145T 6.4/2.6 1.00

f8 or r8

G1 or s1 3

G2 or s2

G3 or s3 3

TE 18/12

ODP

ODP HE

182T 6.4/4.2

182T

9.4

8.6

1.15

ODP 18/9 182T 11.6/4.4 1.15

G4 or s4

3 ODP 18/12 184T 8.5/4.6 1.15

G5 or s5 3 TE 182T 8.2 1.15

G6 or s6

G7 or s7 3

G8 or s8

H1 or t1 5

H2 or t2

H3 or t3 5

TE HE

TE 18/9 182T 10.0/3.6 1.00

TE 18/12

ODP

ODP HE

182T

184T

8.0

184T 8.8/5.5

184T 14.0

13.6

1.15

ODP 18/9 184T 17.7/6.2 1.15

38 80.0 / 72.0%

110

64 84.0 / 70.0%

84.0%

89.5%

81.0 / 67.0%

81.0 / NA%

84.0%

85.5%

84.0 / 70.0%

84.0 / 77.0%

86.5%

89.5%

82.0 / 72.0%

81.0 / 75.0%

87.5%

89.5%

84.0 / 82.0%

87.5%

94 89.5%

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 TE 184T 13.0 1.15 90 87.5%

H6 or t6

H7 or t7 5

H8 or t8

TE HE

TE 18/12

184T 13.0 1.15

TE 18/9 184T 16.0/5.3 1.00

213T 14.0/8.8 1.15

117 90.2%

85 85.0 / 85.0%

107 85.0 / 80.0%

①

Motors have no thermal overload.

②

Refer to page 42 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

i2 or W2 7 1/2 ODP HE 213T 19.4

1.15 121

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

i6 or W6 7 1/2 TE HE 213T 19.2

1.15 126

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

J2 or X2 10 ODP HE 215T 25.2

1.15 138

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

J6 or X6 10

TE 215T 26.0

TE HE 215T 25.0

1.00 138

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

K2 or y2 15 ODP HE 254T 37.8

1.15 215

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 91.0%

K6 or y6 15 TE HE 254T 38.0 1.15 322 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 91.0%

v2 or Z2 20 ODP HE 256T 49.0 1.15 250 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 TEFC 256T 51.0 1.15 287 91.0%

v6 or Z6 20 TE HE 256T 48.2 1.15 368 93.0%

v7 or Z7 20 TE 18/9 284T 52.0/18.0 1.15 346 89.0 / 88.0%

40 5-562.8

motor data

table 41.1 - 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

c1 or n1 3/4

c5 or n5 3/4

d1 or p1 1

d2 or p2 1

d3 or p3 1

ODP

TEFC

ODP

TEFC

ODP

0.8

0.6

1.1

1.4

143T 1.6

ODP HE 143T 1.5

1.35

1.00

1.25

1.15

1.25

1.15

ODP 18/9 143T 1.8/0.8 1.15

d4 or p4 1 ODP 18/12 145T 1.7/1.1 1.15

d5 or p5 1

d6 or p6 1

TEFC 56 1.8

TE HE 143T 1.5

1.15

d7 or p7 1 TEFC 18/9 143T 1.8/0.8 1.00

d8 or p8 1 TEFC 18/12 145T 1.7/1.1 1.00

e1 or Q1 1 1/2

e2 or Q2 1 1/2

ODP

145T 2.2

145T 2.4

1.15

1.00

e3 or Q3 1 1/2 ODP 18/9 145T 2.3/1.0 1.15

e4 or Q4 1 1/2 ODP 18/12 145T 2.4/1.4 1.15

e5 or Q5 1 1/2 TEFC 56 2.4

e6 or Q6 1 1/2 TE HE 145T 2.5

1.15

e7 or Q7 1 1/2 TEFC 18/9 145T 2.0/0.9 1.00

e8 or Q8 1 1/2 TEFC 18/12 145T 2.5/1.4 1.00

f1 or r1 2

f2 or r2 2

f3 or r3 2

ODP

145T 2.9

1.15

1.00

ODP 18/9 145T 3.0/1.3 1.15

f4 or r4 2 ODP 18/12 182T 3.0/2.0 1.15

f5 or r5 2

f6 or r6 2

TE 145T 2.9

TE HE 145T 3.0

1.15

f7 or r7 2 TEFC 18/9 145T 3.2/1.3 1.00

f8 or r8 2

G1 or s1 3

G2 or s2 3

G3 or s3 3

TE 18/12 182T 3.1/1.9 1.15

ODP 182T 4.5

ODP HE 182T 4.3

1.15

ODP 18/9 182T 4.5/1.8 1.15

G4 or s4 3 ODP 18/12 184T 4.6/2.7 1.15

G5 or s5 3

G6 or s6 3

TE 182T 4.1

TE HE 182T 4.0

1.15

N/A

82.5%

84.0%

26 76.0 / 59.0%

39 74.0 / 60.0%

N/A

85.5%

28 73.0 / 58.0%

31 74.0 / 60.0%

84.0%

89.5%

29 80.0 / 65.0%

32 75.0 / 71.0%

N/A

86.5%

39 83.0 / 71.0%

37 80.0 / 72.0%

84.0%

89.5%

33 79.0 / 62.0%

61 80.0 / 70.0%

84.0%

85.5%

42 84.0 / 70.0%

68 81.0 / 77.0%

86.5%

89.5%

60 80.0 / 66.0%

71 82.5 / NA%

110

87.5%

89.5%

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

H7 or t7

5 TE 18/9 184T 7.0/2.5 1.15

H8 or t8

5 TE 18/12 213T 6.9/4.1 1.15

i1 or W1 7 1/2

ODP

i2 or W2 7 1/2 ODP HE

213T

9.8

9.7

1.15

i3 or W3 7 1/2 ODP 18/9 213T 11.8/4.2

1.15

i4 or W4 7 1/2 ODP 18/12 215T 10.0/6.0

1.15

i5 or W5 7 1/2

TE 213T 10.0 1.15

i6 or W6 7 1/2

TE HE 213T 9.6 1.15

i7 or W7 7 1/2 TE 18/9

213T 10.0/4.1 1.15

i8 or W8 7 1/2 TE 18/12 215T 10.3/5.6

1.15

J1 or X1

10 ODP 215T 13.4 1.15

J2 or X2

10 ODP HE 215T 12.6 1.15

J3 or X3

10 ODP 18/9 215T 15.0/5.3 1.15

J4 or X4

10 ODP 18/12 256T 12.0/6.3 1.15

J5 or X5

10 TE 215T 13.0 1.00

J6 or X6

10 TE HE 215T 12.5 1.15

J7 or X7

10 TE 18/9 215T 13.0/5.4 1.15

J8 or X8

10 TE 18/12 254T 13.5/7.5 1.15

K1 or y1 15

ODP 254T 19.3 1.15

K2 or y2 15

ODP HE 254T 18.9 1.15

K3 or y3 15

ODP 18/9 256T 19.3/7.8 1.15

K4 or y4 15 ODP 18/12 256T 18.0/9.5

1.15

K5 or y5 15

TE 254T 20.0 1.15

K6 or y6 15

TE HE 254T 19.0 1.15

K7 or y7 15

TE 18/9 256T 19.5/7.5 1.15

K8 or y8 15

TE 18/12 256T 19.5/11.0 1.15

v1 or Z1 20

ODP 256T 25.0 1.15

v2 or Z2 20

ODP HE 256T 24.5 1.15

v3 or Z3 20

ODP 18/9 256T 25.2/10.0 1.15

v4 or Z4 20 ODP 18/12 286T 24.0/13.0

1.15

v5 or Z5 20

TEFC 256T 25.5 1.15

v6 or Z6 20

TE HE 256T 24.1 1.15

v7 or Z7 20

TE 18/9 284T 26.0/8.7 1.15

v8 or Z8 20

TE 18/12 284T 24.7/14.0 1.15

117

121

160

126

194

138

220

138

213

215

217

250

322

233

250

208 89.5 / 82.5%

270 90.0 / 84.0%

287

368

90.2%

83 86.0 / 83.0%

107 85.0 / 75.5%

88.5%

91.7%

125 85.0 / 72.0%

131 87.0 / 80.0%

89.5%

91.7%

83 84.0 / 74.0%

128 85.0 / 80.0%

89.5%

91.7%

116 83.0 / 71.0%

192 87.0 / 82.0%

89.5%

90.2%

107 86.5 / 77.0%

222 87.0 / 82.0%

91.0%

93.0%

203 88.5 / 81.5%

298 86.0 / 81.0%

91.0%

92.4%

218 88.0 / 82.0%

223 88.0 / 84.0%

91.0%

93.6%

91.0%

93.0%

331 89.0 / 88.0%

361 90.0 / 86.0%

G7 or s7 3

G8 or s8 3

H1 or t1 5

H2 or t2 5

TE 18/9 182T 4.6/1.7 1.15

TE 18/12 184T 4.3/2.6 1.15

ODP 184T 7.0

ODP HE 184T 6.8

1.15

H3 or t3 5 ODP 18/9 184T 9.1/3.2 1.15

H4 or t4 5 ODP 18/12 215T 7.1/4.8 1.15

H5 or t5 5 TE 184T 6.5 1.15

65 84.0 / 70.0%

73 82.5 / 75.5%

87.5%

89.5%

94 84.0 / 73.0%

117 78.0 / 71.0%

90 87.5%

➀

Motors have no thermal overload.

➁

Refer to page 42 for Motor Type abbreviations.

5-562.8

motor data

table 42.1 - 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

type ➁

TE HE

ODP

TEFC

TE HE

ODP

TEFC

TE HE

ODP

TE HE

ODP

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

motor size (Hp)

7 1/2

1 1/2

1/12

1/3

1/2

3/4

➀

Motors have no thermal overload

➁

Motor Type Abbreviations

ODP

ODP HE

Open Drip Proof

Open Drip Proof, High Efficiency

ODP 18/9 Open Drip Proof, 2-speed 1800/900 RPM

ODP 18/12 Open Drip Proof, 2-speed 1800/1200 RPM

TEFC

TE HE

TE 18/9

TE 18/12

TENV

Totally Enclosed

Totally Enclosed, Fan Cooled

Totally Enclosed, High Efficiency

Totally Enclosed, 2-speed 1800/900 RPM

Totally Enclosed, 2-speed 1800/1200 RPM

Totally Enclosed, Non-Ventilating

frame size

215T

254T

256T

182T

184T

213T

215T

145T

182T

143T

amp. draw

10.4

9.6

15.4

16.0

15.2

20.8

20.4

19.5

3.2

5.2

7.8

8.0

7.6

10.3

1.8

2.0

1.7

2.3

2.4

3.4

0.6

0.9

1.1

1.5

1.2

service factor

1.15

1.25

1.15

1.25

1.15

efficiency

(%)

89.5%

90.2%

91.0%

92.4%

91.0%

93.0%

89.5%

87.5%

89.5%

88.5%

89.0%

90.2%

89.5%

84.0%

85.5%

84.0%

86.5%

87.5%

N/A

82.5%

77.0%

85.5%

Weight

(lbs)

154

200

184

250

326

255

287

368

100

117

113

142

192

123

42 5-562.8

dimensions - unit

figure 43.1 - dBG indoor Gravity vented 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 43.2 - dcG indoor Gravity vented cooling package unit dimensions

2 qty (4) Drill Locator Dimples for

Field Drilled Electrical Conduit

Entry Holes (spaced 2.0" apart)

table 43.1 - dBG/dcG indoor Gravity vented unit dimensions (all dimensions in inches)

model Blower type Qty. of

size (digit 16) furnaces a

100/125

150/175

200/225

All

250/300 E, F, G, or H

350/400 E, F, G, or H

500/600

700/800

G or H

B c d e f dimensions

G H J K l n p s

Gas conn.

37.75 19.07 15.21 28.75 18.00 25.00 20.02 39.23 32.06 38.37 12.65 5 40.80 87.77 1/2

37.75 19.07 17.70 28.75 21.00 25.00 20.02 39.23 34.56 38.37 15.14 6 40.80 87.77 1/2

37.75 19.07 21.96 28.75 24.00 25.00 23.99 39.23 38.82 38.37 19.41 7 40.80 87.77 1/2

37.75 23.07 24.09 32.75 27.00 28.00 23.99 43.23 40.94 42.37 21.60 7 44.80 87.77 1/2 / 3/4

3775 23.07 27.13 32.75 30.00 28.00 29.96 43.23 44.05 42.37 24.60 8/10 44.80 87.77 3/4

37.75 23.07 38.63 32.75 42.00 28.00 41.90 43.23 55.57 42.37 36.14 10 44.80 87.77 3/4

37.75 23.07 27.13 32.75 n/a n/a 29.96 43.23 44.05 42.37 24.60 8/10 44.80 120.90 3/4

37.75 23.07 38.63 32.75 n/a n/a 41.90 43.23 55.57 42.37 36.14 10 44.80 120.90 3/4

➀

For Right Hand Access Units - Drill Locator Dimples for Field Drilled Electrical Conduit Entry Holes (spaced 2.0" apart)

➁

For Left Hand Access Units - Drill Locator Dimples for Field Drilled Electrical Conduit Entry Holes (spaced 2.0" apart)

5-562.8

dimensions - unit

figure 44.1 - dBG indoor Gravity vented Blower package unit dimensions with Blower type i, J, K, or l

Qty (4) Drill Locator Dimples for

Field Drilled Electrical Conduit

Entry Holes (spaced 2.0" apart)

500 - 800 model shown figure 44.2 - dcG indoor Gravity vented cooling package unit dimensions with Blower type i, J, K, or l

J Over Roof

7.65

G (INSIDE)

5.29 9.21

3.00

43.23

44.80 qty (4) Drill Locator Dimples for

Field Drilled Electrical Conduit

Entry Holes (spaced 2.0" apart)

table 44.1 - dBG/dcG indoor Gravity vented unit dimensions with Blower type 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

e G J dimensions l n s

u ➂ W ➂ X ➂ conn.

27.13 30.00 29.96 44.05 24.60 8/10 123.35 n/a

38.63 42.00 41.90 55.07 36.14 10 123.35 n/a n/a n/a n/a n/a

Gas

3/4

27.13 n/a 29.96 44.05 24.60 8/10 156.76 29.74 6.5 41.62 3/4

38.63 n/a 41.90 55.57 36.14 10 156.76 29.74 6.5 41.62 3/4

38.63 n/a 41.90 55.57 36.14 10 185.99 29.74 6.5 41.62 3/4

➀

For Right Hand Access Units - Drill Locator Dimples for Field Drilled Electrical Conduit Entry Holes (spaced 2.0" apart)

➁

For Left Hand Access Units - Drill Locator Dimples for Field Drilled Electrical Conduit Entry Holes (spaced 2.0" apart)

➂

Applies to units with Digit 16 = L only.

44 5-562.8

dimensions - Base

figure 45.1 - unit Base dimensions

0.63

2.36

0.75" Suspension

Hanging Locations

(Typical 4 Corners)

Suspension

Point

Lifting

Point

C To end of unit

E Inside

Suspension

Point

Return Air

Opening

24.00 Inside

Lifting

Point g

1.45

4.35

table 45.1 - indoor Gravity vented Blower package units (all dimensions in inches)

model size

100/125

150/175

200/225

250/300

350/400

500/600

700/800

840/960

Blower type

(digit 16) a B c d

dimensions e n K l J m

All

87.77 34.85 81.30

87.77 37.36 81.30

87.77 41.61 81.30

87.77 43.71 81.30

E,F,G, or H 87.77 46.75 81.30

I, J, or K 123.35 46.75 117.26

E,F,G, or H 87.77 58.27 81.30

I, J, or K 123.35 58.27 117.26 n/a n/a n/a n/a n/a n/a n/a n/a

19.52

23.49

29.46

41.40

41.40 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 n/a n/a n/a n/a n/a n/a n/a n/a

32.00

34.50

38.75

40.85

43.89

55.41

6.23

7.49

7.63

8.69

7.21

7.00

G, or H 120.90 46.75 111.68 34.12 29.46 89.14 34.12

I, J, K, or L 156.76 46.75 147.53 34.12 29.46 117.82 82.27

G, or H 120.90 58.27 111.68 34.12 41.40 89.14 34.12

I, J, K, or L 156.76 58.27 147.53 34.12 41.40 117.82 82.27 n/a n/a n/a n/a

43.89

55.41

7.21

7.00

I, J, K, or L 185.99 58.27 176.75 30.31 41.40 147.06 63.36 147.06 55.41 7.00

table 45.2 - indoor Gravity vented cooling package units (all dimensions in inches)

model size

100/125

150/175

200/225

250/300

350/400

Blower type

(digit 16) a

All

116.98

E, F, G, or H 116.98

I, J, or K 152.84

E, F, G, or H 116.98

I, J, or K 152.84

34.85

37.36

41.61

43.71

46.75

58.27

114.07

149.93

114.07

149.93

dimensions e f G J

19.52

23.49

81.88

56.96 32.00

56.96 34.50

56.96 38.75

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

6.23

7.49

7.63

8.69

7.21

7.00

5-562.8

dimensions - coolinG coils

figure 46.1 - dX coil drawing (all dimensions in inches)

Airflow Direction

rows 2 3 4

W 7.5 6 7.5 10

TOP VIEW

1.5

Coil for Right Hand Units

(Digit 9 = R)

Headers on opposite side for Left Hand Units

Distributor Inlet (Liquid

Line) Connection(s)

(Second Inlet on Dual

Circuit Coils)

FRONT VIEW

1.5

SIDE VIEW

Airflow

Direction

Suction Line Connections in direction of airflow

(Second Inlet on Dual Circuit Coils)

table 46.1 - dX coil dimensions

model cooling

size mBH

100/125

All

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

fH H s fl

27.5 30.5 1.5 18

27.5 30.5 1.5 21

27.5 30.5 1.5 24

dX - single circuit i l suction liquid line (Qty) line (Qty) fl i l suction liquid

line (Qty) line (Qty)

25 21 (1) 1.625 (1) ➀ 16.25 26.5 19.25 (2) 1.625

28 24 (1) 1.625 (1) ➀ 19.5 29.75 22.5 (2) 1.625

(2)

➀

31 27 (1) 1.625 (1) ➀

32.5 34.5 0.5 27 34 30 (1) 1.625 (1) ➀

32.5 34.5 0.5 27 34.5 30 (1) 2.125 (1) ➀

32.5 34.5 0.5 30 37 33 (1) 1.625 (1) ➀

32.5 34.5 0.5 30 37.5 33 (1) 2.125 (1) ➀

32.5 34.5 0.5 42 49 45 (1) 1.625 (1) ➀

32.5 34.5 0.5 42 49.5 45 (1) 2.125 (1) ➀

dX - dual circuit

23 33.25 26.0 (2) 1.625

25.5 35.75 28.5 (2) 1.625

28.5 38.75 31.5 (2) 1.625

40.25 50.5 43.25 (2) 1.625

(2) ➀

➀

Liquid line dimensions vary by configuration. Refer to the original order for configured dimensions.

figure 46.2 - chilled Water coil drawing (all dimensions in inches)

Airflow Direction

rows 4 6

W 7.5 10

TOP VIEW

1.5

1.8

Return Water Line

Connection turned 90° in direction of airflow

Coil for Right Hand Units

(Digit 9 = R)

Headers on opposite side for

Left Hand Units

FRONT VIEW

2.25

Airflow

Direction

SIDE VIEW

2.25

Supply Water Line

Connection turned 90° in direction of airflow

1.8

table 46.2 - chilled Water coil dimensions

model size fH H s v fl

100/125

150/175

200/225

250/300

350/400

34.5

1.5

0.5

1.5

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

46 5-562.8

dimensions/WeiGHts

figure 47.1 - remote panel dimensions

5.57

1.50

table 47.3 - 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

7.06

2.81

10.60 3.53 4.58

13.09 6.03 5.82

3.53

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.

2.56

3.38

2.13

table 47.1 - Blower package unit operating Weights

(all weights in pounds)

model Blower type

size (digit 16) unit

100/125

All

236

272

150/175

200/225

All

308

365

250/300 E,F,G, or H 396

250/300 I, J, or K 645

350/400 E,F,G, or H 482

350/400 I, J, or K 763

500/600 G or H 577

500/600 I, J, K, or L 826

700/800 G or H 733

700/800 I, J, K, or L 1014

840/960 I, J, K, or L 1265

motor

filters dampers dampers fresh air f & ra insulation double Wall

(all sections)

table 47.2 - cooling package unit operating Weights

(all weights in pounds)

model size

100/125

150/175

200/225

350/400

Blower type dampers dampers fresh &

(digit 16) unit motor filters fresh air return air

All

343

382

All

423

491

912

See Motor

250/300 E,F,G, or H 526

250/300 I, J, or K 775

Data

350/400 E,F,G, or H 631

I, J, or K

insulation

double Wall

(all sections)

134

101

144

5-562.8

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.

figure 48.1 - filter replacement arrangement for

Blower size (digit 16) a, B, c, d, e, f, G and H

FILTER SPACER

100/125

▼

150/175

FILTER SPACER

3. Remove the two screws holding the manifold to the heat exchanger support.

4. Slide the manifold through the manifold bracket.

5. Clean the orifices and adjust the air shutters as necessary.

6. Follow steps 3-6 in reverse order to install the manifold assembly.

7. Turn on the electric and gas supply.

8. Check the ground union joint for leaks with a soap solution.

Tighten if necessary.

figure 48.3 - manifold assembly removal

SERIAL PLATE

ELECTRICAL

JUNCTION

BOX

MANIFOLD

A A

200/225 250/300

500/600

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

350/400

700/800

figure 48.2 - filter replacement arrangement for

Blower size (digit 16) i, J, K, and l

a a a

NON-ACCESS

SIDE

FILTER

SPACER

a d a

NON-ACCESS

SIDE

FILTER

SPACER

a a c d a a c

250/300

500/600

A = 20'' x 25''

B = 16'' x 25''

C = 20'' x 16''

D = 15'' X 25''

manifold assembly removal to remove the manifold

1. Shut off gas and electric supply.

2. Disconnect gas manifold at ground union joint.

350/400

700/800

840/960

B a

48 5-562.8

BURNER SIDE

ACCESS PANEL

Burner and pilot assembly removal to remove the burner

1. Shut off gas and electric supply.

2. Disconnect the pilot supply line from the gas valve.

3. 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.

4. Remove the screws holding the burner side access panel.

Attached to the panel are the burner retaining pins that align the burner.

5. Slide the burner assembly out. The pilot is attached to the burner assembly.

6. Examine the burner and pilot assembly for cleanliness and/or obstructions as necessary (see Duct Furnace for cleaning instructions).

7. 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.

8. Reconnect the ignition cable and pilot gas supply line.

9. Turn on the electric and gas supply.

figure 48.4 - Burner and pilot assembly removal

AIR SHUTTERS

(NOT SHOWN)

ARE LOCATED

ON THE

MANIFOLD

PILOT

ASSEMBLY

IGNITION

CABLE

PILOT

SUPPLY

LINE

service & trouBlesHootinG

WARNING

When servicing or repairing this equipment, use only factoryapproved service replacement parts. A complete replacement parts list may be obtained by contacting Modine Manufacturing

CAUTION

Do not attempt to reuse any mechanical or electrical controllers which have been wet. Replace defective controller.

IMPORTANT

To check most of the Possible Remedies in the troubleshooting guide listed in Table 50.1, refer to the applicable sections of the manual.

troubleshooting figure 49.1 - Blocked vent safety switch (Bvss) troubleshooting flow chart

YES

Is vent blocked or restricted?

YES

Remove restriction

YES

Is there a negative pressure in space? (see note 2)

Is there spillage after 5 minutes? (see note 1)

Can negative pressure be corrected?

Is vent in compliance with NFGC?

Replace blocked vent switch;

Does switch still trip?

YES NO

YES

Correct negative pressure

Install power vent accessory

YES NO

Correct vent

Note 1:

To determine spillage, place lit match stick (6" - 8" match stick if possible) 2" - 3" into diverter relief opening and determine direction of the flame (or direction of smoke if flame goes out). If flame or smoke comes back at you, there is spillage. The flame or smoke should be pulled in.

Note 2:

One indication of negative pressure is that outside doors tend to be pulled toward inside of space.

YES

Reduce input

Is unit overfired?

Can one or more of the following be done?

• Lengthen vertical vent run

• Insulate vent

• Use larger diameter vent

• Use less restrictive weather cap

YES

Install power exhauster accessory

YES

Does unit still trip?

Install power vent accessory

5-562.8

service & trouBlesHootinG

table 50.1 - troubleshooting

trouble

pilot does not light

possible cause

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.

9. Pilot valve is off.

10. Dirty thermocouple contact.

11. Excessive drafts.

12. Pilot orifice Fitting leak.

main burners do not light (pilot is lit) lifting flames (see figure 51.1)

1. Defective valve.

2. Loose wiring.

3. Defective pilot sensor

4. Defective ignition controller.

5. Improper thermostat wiring.

6. Blocked vent safety switch trippped.

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.)

1. Insufficient primary air.

2. Dirty orifice.

3. Misaligned orifice.

possible remedy

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.

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.

9. Turn gas control knob or lever on combination gas control to pilot position.

10. Be sure thermocouple contact is clean. If problem persists replace thermocouple.

11. Find source and re-direct airflow away from unit.

12. Tighten pilot orifice. Flame impingment on thermocouple may cause thermocouple to become inoperative.

1. Replace valve.

2. Check wiring to gas valve.

3. Replace pilot sensor.

4. Replace ignition controller.

5. Verify wiring compared to wiring diagram.

6. Refer to Figure 49.1

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.

50 5-562.8

service & trouBlesHootinG flashback trouble floating flames (see figure 51.2) flame rollout (see figure 51.3) not enough Heat too much Heat possible cause

1. Too much primary air

2. Main pressure set too high.

3. Orifice too large.

1. Insufficient primary air.

2. Main pressure set too high.

3. Orifice too large.

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.

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.

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 18.1, indicator

49 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.

possible remedy

1. Reduce primary air.

2. Adjust to maximum of 14” W.C.

3. Check orifice size with those listed on the serial plate.

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.

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.

figure 51.1 - lifting flame condition figure 51.2 floating flame condition figure 51.3 flame rollout appearance

5-562.8

model desiGnations

model identification

Duct furnace/make-up air units contain an CSA and ETL/ETL

Canada certified indoor duct furnace. 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 or on the side of unit. The part number for some common replacement parts are listed on the serial plate (See Figure 52.1) and the model identification plate (See Figure 53.1). For a complete description of the model number, see Model Identification.

figure 52.1 - serial plate

52 5-562.8

model desiGnations

figure 53.1 - model identification plate

DBG 75AFRHN10A1AA1AAA1A

01101010199-0002

115/208-230

115

6.6/3.0-3.3

60 1 8.47

10.00

Modine Manufacturing Company

1500 DeKoven Ave., Racine, WI 53403

Phone: 800.828.4328

9F20218

5H71790-

5H63081-20

5H58064-3

5H76183-31

figure 53.2 - model dfG serial number designations 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 53.3 - model dBG/dcG 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

5-562.8

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

___ No

____ Yes ___ No

___ 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

___ 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

___ 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 ___ 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

Customer/Owner instructed in operation and maintenance of unit? ____ Yes ___ No

Name of Person(s) Instructed: ______________________________________________________________

Comments: ____________________________________________________________________________

____________________________________________________________________________

Start-Up Company Name: _______________________________ Phone: __________________________

Signature: _______________________________________________________ Date: ________________

54 5-562.8

model nomenclature for system units

indoor duct furnace model nomenclature

1 2 3

PT UC V

4 5 6

MBH

ATR

12 13 14

GV SS SV

1 - product type (pt)

D - Indoor HVAC Unit

2 - unit configuration (uc)

B - Blower Package - Furnace & Blower

C - Cooling Package - Furnace, Blower, & Cooling Coil Cabinet

3 - venting (v)

G - Gravity

4,5,6 - furnace input rating (mBH) (output on 840 & 960)

100 - 100,000 Btu/Hr Input 500 - 500,000 Btu/Hr Input

175 - 175,000 Btu/Hr Input

250 - 250,000 Btu/Hr Input

400 - 400,000 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)

A - Aluminized Steel

S - 409 Stainless Steel Heat Exchanger/Burner

T - 409 Stainless Steel Heat Exchanger/Burner/Drip Pan

8 - development sequence designation (ds)

F - Single Stage M - 2-stage or Modulating

9 - access side (as)

R - Right Hand L - Left hand

10 - air temperature rise (atr)

H - High 60°-100°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

5 - Electronic Modulation Master

6 - Electronic Modulation Slave

7 - Electronic Modulation 0-10 Vdc

External Input

8 - Electronic Modulation 4-20 mA

External Input

13 - additional safety switches (ss)

4 - No Switches (Standard) 1 - Low Gas Pressure Switch (Premium)

0 - No Switches (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

16 17 18 19 20 21 22 23

BB HP MT 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

C - 9-9 Spider Bearings

H - 15-15 Pillow Block Bearings

I - 18-18 Spider Bearings under 15 Hp

D - 9-9 Pillow Block Bearings

E - 12-12 Spider Bearings

J - 18-18 Pillow Block Bearings under 15 Hp

K - 18-18 Pillow Block Bearings for 15 Hp & up

F - 12-12 Pillow Block Bearings L - 20-18 Pillow Block Bearings

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

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 H - 5 Hp

I - 7-1/2 Hp

J - 10 Hp

K - 15 Hp

V - 20 Hp

18 - motor type (mt)

1 - ODP

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

2 - ODP - High Eff.

3 - ODP, 1800/900 RPM

4 - ODP, 1800/1200 RPM

19 - sheave arrangement (sa)

A - (See Sheave Tables 34.1 to 35.5)

20,21 - air control (ac)

5 - TE

6 - TE - High Eff.

7 - TE, 1800/900 RPM

8 - TE, 1800/1200 RPM

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

5-562.8

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.

commercial products Group

Modine Manufacturing Company

1500 DeKoven Avenue

Racine, WI 53403

Phone: 1.800.828.4328 (HEAT) www.modine.com

Litho in USA

Key features

Gravity vented
Indoor installation
Gas-fired
Duct furnaces
Installation and service instructions

Frequently asked questions

The minimum clearance to combustible material is 3 inches from the vent collar. Refer to Figure 3.1 and Tables 3.2 and 3.3 for complete details.

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

Installation of venting 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.

installation and service manual gas-fired indoor gravity vented duct furnaces/make-up air units models dBG/dcG

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.

if you smell Gas:

1. open windows.

2. don’t touch electrical switches.

3. extinguish any open flame.

4. immediately call your gas supplier.

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

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

special precautions

HaZard intensity levels

table of contents

si (metric) conversion factors table 3.1

unit location

location recommendations

figure 3.1 - combustible material and service clearances

table 3.2 - combustible material clearances

table 3.3 - recommended service clearances

combustion air requirements

sound and vibration levels

unit liftinG

unit mountinG

unit suspension

floor mounted units

figure 4.1 - unit suspension method

figure 4.2 - floor mounted units

duct installation

figure 5.1 - furnace discharge duct connection

figure 5.2 - recommended field installed discharge duct configurations for Blower package units

figure 5.3 - Blower section and cooling cabinet discharge duct connections

venting

table 6.1 - ansi venting requirements

General venting air instructions

table 7.1 - minimum Height from roof to lowest discharge opening

figure 7.1 - Gravity vented duct furnace venting

(pitched roof)

figure 7.2 - Gravity vented duct furnace venting

(obstructed)

Gas connections

figure 8.1 - recommended sediment trap/manual shut-off valve installation - side or Bottom Gas connection

table 8.1 - Gas pipe capacities

electrical connections

table 9.1 - low voltage (24v) maximum Wire length

(feet)

table 9.2 - number of Wires per terminal

figure 9.1 - recommended accessory field installed disconnect switch mounting locations

cooling coil units

figure 10.1 - cooling section

direct expansion (dX) piping

figure 10.2 - General dX piping

table 11.1 - cooling coil performance limits

chilled fluid piping

figure 11.1 - General chilled fluid piping

operation

General - all coils

chilled fluid coils - initial start-up

maintenance

General

start-up procedure

pilot Burner adjustment

to adjust the pilot flame

figure 13.1 - correct pilot flame

main Burner adjustment

to adjust the manifold pressure

figure 14.1 - checking manifold pressure with

“u” tube manometer

propane Gas flame control

figure 14.2 - maxitrol modulating valve adjustments air shutter adjustment

natural Gas flame control

table 14.1 - manifold pressure and Gas consumption

Blower adjustments

figure 15.1 - motor sheave adjustment

damper linkage adjustment

figure 15.3 - damper linkage adjustment

figure 15.2 - Belt tension adjustment

control operating sequence

lubrication recommendations

single-stage Gas controls