Modine Manufacturing IBS Installation And Service Manual

Document

5-594.10
5H0768560001
December, 2020
INSTALLATION AND SERVICE MANUAL
indirect gas-fired indoor separated combustion make-up air units
models DBS/DCS
IBS/ICS
All models approved for use in California by the CEC.
CAUTION
To prevent premature heat exchanger failure
do not locate ANY gas-fired units in areas
where chlorinated, halogenated, or acid
vapors are present in the atmosphere.
FOR YOUR SAFETY
WARNING
1. 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.
2. Installing, starting up and servicing heating,
ventilation and air conditioning equipment
poses significant hazards and requires
specialized knowledge of Modine products
and training in performing those services.
Failure to have any service properly
performed by, or making any modification
to Modine equipment without the use of
qualified service personnel could result in
serious injury to person and property,
including death. Therefore, only qualified
service personnel should work on any
Modine products.
WHAT TO DO IF YOU SMELL GAS:
1. Open windows.
2. Do not try to light any appliance.
3. Do not touch any electrical switch; do not
use any phone in your building.
4. Extinguish any open flame.
5. Immediately call your gas supplier from
a neighbor’s phone. Follow the gas
supplier’s instructions. If you can not
reach your gas supplier, call your fire
department.
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.
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 / SI (METRIC) CONVERSION FACTORS
SPECIAL PRECAUTIONS
WARNING
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.
(continued from previous column)
10. Ensure that the supply voltage to the appliance, as
indicated on the serial plate, is not 5% greater than the
rated voltage.
11. When servicing or repairing this equipment, use
only Modine-approved service replacement parts. A
complete replacement parts list may be obtained by
contacting Modine Manufacturing Company. Refer
to the rating plate on the appliance for complete
appliance model number, serial number, and company
address. Any substitution of parts or controls not
approved by Modine will be at the owners risk.
HAZARD INTENSITY LEVELS
1. DANGER: Indicates an imminently hazardous situation
which, if not avoided, WILL result in death or serious injury.
CAUTION
2. WARNING: Indicates a potentially hazardous situation which,
if not avoided, COULD result in death or serious injury.
3. CAUTION: Indicates a potentially hazardous situation which,
if not avoided, MAY result in minor or moderate injury.
4. IMPORTANT: Indicates a situation which, if not avoided,
MAY result in a potential safety concern.
1.
The concentric vent adapter box must be installed inside
of the structure or building. Do not install this box on the
exterior of a building or structure.
Purging of air from gas lines should be performed as
described in ANSI Z223.1 - latest edition “National Fuel
Gas Code”, or in Canada in CAN/CGA-B149 codes.
Ensure that the supply voltage to the appliance, as
indicated on the serial plate, is not less than the rated
voltage.
Do not reuse any mechanical or electrical component
which has been wet. Such components must be
replaced.
2.
DANGER
3.
Appliances must not be installed where they may be exposed
to a potentially explosive or flammable atmosphere.
4.
WARNING
Failure to follow proper lifting instructions and applicable
safety procedures could result in property damage,
serious injury, or death. Lifting should only be done by a
qualified rigging company. Use ALL lifting points. Test lift
to ensure proper balance and rigging.
2. Gas fired heating equipment must be vented - do not
operate unvented.
3. A built-in power exhauster is provided - additional
external power exhausters are not required or permitted.
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&quot; W.C. (1/2 psi).
6. Disconnect power supply before making wiring
connections or working on this equipment. Follow all
applicable safety procedures to prevent accidental
power up. Failure to do so can result in injury or death
from electrical shock or moving parts and may cause
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. Any original factory wiring that requires replacement
must be replaced with wiring material having a
temperature rating of at least 105&deg;C.
9. 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.
(continued next column)
IMPORTANT
1.
2
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.
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%.
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 23 for
Blower Adjustments.
Start-up and adjustment procedures should be
performed by a qualified service agency.
To check most of the Possible Remedies in the trouble&shy;
shooting guide listed in Tables 52.1 and 53.1, refer to the
applicable sections of the manual.
2.
3.
4.
5.
SI (METRIC) CONVERSION FACTORS
To
Convert
Multiply By
To Obtain
To
Convert
Multiply By
“W.C.
0.24
kPa
CFH
1.699
m3/min
0.037
mJ/m3
To Obtain
psig
6.893
kPa
Btu/ft3
&deg;F
(&deg;F-32) x 0.555
&deg;C
pound
0.453
kg
inches
25.4
mm
Btu/hr
0.000
kW
feet
0.305
meters
gallons
3.785
liters
CFM
0.028
m3/min
psig
27.7
“W.C.
5-594.10
TABLE OF CONTENTS / SPECIAL DESIGN REQUESTS / STORAGE
Table of Contents
Inspection on Arrival . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SI (Metric) Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Design Requests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Storage Prior to Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Unit Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Combustible Material and Service Clearances . . . . . . . . . 4
Unit Mounting Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Unit Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Duct Connection to Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Utility Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Considerations for Elevation . . . . . . . . . . . . . . . . . . . . . . .14
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cooling Coil Specifications and Installation . . . . . . . . . . . 18
Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pilot Burner Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Main Burner Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 21
Air Shutter Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Blower Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Lubrication Recommendations . . . . . . . . . . . . . . . . . . . . 23
Damper Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . 23
Furnace Control Operating Sequence . . . . . . . . . . . . . . 24
Variable Air Volume Applications . . . . . . . . . . . . . . . . . . 25
Cooling Coil Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Component Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
General Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Pressure Drop and Blower Performance Data . . . . . . . . . . . . 38
Blower Sheave Adjustment and Assembly Data . . . . . . . . . . . 42
Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Cooling Coil Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Service &amp; Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Start-Up Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Model Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Model Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Commercial Warranty . . . . . . . . . . . . . . . . . . . . . . . . Back Page
SPECIAL DESIGN REQUESTS
Modine Manufacturing Company will sometimes build units
with special features as requested by the customer. This
manual only covers standard features and does not include any
changes made for special feature requests by the customer.
Units built with special features are noted with a 5-digit SPO
(Special Product Order) Number on the Serial Plate.
STORAGE PRIOR TO INSTALLATION
If the unit is stored outside prior to installation, the unit should
be covered.
5-594.10
3
UNIT LOCATION / UNIT MOUNTING METHODS
Figure 4.1 - Combustible Material Clearances
UNIT LOCATION
DANGER
Appliances must not be installed where they may be exposed
to a potentially explosive or flammable atmosphere.
Model Size Access Side (A)
75 thru 175
1&quot;
200 thru 960
2&quot;
TOP = 3&quot;
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.
NON-ACCESS
SIDE = 0&quot;
Location Recommendations
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 4.1 and Table 4.2.
6. Units installed downstream of refrigeration systems, or
exposed to inlet air temperatures of 40&deg;F or less, may
experience condensation, therefore, provisions should
be made for disposal of condensate. Means have been
provided in the bottom pan of the unit to accommodate a
condensate drain line connection flange.
7. When locating units, it is important to consider that the
combustion air and exhaust vent piping must be connected
to the outside atmosphere. The maximum equivalent
lengths are listed in Table 7.1 on page 7.
8. In garages or other sections of aircraft hangars such as
offices and shops which communicate with areas used
for servicing or storage, keep the bottom of the unit at
least 7&quot; above the floor. In public garages, the unit must
be installed in accordance with the Standard for Parking
Structures NFPA #88A and the Standard for Repair
Garages NFPA#88B. In Canada, installation of unit
heaters in airplane hangars must be in accordance with
the requirements of the enforcing authority, and in public
garages in accordance with the current CAN/CGA-B149
codes.
9. Do not install units in locations where gas ignition system is
exposed to water spray, rain, or dripping water.
10. All mechanical equipment generates some sound
and vibration that may require attenuation. Libraries,
private offices and hospital facilities will require more
attenuation, and in such cases, an acoustical consultant
may be retained to assist in the application. Locating
the equipment away from the critical area is desirable
within ducting limitations. Generally, a unit should be
located within 15 feet of a primary support beam. Smaller
deflections mean lesser vibration and noise transmission.
ACCESS
SIDE
1.
4
A
BOTTOM = 1&quot;
j A 3'' minimum clearance to combustible material is required from the vent collar.
Table 4.2 - Recommended Service Clearances
Model Size
Access Side
75
18”
100/125
20”
150/175
25”
200/225
27”
250/300
30”
350/400
41”
500/600
30”
700/800
41”
840/960
41”
Non-Access Side
Top
6&quot;
10”
UNIT MOUNTING METHODS
Determine the method of mounting that will be used. 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 4.1 and Table 4.2 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.
Unit Suspension
Four 3/4&quot; diameter suspension hanging locations are provided
in the base rail assembly of the unit. Refer to Figure 46.1 for
Suspension Hanging Locations and Figure 5.1 demonstrates
how the unit should be suspended and fastened to the unit base
rail. If required, vibration isolators may be added.
5-594.10
UNIT MOUNTING METHODS / UNIT LIFTING
Figure 5.1 - Unit Suspension Method
ELECTRICAL
SECTION
DOOR
UNIT LIFTING
WARNING
SUSPENSION
RODS
Failure to follow proper lifting instructions and applicable
safety procedures could result in property damage, serious
injury, or death. Lifting should only be done by a qualified
rigging company. Use ALL lifting points. Test lift to ensure
proper balance and rigging.
BLOWER
SECTION
DOOR
Rigging and lifting of the units should only be done by a
qualified rigging company and follow appropriate industry
standards, including but not limited to the appropriate sections
of ASME B30, OSHA 1910, and OSHA 1926.
HEATER
SERVICE
DOOR
(1) 3/4&quot; NUT &amp;
LOCKWASHER
(2) 3/4&quot; NUTS &amp;
LOCKWASHER
NOTE: SUSPENSION RODS,
LOCKWASHERS, AND NUTS
BY OTHERS
Floor Mounted Units
For floor installations, the floor structure must be adequately
designed to support the live weight load of the unit and any
other required support structure. Additional reinforcement should
be provided, if necessary. The floor should include threaded
5/8-inch anchor bolts spaced according to Figure 5.2 and Table
5.1, for securing the unit in place. Anchor bolts should extend at
least 1-1/2&quot; above the surface of the floor to allow clearance for
mounting washers, nuts and bolts (mounting washers, nuts, and
bolts by others).
1.
Follow site preparation instructions for overhead
suspension, floor mounting, equipment stand before
installation.
2.
Check the Serial Plate(s) of unit with plans to be sure unit
is properly located. Although units may look outwardly
similar, their function, capacities, options, and accessories
will often vary.
3.
Check unit dimensions of both the unit base and the
installation location where the unit will be installed.
4.
The provisions for lifting are dependant on how the unit
was shipped:
Figure 5.2 - Floor Mount Units Anchor Bolt Locations
A
B
5/8 Dia. (4)
C
Digit 2=B
41.37
41.37
41.37
41.37
82.50
b.
All units with extended blower cabinets (Model Digit
16=I through L) 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 for safe unit relocation (refer to the Dimensions
for base rail lifting hole locations). See the following
note #5. If the unit must be lifted from the bottom for
final installation, be sure to properly support the unit
over its entire length to prevent damage.
When lifting the equipment with a crane, connect sturdy
steel cables, chains, or straps. For stability in lifting and
lowering and to prevent damage to the unit, include a
spreader bar. Avoid twisting or uneven lifting of the unit.
Test lift the unit to check for proper rigging balance before
hoisting to the desired installation location.
6.
Position the unit to its ductwork or where ductwork will be
located and suspend or floor mount the unit. For proper
operation, the unit must be installed in a level horizontal
position. Use a spirit level to ensure that the unit is
suspended or floor mounted correctly.
7.
Refer to the applicable sections to make Venting, Gas
Connec&shy;tions, Electrical Connections, and Cooling Coil
Connections. Make final unit connections to the electric
power supply and remote control circuits. Caulk all utility
line clearance holes on the unit after connections are
completed.
8.
Refer to the applicable sections to make final unit
connections for venting, gas and electrical utility connec&shy;
tions, control wiring, and cooling system connections if
equipped. Caulk all utility line clearance holes on the unit
after connections are completed.
Table 5.1 - Floor Anchor Bolt Locations (inches)
B
All
33.85
36.36
40.61
42.71
45.75
45.75
57.27
57.27
45.75
45.75
57.27
57.27
57.27
All units with standard blower cabinets (Model Digit
16=A through H) 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.
5.
C
Model Blower Type
A
Size
(Digit 16) Digit 2=B Digit 2=C
75
All
86.27
110.25
100/25
All
86.37
110.25
150/175
All
86.37
110.25
200/225
All
86.37
110.25
250/300 E,F,G, or H
86.27
110.25
250/300
I,J, or K
112.12
146.10
350/400 E,F,G or H
86.27
110.25
350/400
I,J, or K
122.2
146.10
500/600
G or H
127.39
500/600
I,J, or K
163.25
700/800
G or H
127.39
700/800
I,J,K, or L
163.25
840/960
I,J,K, or L
204.39
-
a.
5-594.10
5
DUCT CONNECTIONS / UTILITY CONNECTIONS / UNIT INSTALLATION
DUCT CONNECTION TO UNIT
1.The furnace discharge (units with Model Digit 2=B) is
designed to accept straight ductwork (see Figure 6.1.).
The blower section end and bottom openings (all units) and
cooling cabinet section discharge (units with Model Digit 2=C)
are designed to accept 90&deg; flanged ductwork (see Figure 6.2).
Provide an airtight seal between the ductwork and the
furnace. Seams with cracks in the ductwork should be
caulked and/or taped and be of permanent type. All duct
connections MUST be airtight to prevent air leakage.
2.Provide uniform air distribution over the heat exchanger.
Use turning vanes where required to obtain uniform air
distribution. (See Figure 6.3).
3.Provide removable access panels on the downstream side
of the ductwork. (See Figure 6.1.) 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 6.3 - Recommended Field Installed Discharge
Duct Configurations for Blower Package Units
DIMENSION “B” SHOULD NEVER
BE LESS THAN 1/2 OF DIMENSION “A”
Figure 6.1 - Furnace Discharge Duct Connection
TURNING
VANES
(3” MAX)
PROVIDE LEAK TIGHT ACCESS
PANELS IN DISCHARGE DUCT
FOR HEAT EXCHANGER INSPECTION.
TURNING
VANES
(3” MAX)
PROVIDE LEAK TIGHT ACCESS
PANELS IN DISCHARGE DUCT
FOR HEAT EXCHANGER INSPECTION.
CE
NA
CT
DU
R
FU
K
OR
TW
C
DU
STRAIGHT
DUCTWORK
Utility Connections
ACCESS
PANEL
Utility and control connections can be made to the unit from the
bottom or through the fixed side panels for floor mounted units.
Holes can be made in fixed side panels to accommodate utility
connections for any model or as specified according to the unit
dimensional drawings. Sealing of holes cut in the unit casing for
utility connections should be done with care to prevent air leaks.
Figure 6.2 - Blower Section Inlet and Cooling Coil
Section Discharge Duct Connections
Unit Installation
BLOWER AND/OR
COOLING COIL
CABINET
1/2&quot;
DUC
TW
OR
Refer to the applicable sections to make Venting, Gas Connec&shy;
tions, Electrical Connections, and Cooling Coil Connections.
Make final unit connections to the electric power supply and
remote control circuits. Caulk all utility line clearance holes on
the unit after connections are completed.
K
90&deg;
FLANGED
DUCTWORK
6
5-594.10
INSTALLATION - VENTING
WARNING
1. Gas fired heating equipment must be vented - do not
perate unvented.
2. A built-in power exhauster is provided - additional
external power exhausters are not required or permitted.
3. If you are replacing an existing heater, it may be
necessary to resize the venting systems. Improperly
sized venting systems can result in vent gas leakage or
the formation of condensate. Refer to the National Fuel
Gas Code ANSI Z223.1 or CSA B149.1 latest edition.
Failure to follow these instructions can result in serious
injury or death.
4. Under no circumstances should two sections of double
wall vent pipe be joined together within one horizontal
vent system due to the inability to verify complete seal
of inner pipes.
A3.All heaters come with factory installed vent and combustion
air adapters for attaching the pipe to the heater. The pipe
diameters are 4&quot; for model sizes 75-175 and 6&quot; for model
sizes 200-400. All units are classified as Category III
vented appliances, which defined by ANSI is positive
pressure, non-condensing, and requires the vent system to
be gastight. Attach the vent pipe to the adapter with 3
corrosion resistant screws. (Drill pilot holes through the
vent pipe and adapter prior to screwing in place). Vent pipe
must not be smaller than the connector size. Category III
vent systems listed by a nationally recognized agency and
matching the diameters specified may be used. Different
brands of vent materials may not be intermixed.
A4.Limit the total equivalent vent pipe length to a minimum of
5' and a maximum as shown in Table 7.1, making the vent
system as straight as possible. Total equivalent vent pipe
length must include elbows. The equivalent length of a 4&quot;
elbow is 5' and for a 6&quot; elbow is 7'.
Table 7.1 - Individual Total Equivalent Lengths
for Combustion Air and Exhaust Vent Pipes
CAUTION
Installation must conform with local building codes or in the
absence of local codes, with Part 7, Venting of Equipment, of
the National Fuel Gas Code, ANSI Z223.1 (NFPA 54) - latest
edition. In Canada installation must be in accordance with
CSA B149.1.
The separated combustion duct furnaces must be vented with
the proper passageway as described in these instructions to
convey flue gases from the unit or the vent connector to the
outside atmosphere. The heaters must also have a separate
combustion air intake pipe to bring in fresh air for combustion
from the outside atmosphere.
The venting instructions are organized in sections, based on
installation type. The sections are identified as follows:
Section
Installation Instructions by Vent System Type
A
General Instructions for ALL installations
B
VERTICAL 2-PIPE vent systems j
C
HORIZONTAL 2-PIPE vent systems j
D
HORIZONTAL AND VERTICAL CONCENTRIC
vent systems j
j
The differences between Vertical and Horizontal vent systems in 2-Pipe or
Concentric Vent configurations will be identified in “Section A - General
Instructions – All Units”.
Section A - General Instructions - All Units
A1.If the heater being installed is replacing existing equipment
and using the existing vent system from that equipment,
inspect the venting system for proper size and horizontal
pitch, as required in the National Fuel Gas Code ANSI
Z223.1 or CSA B149.1 Installation Code-latest edition and
these instructions. Determine that there is no blockage or
restriction, leakage, corrosion and other deficiencies, which
could cause an unsafe condition.
A2.The combustion air and vent pipes should be galvanized
steel or other suitable corrosion resistant material. Follow
the National Fuel Gas Code for minimum thickness of vent
material. The minimum thickness for connectors varies
depending on the pipe diameter. Do not vent unit with PVC
or other forms of plastic venting material.
Model Size
75
100, 125, 150, 175
200, 225
250, 300
350, 400
Minimum (ft)
5
5
5
5
5
Maximum (ft)
48
55
70
63
70
A5.A minimum of 12&quot; straight pipe is recommended from the
flue outlet before turns in the vent pipe.
A6.Horizontal sections of vent and combustion air pipes are
to be installed with a minimum downward slope from the
appliance of 1/4 inch per foot and suspended securely
from overhead structures at points not greater than 3'
apart.
A7.Fasten individual lengths of vent together with at least
three corrosion resistant sheet metal screws.
A8.Keep single wall vent pipe at least 6&quot; from combustible
materials. For double wall vent pipe, follow the vent pipe
manufacturer’s clearances to combustibles. The minimum
distance from combustible materials is based on the
combustible material surface not exceeding 160&deg;F.
Clearance from the vent pipe (or the top of the unit) may
be required to be greater than 6&quot; if heat damage other
than fire could result (such as material distortion or
discoloration).
A9.Avoid venting through unheated space when possible.
When venting does pass through an unheated space or if
the unit is installed in an environment that promotes
condensation, insulate runs greater than 5' to minimize
condensation. Inspect for leakage prior to insulating and
use insulation that is noncombustible with a rating of not
less than 400&deg;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 9.1.
A10.When the vent passes through a combustible INTERIOR
wall or floor, a metal thimble 4&quot; greater than the vent
diameter is necessary. If there is 6' or more of vent pipe
in the open space between the appliance and where the
vent pipe passes through the wall or floor, the thimble
need only be 2&quot; greater than the diameter of the vent pipe.
If a thimble is not used, all combustible material must be
cut away to provide 6&quot; of clearance. Where authorities
have jurisdiction type B vent may be used for the last
section of vent pipe to maintain clearance to combustibles
while passing through wall or floor. See Figure 8.1. Any
material used to close the opening must be
noncombustible.
5-594.10
7
INSTALLATION - VENTING
Horizontal Venting
Vertical Venting
Figure 8.1 - Venting Through Combustible Roof or Wall
LISTED
CAP
ROOF
FLASHING
LISTED
CAP
ROOF
FLASHING
DOUBLE WALL
PIPE
Table 8.1 - Vent Termination Clearances
LISTED
THIMBLE
SINGLE WALL
PIPE
LISTED
THIMBLE
SINGLE WALL
PIPE
MODINE
SPECIFIED
CAP
CLEARANCE
SPECIFIED BY
TYPE B VENT
MANUFACTURER
SINGLE WALL
PIPE
CLEARANCE
SPECIFIED BY
TYPE B VENT
MANUFACTURER
SINGLE WALL
PIPE
MODINE
SPECIFIED
CAP
DOUBLE WALL
PIPE
j See Instruction A12 for attaching single wall pipe to double wall pipe
A11.All seams and joints of un-gasketed single wall pipe must
be sealed with metallic tape (3M aluminum foil tapes 433
or 363 are acceptable) or silastic suitable for temperatures
up to 400&deg;F. Wrap the tape two full turns around the vent
pipe. One continuous section of double wall vent pipe may
be used within the vent system. Refer to instruction A12 in
“Section A – General Instructions – All Units” for attaching
double wall pipe to single wall pipe.
A12.The following are General Instructions for Double Wall
(Type B) Terminal Pipe Installation. Under no
circumstances should two sections of double wall vent
pipe be joined together within one horizontal vent system
due to the inability to verify complete seal of inner pipes.
How to attach a single wall vent terminal to
double wall (type B) vent pipe:
1. Look for the “flow” arrow on the vent pipe.
2. Slide the vent terminal inside the exhaust end of the
double wall vent pipe.
3. Drill (3) holes through the pipe and the vent terminal.
Using 3/4&quot; long sheet metal screws, attach the cap to
the pipe. Do not over tighten.
How to connect a single wall vent system to a
double wall (type B) vent pipe:
Structure
Forced air inlet within 10 feet
Combustion air inlet of another
appliance
Door, window, gravity air inlet,
or any building opening
Electric meter, gas meter, gas
regulator, and relief equipment j
Gas regulator j
Adjoining building or parapet wall
Adjacent public walkways
Grade (ground level)
Minimum Clearances for
Vent Terminal Location
3 feet above
6 feet all directions
4 feet horizontal and below
1 foot above
4 feet horizontal (U.S.)
6 feet horizontal (Canada)
3 feet horizontal (U.S.)
6 feet horizontal (Canada)
6 feet all directions
7 feet all directions
3 feet above k
j Do not terminate the vent directly above a gas meter or regulator.
k The vent must be at least 6&quot; higher than anticipated snow depth.
A21.Vertical combustion air pipes should be fitted with a tee
with a drip leg and a clean out cap to prevent against the
possibility of any moisture in the combustion air pipe from
entering the unit. The drip leg should be inspected and
cleaned out periodically during the heating season.
A22.In addition to following these General Instructions, specific
instructions for Vertical and Horizontal vent systems in
2-Pipe or Concentric Vent configurations must also be
followed. The following outlines the differences:
Vertical Vent System Determination
1.Slide the single wall pipe inside the inner wall of the
double wall pipe.
2. Drill (3) holes through both walls of the single and
double wall vent pipes. Using 3/4&quot; sheet metal screws,
attach the two pieces of pipe. Do not over tighten.
3. The gap between the single and double wall pipe must
be sealed but it is not necessary to fill the full volume of
the annular area. To seal, run a large bead of 400&deg;F
silastic around the gap.
A13 Do NOT vent this appliance into a masonry chimney.
A14.Do NOT use dampers or other devices in the vent or
combustion air pipes.
A15.The venting system must be exclusive to a single
appliance, and no other appliance is allowed to be vented
into it.
A16.Precautions must be taken to prevent degradation of
building materials by flue products.
A17.Single wall vent pipe must not pass through any
unoccupied attic, inside wall, concealed space, or floor.
A18.Uninsulated single wall vent pipe must not be used
outdoors for venting appliances in regions where the 99%
winter design temperature is below 32&deg;F.
8
A19.Long runs of horizontal or vertical combustion air pipes
may require insulation in very cold climates to prevent the
buildup of condensation on the outside of the pipe where
the pipe passes through conditioned spaces.
A20.Vent termination clearances must bemaintained:
•Vertical vent systems terminate vertically (up) (an
example is shown in Figure 9.1).
• Determine the venting configuration as follows:
&gt; For two building penetrations through the wall or roof
(one for the combustion air inlet pipe and one for the
vent pipe), proceed to “Section B - Vertical 2-Pipe
Venting”.
&gt; For a single larger building penetration through the
wall or roof, through which both the combustion air
inlet and vent pipes will pass, proceed to “Section D Horizontal and Vertical Concentric Venting”.
&gt; For all other cases, proceed to the next section for
Horizontal Vent System Determination.
Horizontal Vent System Determination
•
•
Horizontal vent systems terminate horizontally (sideways) (an example is shown in Figure 10.1).
Determine the venting configuration as follows:
&gt; For two building penetrations through the wall or roof
(one for the combustion air inlet pipe and one for the
vent pipe), proceed to “Section C - Horizontal 2-Pipe
Venting”.
&gt; For a single larger building penetration through the
wall or roof, through which both the combustion air
inlet and vent pipes will pass, proceed to “Section D Horizontal and Vertical Concentric Venting”.
5-594.10
INSTALLATION - VENTING
Figure 9.2 - Vertical Venting - 2 Pipes Flat Roof
B1. This section applies to vertically vented 2-pipe (one
combustion air inlet pipe and one vent pipe) vent systems
and is in addition to “Section A - General Instructions - All
Units”.
B2. Vertical vent systems terminate vertically (up).
B3. It is recommended to install a tee with drip leg and clean
out cap as shown in Figures 9.1 or 9.2.
B4. The combustion air and vent terminals must be Modine part
number:
• 5H072285-0001 (Item Code 27866) for 4&quot; vent pipe
• 5H072285-0002 (Item Code 27868) for 6&quot; vent pipe
B5. Vertical vents must terminate a minimum horizontal and
vertical distance from roof lines and adjacent walls or
obstructions. These minimum distances are outlined in
Figure 9.1 and Table 9.1 or Figure 9.2 and Table 9.2.
B6. The vent must terminate at least 1 foot above and 16
inches horizontally from the combustion air inlet.
B7. Once venting is complete, proceed to section titled
“Installation - Gas Connections”.
“H” FEET
MINIMUM PER
TABLE 8.1
10 FEET OR LESS
TO ROOF PEAK
2 FEET MINIMUM
12&quot;
MINIMUM
ROOF
FLASHING
MAINTAIN MINIMUM
CLEARANCE TO
COMBUSTIBLES
COMBUSTION AIR
*SIZE ACCORDING
TO EXPECTED
SNOW DEPTH
USE LISTED
THIMBLE
THROUGH
CEILING
TEE WITH
DRIP LEG AND
CLEANOUT CAP
12&quot;
MINIMUM
Table 9.2 - Minimum Height Above Adjacent Wall
Less than 10 Feet Away
&quot;D&quot;
16&quot; MINIMUM
LISTED AIR
INLET TERMINAL
LISTED AIR
INLET TERMINAL
“H” FEET MINIMUM
ABOVE WALL OR
ADJOINING
BUILDING PER
TABLE 7.2
3 FEET
MINIMUM*
Figure 9.1 - Vertical Venting - 2 Pipes Sloped Roof
LISTED VENT
TERMINAL
LISTED VENT
TERMINAL
DISTANCE “D” TO
WALL OR ADJOINING
BUILDNG
EXHAUST
Section B - Vertical 2-Pipe Vent System
Installation
&quot;H&quot;
10 Feet or Less
2 Feet Minimum
Greater than 10 Feet
No Additional Height Required
(continued next page)
“H” FEET
MINIMUM PER
TABLE 8.1
X
ROOF PITCH IS:
X / 12
ROOF
FLASHING
12&quot;
COMBUSTION AIR
MAINTAIN MINIMUM
CLEARANCE TO
COMBUSTIBLES
EXHAUST
USE LISTED
THIMBLES
THROUGH ROOF
AND CEILINGS
TEE WITH
DRIP LEG AND
CLEANOUT CAP
12&quot;
MINIMUM
Table 9.1 - Minimum Height from Roof to Lowest
Discharge Opening
Roof Rise
“X” (in)
Equivalent
Roof Pitch
Minimum Height
“H” (ft) j
0-10
10-12
12-14
14-16
16-18
18-21
Flat to 10/12
10/12 to 12/12
12/12 to 14/12
14/12 to 16/12
16/12 to 18/12
18/12 to 21/12
3.00
4.00
5.00
6.00
7.00
8.00
j Increase &quot;H&quot; as required to accommodate snow depth.
5-594.10
9
INSTALLATION - VENTING
Section C - Horizontal 2-Pipe Vent Installation
C1. This section applies to horizontally vented 2-pipe vent
systems (one combustion air inlet pipe and one vent pipe) and
is in addition to “Section A - General Instructions - All Units”.
C2.Horizontal vent systems terminate horizontally (sideways).
C3. Horizontal vents must be terminated with a Modine p/n:
• 5H072285-0001 (Item Code 27866) for 4&quot; vent pipe
• 5H072285-0002 (Item Code 27868) for 6&quot; vent pipe
The cap must terminate a minimum distance from the
external wall, as summarized in Figure 10.1.
C4. The termination of horizontally vented system must extend
12 inches beyond the exterior surface of an exterior wall.
C5. The combustion air pipe must be a minimum of 16 inches
below the vent pipe, and 24 inches from the exterior wall.
C6. Construct the vent system as shown in Figure 10.1.
Figure 10.1 - Horizontal 2-Pipe Venting
24'' MIN.
MUST USE THIMBLE
THROUGH WALL
TERMINAL
SUPPORT BRACKET
(See Fig. 9.2 for detail)
Section D - Concentric Vent System
Installation
CAUTION
The concentric vent adapter box must be installed inside of
the structure or building. Do not install this box on the exterior
of a building or structure.
D1. This section applies to both horizontally and vertically
vented concentric vent systems as defined in “Section A –
General Instructions – All Units”, and is in addition to the
instructions in that section.
D2. When utilizing the concentric vent option, it should have
been predetermined whether the appliance will be
horizontally or vertically vented. Before proceeding, verify
that the concentric vent kit received contains the correct
components for the installation:
For Vertically Vented Units (Refer to Figure 10.3):
PITCH COMBUSTION AIR
PIPE DOWNWARD FROM
APPLIANCE 1/4&quot; PER FOOT
75-175
33356
(3H0349290003)
Kit Contents
Part Number
Concentric Vent Adapter Box 3H0373840004
Outlet Vent Termination Cap 5H0722850001
Combustion Air Inlet Terminal 5H0751540004
Model Size (Digits 4-6)
Kit Part Number
12''
ADJACENT
BUILDING
EXHAUST
TERMINAL
16'' MIN.
24'' MIN.
COMBUSTION AIR
SUPPORT BRACKET
(See Fig. 9.2 for detail)
TEE WITH DRIP
LEG AND
CLEANOUT CAP
AT LOW POINT
OF VENT SYSTEM
200-400
33357
(3H0349290004)
Part Number
3H0373840005
5H0722850002
5H0751540006
Figure 10.3 - Vertical Concentric Vent Kit Components
PITCH VENT PIPE DOWNWARD
FROM APPLIANCE 1/4&quot; PER FOOT
C7. When horizontal vents pass through a combustible wall (up
to 8 inches thick), the vent passage must be constructed
and insulated as shown in Figure 10.2.
C8. The vent must be supported as shown in Figure 10.2.
C9. When condensation may be a problem, the vent system
shall not terminate over public walkways or over an area
where condensate or vapor could create a nuisance or
hazard or could be detrimental to the operation of
regulators, relief openings, or other equipment.
Figure 10.2 - Exhaust Vent Construction Through
Combustible Walls and Support Bracket
Combustion Air
Inlet Terminal
6&quot; Min.
Outlet Vent
Termination Cap
12&quot; Min.*
*Size according
to expected
snow depth.
Concentric
Vent Adapter
Box
Combustion Air
Exhaust
Building
Roof / Ceiling
For Horizontally Vented Units (Refer to Figure 10.4):
75-175
200-400
32161
32162
(3H0349300003) (3H0349300004)
Kit Contents
Part Number
Part Number
Concentric Vent Adapter Box 3H0373840004 3H0373840005
Outlet Vent Termination Cap 5H0751500001 5H0751500002
Combustion Air Inlet Guard
3H0349320004 3H0349320006
Model Size (Digits 4-6)
Kit Part Number
C10. Maintain a 1/4&quot; per foot downward slope away from the
heater and place a drip leg with clean out near the exit of
the vent as shown in Figure 10.1, or allow the condensate
to drip out the end.
C11.For a vent termination located under an eave, the
distance of the overhang must not exceed 24&quot;. The
clearance to combustibles above the exterior vent must
be maintained at a minimum of 12&quot;. Consult the National
Fuel Gas Code for additional requirements for eaves that
have ventilation openings.
C12.Once complete, proceed to section titled “Installation Gas Connections”.
10
5-594.10
Figure 10.4 - Horizontal Concentric Vent Kit
Components
Concentric
Vent Adapter
Box
Combustion Air
Intake Guard
14&quot; Min.
Outlet Vent
Termination Cap
1&quot; Min.
Building Side Wall
INSTALLATION - VENTING
D3. Once the kit contents have been verified as correct for the
direction of venting, the concentric vent adapter box is to
be installed. Determine the location of the box. Be sure to
maintain all clearances as listed in these instructions.
D4. The adapter box is to be mounted on the interior side of the
building. It must not be mounted outside the building. The
adapter box has integral mounting holes for ease of
installation. When horizontal venting multiple units, the
minimum spacing between any sides of the adapter boxes
must be 18&quot; and boxes must not overlap in the vertical
plane (above or below). When condensation may be a
problem, the vent system shall not terminate over public
walkways or over an area where condensate or vapor could
create a nuisance or hazard or could be detrimental to the
operation of regulators, relief openings, or other equipment.
D5. The adapter box can be mounted flush to the wall (for
horizontal kits) or to the ceiling (for vertical kits). The box
can also be offset from the wall or ceiling by using field
supplied brackets. When mounting the box, consider
serviceability and access to the vent and combustion air
pipes. If the box is to be mounted using field supplied
brackets, these brackets must be strong enough to rigidly
secure the box to the wall or ceiling, and should be made
from corrosion resistant material.
D6. Determine the length of the vent pipe and combustion air
inlet pipe for the selected location. THE VENT PIPE WILL
PASS THROUGH THE CONCENTRIC VENT BOX. THE
LAST SECTION OF VENT PIPE IS A CONTINUOUS
LENGTH OF DOUBLE WALL “B” VENT. See section A12
for attaching and terminating double wall pipe. Begin with
pipe lengths on the concentric pipe side of the adapter box
referring to Figure 11.1. These pipes will extend through
the building wall or roof as well as any added length for the
thickness of the wall and the offset from any field installed
brackets.
For Vertical Concentric Vent Kits
(refer to Figure 10.3):
D9. Slide the combustion air pipe over the vent pipe and attach
to the air inlet of the concentric adapter box, as shown in
Figure 11.1, using at least 3 corrosion resistant sheet metal
screws. Seal the joint and seam using sealant suitable for
temperatures up to 400&deg;F.
D10. Place this assembly (the adapter box, vent pipe and
combustion air pipe) through the wall or roof and verify
that the distance requirements as defined in Step D7 are
met. Securely attach the assembly building.
D11. From outside the building, caulk the gap between the
combustion air intake pipe and the building penetration.
D12. Attach the combustion air intake and vent pipe terminations
as follows:
Figure 11.1 - Adapter Box with Combustion Air Intake
Pipe Attached
Combustion Air
Pipe Attached
Outlet Vent
Pipe Extended
Through Box
4.57”
A
B
Model Sizes
A
B
75-175
13.33&quot;
18.84&quot;
200-400
17.00&quot;
15.27&quot;
For Vertical Concentric Vent Kits
(refer to Figure 10.3):
• Slide the combustion air cap down over the vent pipe and
• The bottom of the combustion air intake pipe must
terminate above the snow line, or at least 12 inches
above the roof, whichever distance is greater.
• The bottom of the vent cap must terminate at least 6
inches above the top of the combustion air intake cap.
fasten it to the combustion air pipe with at least 3
corrosion resistant sheet metal screws.
• Attach the vent cap to the vent pipe using at least 3
corrosion resistant sheet metal screws. Refer to
instruction A12 for connecting terminal to double wall
pipe.
• Caulk the gap between the combustion air cap and the
vent pipe with silicone sealant, or other appropriate
sealants suitable for metal to metal contact and for
temperatures up to 400&deg; F.
For Horizontal Concentric Vent Kits
(refer to Figure 10.4):
• The combustion air intake pipe must terminate at least
1 inch from the wall to prevent water from running down
the wall and into the pipe.
• The back of the vent cap must terminate at least 14
inches from the combustion air intake pipe.
D7.Cut the concentric side vent and combustion air pipes to
the proper length as determined in the previous step. Note
that the vent pipe diameter is 4&quot; and the combustion air
intake pipe diameter is 6&quot; for model sizes 75-175, and 6”
and 8” respectively for model sizes 200-400. The pipes
must be single wall galvanized or stainless steel material,
except for the last section of vent pipe, which must be one
continuous length of double wall B-vent extended through
the concentric vent box and combustion air inlet pipe on
the concentric side of the box.
D8.Allow the concentric side vent pipe to pass through the
concentric vent adapter box, as shown in Figure 11.1.
Attach the double wall vent pipe to the single wall vent
pipe that goes to the unit. Be sure to seal the joint and
the open area around the double wall vent. Seal all joints
and seams using sealant suitable for temperatures up to
400&deg;F.
For Horizontal Concentric Vent Kits
(refer to Figure 10.4):
• Attach the combustion air intake guard using corrosion
resistant screws at the end of the combustion air intake
pipe to prevent animals and debris from entering.
• Attach the vent cap to the vent pipe using at least 3
corrosion resistant sheet metal screws.
D13.Install vent pipe and combustion air pipe between unit
heater and concentric vent adapter box as outlined in
“Section A – General Instructions – All Units”.
D14.Once venting is complete, proceed to the section titled
“Installation - Gas Connections”.
5-594.10
11
INSTALLATION - GAS CONNECTIONS
Gas Connections
5.
WARNING
1.
2.
3.
ll field gas piping must be pressure/leak tested prior to
A
operation. Never use an open flame. Use a soap solution or
equivalent for testing.
Gas pressure to appliance controls must never exceed
14&quot; W.C. (1/2 psi).
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.
6.
Figure 12.2
Recommended Sediment Trap/Manual Shut-off Valve
Installation - Side or Bottom Gas Connection
GAS
SUPPLY LINE
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.
GAS
SUPPLY LINE
IMPORTANT
2.
3.
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.
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 Model Digits 4-6 of the Model Nomenclature on
page 57 and the value on the unit Model ID plate (not
individual furnace serial plates) to determine the gas
heating capacity in Thousands of Btu/hr (MBH). The
Model ID plate is located on the blower section electrical
compartment door. See Figure 12.1 for an example Model
ID plate.
SEDIMENT
TRAP
7.
Figure 12.1 - Model ID Plate Example
DBS960SMRHN20F2IQ5DBA00
4.
12
For the length of pipe necessary, determine the pipe
diameter from Tables 13.1 or 13.2 for the unit heating
capacity. Where several units are served by the same main,
the total capacity and length of main must be considered.
While the gas connection(s) on the unit may be smaller
than the required supply pipe diameter, do not use pipe
sizes smaller than what is required leading up to the unit.
At the unit, reduce the pipe size down to the appropriate
size (sizes 75-225 are 1/2&quot; connections, 250-960 are 3/4&quot;
connections). Avoid pipe sizes smaller than 1/2&quot;. The inlet
pressure to the unit must be 6-7&quot; W.C. for natural gas and
11-14&quot; W.C. for propane gas. When sizing the inlet gas
pipe diameter, be sure the unit supply pressure can be met
after the line pressure drop has been subtracted. If the line
pressure drop is too high, refer to NFPA 54 National Fuel
Gas Code for other gas pipe capacities.
5-594.10
MANUAL GAS
SHUT-OFF VALVE
GROUND
JOINT
UNION
W/ BRASS
SEAT
j
TO
CONTROLS
PLUGGED
1/8&quot; NPT TEST
GAGE CONNECTION
3&quot;
MIN.
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.
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&quot; NPT plugged tapping
accessible for test gauge connection (See Figure 12.2).
Verify the manual shut-off valve is gas tight on an annual
basis.
Provide a sediment trap before each unit in the line where
low spots cannot be avoided. (See Figure 12.2).
j M
anual shut-off valve is in the “OFF” position
when handle is perpendicular to pipe.
When Pressure/Leak testing, pressures above 14&quot; 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&quot; W.C. (1/2 psi) or below, close the
manual shut-off valve on the appliance before testing.
INSTALLATION - GAS CONNECTIONS
Table 13.3 - Burner Orifice Sizing and Gas Consumption
Table 13.1 - Gas Pipe Capacities - Natural Gas j
Capacity in MBH by Nominal Pipe Diameter
Pipe
Length (ft)
10
20
30
1∕2”
138
95
76
3∕4”
287
197
159
1”
540
371
298
1 1∕4” 1 1∕2” 2” 2 1∕2” 3”
1,113 1,659 3,203 5,103 9,009
762 1,145 2,195 3,507 6,195
612
917 1,764 2,814 4,977
40
50
60
70
80
90
100
125
150
175
200
250
65
58
53
48
44
42
40
35
32
29
27
24
135
120
109
100
93
87
83
74
66
61
57
50
255
226
205
188
175
165
155
138
125
114
107
95
524
464
420
386
360
338
319
282
256
235
219
194
784
695
630
580
540
506
478
423
384
353
329
291
1,512
1,344
1,218
1,113
1,038
974
921
816
739
680
632
561
2,405
2,132
1,932
1,775
1,659
1,554
1,470
1,302
1,176
1,082
1,008
894
75
100
4,253
3,770
3,423
3,150
2,930
2,741
2,594
2,300
2,079
1,911
1,785
1,575
125
150
175
200
225
250
Gas pipe capacities based on Table 6.2.1(a) of NFPA 54 for schedule 40
metallic pipe with inlet pressure less than 2 psi, with a pressure drop of 0.3&quot;
w.c. and gas specific gravity of 0.60.
300
350
Table 13.2 - Gas Pipe Capacities - Propane Gas k
Pipe
Length (ft)
10
20
30
40
50
60
80
100
125
150
175
200
250
1∕2”
291
200
160
137
122
110
101
94
89
84
74
67
62
Capacity in MBH by Nominal Pipe Diameter
3∕4”
1” 1 1∕4” 1 1∕2” 2” 2 1∕2” 3”
608 1,150 2,350 3,520 6,790 10,800 19,100
418
787 1,620 2,420 4,660 7,430 13,100
336
632 1,300 1,940 3,750 5,970 10,600
287
541 1,110 1,660 3,210 5,110 9,030
255
480
985 1,480 2,840 4,530 8,000
231
434
892 1,340 2,570 4,100 7,250
212
400
821 1,230 2,370 3,770 6,670
197
372
763 1,140 2,200 3,510 6,210
185
349
716 1,070 2,070 3,290 5,820
175
330
677 1,010 1,950 3,110 5,500
155
292
600
899 1,730 2,760 4,880
140
265
543
814 1,570 2,500 4,420
129
243
500
749 1,440 2,300 4,060
Gas pipe capacities based on Table 6.3.1(d) of NFPA 54 for schedule 40
metallic pipe with inlet pressure of 11.0&quot; w.c., with a pressure drop of 0.5&quot; w.c.
and gas specific gravity of 1.50.
Gas Type
Model
Size
400
500
l
600
l
700
l
800
l
840
m
960
m
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
Natural j
Propane k
72.1
20
96.1
30
120.2
25
144.2
30
168.3
27
192.3
23
216.3
20
240.4
25
288.7
20
336.5
27
384.6
23
240.4
25
288.7
20
336.5
27
384.6
23
336.5
27
384.6
23
30.0
39
40.0
45
50.0
42
60.0
45
70.0
43
80.0
42
90.0
39
100.0
42
120.0
39
140.0
43
160.0
42
100.0
42
120.0
39
140.0
43
160.0
42
140.0
43
160.0
42
Orifice
Qty
1
2
2
3
3
3
3
4
4
6
6
4
4
6
6
6
6
j Based on natural gas properties of 1050 Btu/ft&sup3; and specific gravity of 0.60.
k Based on propane gas properties of 2500 Btu/ft&sup3; and specific gravity of 1.50.
l Model sizes 500-800 contain 2 furnaces. Values shown are per furnace.
m Model sizes 840-960 contain 3 furnaces. Values shown are per furnace.
5-594.10
13
INSTALLATION - GAS CONNECTIONS
Considerations for Elevation
The standard ratings for Models DBS/DCS are certified for
elevations up to 2000 feet above sea level. Operation at
elevations above 2,000 feet requires ratings be reduced 4% for
each 1000 feet above sea level per ANSI Z223.1. The exception
is for units in Canada, CSA requires that ratings be reduced 10%
for elevations between 2,001 and 4500 feet. The following
instructions are for units that will be installed over 2,000 feet
elevation. If this does not apply, you may skip ahead to the
Electrical Connections section on page 15.
Equation 14.1 - Manifold Pressure for Gas Heating
Values Different Than Shown in Table 14.1
Where:
MPELEV = Manifold Pressure (&quot; W.C.) at installed
elevation
Manifold Pressure Adjustment
BTUTBL = BTU/ft&sup3; content of gas from Table 14.1
The unit manifold pressure is factory set for operation at
elevations up to 2000 feet as follows:
BTUACT = BTU/ft&sup3; content of gas obtained from the
utility company
• For Natural Gas units, 3.5&quot; W.C. based on a gas heating value
of 1,050 BTU/ft3.
• For Propane Gas units, 10.0&quot; W.C. based on a gas heating
value of 2,500 BTU/ft&sup3;.
For higher elevations, some utility companies may derate the
BTU content (heating value) of the gas provided at altitude to a
lower value to allow certain heating appliances to be used with
no manifold pressure adjustments. For this reason it is necessary
that the supplying utility be contacted for detailed information
about the gas type and BTU content (heating value) before
operating any heater. Table 14.1 shows the standard derated
heating values of natural and propane gases at various
elevations.
Table 14.1
Gas Heating Values at Altitude (Btu/ft&sup3;) jkln
Altitude (ft)
Natural Gas
0-2,000
2,001-3,000
3,001-4,000
4,001-4,500
4,501-5,000
5,001-6,000
6,001-7,000
7,001-8,000
8,001-9,000
9,001-10,000
1,050
2,500
929 l
892 l
874 l
856
822
789
757
727
698
2,212 m
2,123 m
2,080 m
2,038
1,957
1,879
1,803
1,731
1,662
= Manifold Pressure (&quot; W.C.), at Sea Level
(use 3.5&quot; W.C. for natural gas and
10.0&quot; W.C. for propane)
NOTE: For units equipped with two-stage or modulating gas
controls, only the high fire manifold pressure needs to be
adjusted. No adjustments to the low fire manifold pressure are
necessary on these units.
Selection of the Proper High Altitude Kit
All units installed at elevations greater than 2000 feet above sea
level require a kit, in addition to potential manifold pressure
adjustment outlined in the previous step. To determine the proper
kit to use, refer to Table 14.2. For more information, refer to the
latest revision of Modine Bulletin 75-530.
Table 14.2 - High Altitude Kit Selection Table jklm
Propane
Item Code by Elevation Above Sea Level (ft)
j
Values shown are for 3.5&quot; W.C. manifold pressure for Natural Gas and 10.0&quot;
W.C. for Propane Gas. If the local utility supplies gas with a different Btu/ft&sup3;
value, use Equation 14.1 to calculate the required manifold pressure.
k
Gas heating values shown are derated 4% per 1,000' of elevation (10%
between 2,000' and 4,500' elevation in Canada) in accordance with ANSI
Z223.1 and CSA-B149, respectively.
l 945 Btu/ft&sup3; for Canada
m 2,250 Btu/ft&sup3; for Canada
n
When installed at altitudes above 2,000', a pressure switch may need to be
changed. Refer to Table 14.2 to determine if a switch change is required.
Model Size
2,001- 2,501- 4,501- 5,001- 5,501- 6,501- 7,0012,500 4,500 5,000 5,500 6,500 7,000 7,500
75
67248 67248 67248 67248 67248 67248 67248
100
67248 67248 67248 67248 77785 77785 68406
125
67248 77786 77786 77786 77785 77785 68406
150
77787 77786 77786 77786 77785 77785 68406
175
77786 77786 68408 68408 68408 68410 68410
200
67248 67248 67248 67248 67248 67248 67248
225
67248 67248 67248 67248 67248 67248 67248
250/500
67248 67248 67248 67248 67248 67248 67248
300/600
67248 67248 67248 67248 67248 67248 67248
350/700/840 67248 67248 67248 77786 77785 77785 68406
400/800/960 77786 77786 77785 77785 77785 68410 68410
j Applies to both installations in the U.S. and Canada.
k Applies to both natural and propane gas.
If the utility is supplying gas with heating values SAME as shown
in Table 14.1, the manifold pressure should remain set to 3.5&quot;
W.C. for natural gas and 10.0&quot; W.C. for propane gas and you
may proceed to the section on this page titled “Selection of the
Proper High Altitude Kit”.
If the utility is supplying gas with heating values DIFFERENT
than shown in Table 14.1, use Equation 14.1 to determine the
appropriate manifold pressure for the elevation and gas heating
value being supplied. Note what that value is, as it will be
needed later for Start-Up. Proceed to the section on this page
titled “Selection of the Proper High Altitude Kit”.
14
MPSL
l
Sizes 75-400 require a kit qty. of 1, sizes 500-800 require a kit qty of 2,
sizes 840-960 require a kit qty of 3.
m
All kits include a High Altitude Conversion Label and Installation Instructions.
Additionally, all kits except 67248 include a Pressure Switch to replace the
standard switch.
If a unit is to be installed at higher elevations AND converted
from natural gas to propane gas operation, a propane conversion
kit must be used in conjunction with the manifold pressure
adjustment and high altitude kit listed above. For the Selection
and Installation Instructions for propane conversion kits, please
see the latest revision of Modine Bulletin 75-511.
5-594.10
INSTALLATION - ELECTRICAL CONNECTIONS
Electrical Connections
7.
WARNING
1. Disconnect power supply before making wiring connections
or working on this equipment. Follow all applicable safety
procedures to prevent accidental power up. Failure to
do so can result in injury or death from electrical shock or
moving parts and may cause 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&deg;C.
4. Ensure that the supply voltage to the appliance, as
indicated on the serial plate, is not 5% greater than rated
voltage.
The wire gauge must be sized according to the National
Electric Code or CSA code based on the power supply
voltage, amp draw, and length of run. Refer to the Table 15.1
for maximum wire lengths.
Table 15.1 - 24V and Digital Control Wire Lengths
3.
4.
5.
6.
Digital Control Wiring
n/a
n/a
75
125
175
120
200
300
500
n/a
• Push a small flat-head screwdriver into the square hole on
the terminal. Press firmly until the screwdriver hits the
back stop and opens the terminal (see Figure 15.1).
• Remove approximately 3/8” of insulation from the end of
the wire and push the stripped wire into the oval hole in
the terminal.
1. Ensure that the supply voltage to the appliance, as
indicated on the serial plate, is not 5% less than the rated
voltage.
2. Do not reuse any mechanical or electrical component
which has been wet. Such components must be replaced.
2.
24V Control Wiring
22
20
18
16
14
FOR UNITS WITH MODEL DIGIT 12=9 (MODINE
CONTROL SYSTEM OPTION): For field wiring to the
factory terminal strip, the terminal strip connections are
designed to clamp down on the wires. To properly connect
the wires to the terminal strip:
8.
CAUTION
1.
Maximum Distance (feet) from
Control Device to Unit
Minimum
Recommended
Wire Gauge
Installation of wiring must conform with local building codes,
or in the absence of local codes, with the National Electric
Code ANSI/NFPA 70 - Latest Edition. Unit must be
electri&shy;cally grounded in conformance to this code. In
Canada, wiring must comply with CSA C22.1, Part 1,
Electrical Code.
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.
External electrical connections to be installed include:
•
Supply power (120, 208, 240, 480, or 600 volts).
•
Thermostats, remote monitoring panels, building
pressure sensors, time clocks, or any other accessory
control devices that may be supplied (24 volts).
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.
Refer to the unit dimensional drawings in this document
for the location of the drill locator dimples in the side and
bottom of the unit for field drilling the hold for the electrical
conduit entry.
Control wiring consists of both 24V analog control wiring and
for models with Model Digit 12=9, low current digital control
signal wiring. To avoid signal interference, the two types
should be run in conduit separate from power wiring. The
analog control wiring should be shielded at one end of the
wiring run. Wiring should be stranded, twisted, and shielded
communication wire.
• Remove the screwdriver. Pull on the wire to make sure
that it is securely clamped in the terminal.
• Make sure that the terminal clamp is in contact with bare
wire (insulation removed).
Figure 15.1 - Terminal Strip Wiring (Model Digit 12=9)
Oval Holes
for Wiring
(two rows each)
Square Holes
for Wire Release
(two rows each)
Terminal
Numbers
Test Probe
Points
(continued next page)
5-594.10
15
INSTALLATION - ELECTRICAL CONNECTIONS
Depending on the configuration of the unit controls,
there may be sensors that are field installed. Review the
unit ordered to verify that the sensors supplied match
the configuration of the unit. The following are sensors
that may be included for field installation (for installation
instructions, refer to the instructions included with the
individual sensors):
• Supply Air Temperature Sensor
This sensor is required on all units and is mounted in the
supply air ductwork downstream of the unit discharge.
• Outdoor Air Sensor
This sensor is required on all units except 100% return air
units. The sensor is duct mounted in the inlet ductwork.
• Return Air Sensor
This sensor is required on all units that have a mixture of
outside and return air. The sensor is mounted in the
return air ductwork.
• Space Temperature/Humidity Sensor
This sensor is required on all units that have space
temperature/humidity reset control.
• Building Pressure Sensor
This sensor is required on all units that have space
pressure control, either through modulating dampers or
variable frequency drive control on the supply air blower.
Figure 16.1 - Recommended Field Installed
Disconnect Switch Mounting Location
• Duct Pressure Sensor
This sensor is required on all units that have duct
pressure control through variable frequency drive control
on the supply air blower.
• Space CO2 Sensor
This sensor is required on all units that have demand
based ventilation control based on space CO2
concentration.
• Duct Mounted Smoke Detector
This sensor is mounted in the supply air or return air
ductwork.
For further instructions on the above sensor(s), refer to
the installation instructions that shipped with the
sensor(s).
10. Make sure all multi-voltage components (motors,
transformers, etc.) are wired in accordance with the power
supply voltage.
11. 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 26.1) 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
required by the National Electric Code as shown in Figure
16.1. For fusible disconnect switches, refer to the Model
Identification plate for the fuse size and type.
12. The power supply must be within 5% percent of the voltage
rating and each phase must be balanced within 2 percent of
each other. If not, advise the utility company.
13. All outdoor electrical connections must be weatherized to
prevent moisture from entering the electrical compartment.
16
5-594.10
BLOWER
SERVICE
DOOR
ELECTRIC SUPPLY
COMPONENTS MUST
BE CLEAR OF
SERVICE DOORS
DISCONNECT
SWITCH WIRING,
AND CONNECTOR
ELECTRIC
SUPPLY
ELECTRICAL
SECTION DOOR
9.
HEATER
SERVICE
DOOR
LEFT HAND ACCESS
UNIT SHOWN
THIS PAGE INTENTIONALLY LEFT BLANK
5-594.10
17
INSTALLATION - COOLING COIL UNITS
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 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. 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&quot;
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&quot; 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&quot;, 5&quot;, 6&quot;, 7.5&quot;, 8.5&quot;, and 10&quot; deep coils.
Figure 18.1 - Cooling Section
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 &quot;flash&quot; 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 18.2 - General DX Piping
SUCTION HEADER
DISTRIBUTOR
EQUALIZER LINE
LIQUID LINE
COIL
NOZZLE
EXPANSION
VALVE
(BY OTHERS)
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.
Optional Factory
3.
F
or DX coils, the use of filter-dryers in the system piping is
Installed
recommended along with a sight glass that has a moisture
DX or Chilled
indicator.
Water coil.
4. Connect the suction line and suction connection.
5. Install the expansion valve (By Others). Follow the
Fin spacings
expansion valve manufacturer's recommendations for
of 6,8,10,12
installation to avoid damaging the valve.
or 14 fins per inch
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.
Adjustable
mounting bracket
7. If the coil holds pressure, the installation can be considered
for 2,3,4 and 6 row
leak free. If the pressure drops by 5 psi or less,
coils
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
Full coverage
3-way sloping
leak, which should be isolated and repaired. Be sure to
409 stainless
check valves and fittings as potential sites for leakage or
steel drain pan
bleed.
8.
Use a vacuum pump to evacuate the coil and any
Right or left hand coil
1” stubbed drain
interconnecting piping that has been open to atmosphere.
header access to match
connection
Measure the vacuum in the piping using a micron gauge
gas controls
located as far from the pump as possible (the vacuum at
the pump will be greater than the rest of the system).
Condensate Drain Pan Trap
Evacuate the coil to 500 microns or less then close the
The condensate drain line needs to include a P-trap immediately
valve between the pump and the system. If the vacuum
downstream of the connection to the unit. This trap should
holds to 500 microns or less for one minute, the system
extend at least two inches below the connection to prevent air
is ready to be charged or refrigerant pumped down in
pressure from forcing air into the unit. The trap should be primed
another portion of the system can be opened to the coil.
with a water/glycol solution to prevent freezing.
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.
18
5-594.10
Optional double
wall construction
DX single circuit (shown) and
dual circuit coils available
INSTALLATION - COOLING COIL UNITS
Figure 19.1 - General Chilled Fluid Piping
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.
Air
w
n
tur
Air Vent
Chilled Fluid Piping
Flo
Re
Vent Plug
Gate Valve
To prevent noise and coil damage from water hammer, 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.
The outlet manifold should have a drain installed on the bottom
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.
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.
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.
4. Fill the coil with water with all air vents open 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.
5. Close all vents and perform a 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.
Supply
Tee
Drain Plug
Dirt Leg
Union
Cap
Table 19.1 - Cooling Coil Performance Limits
Cooling Model
Type
Size
DX
Chilled
Water
Min
CFM
75
688 l
100
802 m
125
937
150
1,125
175
1,312
200
1,500
225
1,687
250
1,875
300
2,250
350
2,625
400
3,000
75
609
100
750
125
937
150
1,125
175
1,312
200
1,500
225
1,687
250
1,875
300
2,250
350
2,625
400
3,000
Single Circuit
Dual Circuit
Max
CFM j
Area
(ft2)
Max
CFM j
Area
(ft2)
Max
Cooling
(Tons) k
1,891
3.44
1,707
3.10
9.4
2,206
4.01
2,048
3.72
11.4
2,521
4.58
2,416
4.39
13.4
3,352
6.09
3,165
5.76
18.1
3,724
6.77
3,538
6.43
20.2
5,214
9.48
4,996
9.08
27.3
1,676
3.05
n/a
n/a
10.6
2,011
3.66
n/a
n/a
12.6
2,372
4.31
n/a
n/a
14.8
3,214
5.84
n/a
n/a
19.3
3,592
6.53
n/a
n/a
21.3
5,073
9.22
n/a
n/a
29.3
j Based on 550 feet per minute (FPM) coil face velocity.
k Based on 95&deg;F/75&deg;F Entering Dry Bulb/Wet Bulb.
l Model Size 75 minimum CFM for DX Dual Circuit is 621.
m Model Size 100 minimum CFM for DX Dual Circuit is 745.
5-594.10
19
START-UP PROCEDURE
Start-Up Procedure
IMPORTANT
1. To prevent premature heat exchanger failure, observe
heat exchanger tubes by looking at the heat exchanger
through the field installed access openings in connecting
ductwork in blower package units or the unit access
doors in cooling package units. If the bottom of the
tubes become red while blower and duct furnace are in
operation, check to be sure the blower has been set to
the proper rpm for the application. Refer to page 23 for
Blower Adjustments.
2. Start-up and adjustment procedures should be performed
by a qualified service agency.
Refer to page 55 for the Start-up Checklist.
1. Turn off power to the unit at the disconnect switch. Check
that fuses or circuit breakers are in place and sized
correctly. Turn all hand gas valves to the “OFF” position.
2. Remove the duct furnace and blower exterior panels and
open the electrical compartment door.
3. Check that the supply voltage matches the unit supply
voltage listed on the Model Identification plate. Verify that
all wiring is secure and properly protected. Trace circuits to
insure that the unit has been wired according to the wiring
diagram.
4. Check to insure that the venting system is installed and
free from obstructions.
5. Check to see that there are no obstructions to the intake
and discharge of the unit.
6. Check the belt tension and sheave alignment. Refer to
Blower Adjustments for proper belt tension.
7. Check bearings for proper lubrication. For units provided
with pillow block bearings (See Model Nomenclature),
refer to Lubrication Recommendations for lubrication
requirements.
8. Check to make sure that all filters are in place and that they
are installed properly according to direction of air flow.
9. Perform a visual inspection of the unit to make sure no
damage has occurred during installation.
10. Turn on power to the unit at the disconnect switch. Check
to insure that the voltage between duct furnace electrical
box terminals 1 and 2 is 24V.
11. Check the thermostat, ignition control, gas valve, and
supply fan blower motor for electrical operation. If these do
not function, recheck the wiring diagram. Check to insure
that none of the Control Options have tripped.
12. For units with a return air damper, the return air damper
linkage needs to be adjusted. Refer to Damper Linkage
Adjustment.
13. Check to make sure that the damper opens properly
without binding.
14. Check the blower wheel for proper direction of rotation
when compared to the air flow direction arrow on the
blower housing. Blower wheel rotation, not air movement,
must be checked as some air will be delivered through the
duct furnace with the blower wheel running backwards.
15. Check the blower speed (rpm). Refer to Blower
Adjustments for modification.
16. Check the motor speed (rpm).
17. Check the motor voltage. On three phase systems, check
to make sure all legs are in balance.
18. Check the motor amp draw to make sure it does not
exceed the motor nameplate rating. On three phase
systems, check all legs to insure system is balanced.
20
19. Recheck the gas supply pressure at the field installed
manual shut-off valve. The minumum inlet pressure should
be 6&quot; W.C. on natural gas and 11&quot; W.C. on propane gas.
The maximum inlet pressure for either gas is 14&quot; W.C. If
inlet pressure exceeds 14&quot; W.C., a gas pressure regulator
must be added upstream of the combination gas valve.
20. Open the field installed manual gas shut-off valve.
21. Open the manual main gas valve on the combination gas
valve. Call for heat with the thermostat and allow the pilot
to light. On a call for heat the power exhauster relay will
energize the power exhauster motor. Once the power
exhauster motor reaches full speed, a differential pressure
switch will close before the pilot can light. If the pilot does
not light, purge the pilot line. If air purging is required,
disconnect the pilot line at outlet of pilot valve. In no case
should line be purged into heat exchanger. Check the pilot
flame length (See Pilot Flame Adjustment).
22. Once the pilot has been established, check to make sure
that the main gas valve opens. Check the manifold gas
pressure (See Main Gas Adjustment) and flame length (See
Air Shutter Adjustment) while the supply fan blower is
operating.
23. Check to insure that gas controls sequence properly
(See Control Operating Sequence). Verify if the unit has
any additional control devices and set according to the
instructions in the Control Options.
24. Once proper operation of the unit has been verified, remove
any jumper wires that were required for testing.
25. Close the electrical compartment door.
26. Replace all exterior panels.
Pilot Burner Adjustment
The pilot burner is orificed to burn properly with an inlet pressure
of 6-7&quot; W.C. on natural gas and 11-14&quot; W.C. on propane gas.
Final adjustment must be made after installation. If the pilot
flame is too long or large, it may cause soot and/or impinge on
the heat exchanger causing failure. If the pilot flame is too short,
it may cause poor ignition or result in the controls not opening
the combination gas control. A short flame can be caused by a
dirty pilot orifice. The pilot flame 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&quot; to 1&quot; long and
encompassing 3/8&quot;-1/2&quot; of the tip of the thermocouple or
flame sensing rod (See Figure 20.1).
4. Replace the cap from the pilot adjustment screw.
Figure 20.1 - Correct Pilot Flame
5-594.10
FLAME
SENSING ROD
3/4&quot; to 1&quot;
START-UP PROCEDURE
Main Burner Adjustment
7.
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.
Check/Adjust Pressure at the Combination Gas Valve
This section applies to all units, regardless of gas control type.
1. Turn the field installed manual shut-off valve to &quot;OFF&quot;.
2. Remove the 1/8&quot; pipe plug in the pipe tee or gas valve and
attach a U-tube type water manometer which is at least 12&quot;
high and capable of reading to 0.1&quot; W.C. See Figure 21.1.
3. Turn the field installed manual gas shut-off valve to “ON”.
Figure 21.1 - Checking Manifold Pressure with “U”
Tube Manometer
U-TUBE
MANOMETER
MANIFOLD
TEE
4.
5.
Create a high fire call for heat from the thermostat.
Determine the correct high fire manifold pressure, which
depends on gas type and gas control type. Review the
furnace Model Digit 11 and 12 (not the system model
number) and adjust the main gas pressure regulator spring
to achieve the proper manifold pressure as shown in Table
21.1. For location of regulator adjustment, refer to the
combination gas control literature supplied with the unit.
8.
9.
Check/Adjust Pressure for the Modulating Valve
This section only applies to units with Electronic Modulation gas
controls (Model Identification Digit 12=4, 7, 8, or 9). Refer to the
appropriate instructions for the valve type on the unit.
For Units with Model Digit 12=4, 7, or 8:
The low fire gas pressure needs to be adjusted. This needs to
be repeated on each furnace in multiple furnace units. Using
Figure 21.2 for item locations, this is accomplished as follows:
1. Disconnect power.
2. Remove all wires from Maxitrol Amplifier terminal “3” or duct
furnace terminal “43” (if available).
3. Turn on power at the disconnect switch.
4. 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.
5. Using minimum adjusting screw (9), adjust low fire manifold
pressure to 0.56&quot; W.C. for natural gas and 1.6&quot; W.C. for
propane gas.
6. Replace plunger and spring retainer, spring, and maximum
adjusting screw in proper order.
7. Using maximum adjustment screw (4), adjust high fire
manifold pressure to 3.5&quot; W.C. for natural gas and 10&quot; W.C.
for propane gas.
8. Disconnect power.
9. Replace cover plate (2) and re-install all wires from Maxitrol
amplifier terminal “3” or duct furnace terminal “43”.
10. After adjustment, move the field installed manual shut-off
valve to the “OFF” position and replace the 1/8&quot; pipe plug.
(continued next page)
Figure 21.2 - Maxitrol Modulating Valve Adjustments
Table 21.1 - Manifold Gas Pressure - Main Valve
Furnace
Model Digit 11
N
(Natural)
P
(Propane)
Furnace
Model Digit 12
1, 2, 4, 7, 8
9
1, 2, 4, 7, 8
9
1
Manifold Pressure
3.5”
4.0”
10.0”
10.5”
j For units with Model Digit 12=9 and multiple furnaces, only one furnace
will be Model Digit 12=9, the additional furnaces will be Model Digit 12=2,
therefore pressures will be different for those furnaces.
6.
After adjustment, move the field installed manual shut-off
valve to the “OFF” position, remove the manometer, and
replace the 1/8&quot; pipe plug.
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.
Proceed to the section &quot;Air Shutter Adjustment&quot;.
10
5-594.10
3
4
5
9
8
7
6
If the unit has Electronic Modulation gas controls (Model
Identification Digit 12=4, 7, 8, or 9), skip steps 7 through
9 in this section and proceed to the next section &quot;Check/
Adjust Pressure for the Modulating Valve&quot;, otherwise
continue to the next step.
2
1. TOP HOUSING
2. COVER PLATE
3. SEAL GASKET
4. MAX ADJUSTMENT SCREW
5. MAX ADJUSTMENT SPRING
6. SOLENOID
7. MIN ADJUSTMENT SPRING
8. PLUNGER
9. MIN ADJUSTMENT SCREW
10. MIN ADJUSTMENT SCREW STOP
21
START-UP PROCEDURE
Check/Adjust Pressure for the Modulating Valve
(continued)
d.
11. 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.
12. Proceed to the section &quot;Air Shutter Adjustment&quot;.
7.
8.
Figure 22.1 - Maxitrol EXA Modulating Valve
BUTTON #2
SUPPLY POWER TERMINALS
CONTROL SIGNAL TERMINALS
BUTTON #1
1
2
3
4
POSITION FEEDBACK
WIRING TERMINALS
DIP SWITCHES
(1=“OFF”, 2=“ON”, 3=“OFF”)
ON
22
6.
1 2 3
For Units with Model Digit 12=9:
The high fire gas pressure needs to be adjusted first, followed
by the low gas pressure. For multiple furnace units, this is only
required on the duct furnace that has the modulating valve
(Model Digit 12=9). This is accomplished as follows:
1. Verify the main valve (valve before the modulating valve)
outlet pressure has been set to 4.0” W.C. for natural gas
or 10.5&quot; W.C. for propane gas per instructions and Table
21.1 on the previous page. For multiple furnace units, the
furnaces without the modulating valves are to remain at 3.5&quot;
W.C. for natural gas or 10.0&quot; W.C. for propane gas. For
location of regulator adjustment, refer to the combination
gas control literature supplied with the unit.
2. The Maxitrol EXA modulating valve series has a cover
secured with two screws that must be removed. Once
removed, there are a bank of (3) DIP switches and two
buttons and a communication LED for the user interface as
shown in Figure 22.1.
3. Verify that the DIP switches are properly set to the &quot;OFF&quot;
position for switches 1 and 3 and &quot;ON&quot; for switch 2.
4. Adjust the High Fire Setting as follows:
a. Enable the unit controls and create a call for heat.
b. Press and hold Button #1 on the modulating valve until
the LED lights solid red, then release.
c. With the valve now in the high fire setting mode,
confirm or adjust the high fire manifold pressure to be
3.5&quot; W.C. If the pressure needs to be adjusted, press
or hold Button #1 to increase gas flow and press or
hold Button #2 to decrease gas flow.
d. If 3.5&quot; W.C. cannot be attained, recheck the inlet gas
pressure as described previously. After addressing
any issues, if 3.5&quot; W.C. still cannot be attained, step
the valve closed using button #2 to the point where
manifold pressure begins to be impacted. If the
pressure at that point is less than 3.3&quot; W.C., recheck
your inlet pressure with the unit operating and adjust
as required.
e. Save the setting by simultaneously holding Buttons
#1 and #2 until the LED turns OFF. If this is not
performed within 5 minutes, the control will default
to the previously saved settings and return to normal
operating mode.
4. Adjust the Low Fire Setting as follows:
a. Press and hold Button #2 on the modulating valve until
the LED light blinks red, then release.
b. With the valve now in the low fire setting mode, confirm
or adjust the low fire manifold pressure to be no less
than the minimum shown on the furnace serial plate
in the box called “Min. Manifold Pressure”. If the
pressure needs to be adjusted:
c. Press or hold Button #1 to increase gas flow and #2 to
decrease gas flow. It is best to push and release button
#2 to single step the valve to the minimum manifold
pressure. Holding the button is likely to cause the valve
to close too far and lose flame.
5.
Save the setting by simultaneously holding Buttons
#1 and #2 until the LED turns OFF. If this is not
performed within 5 minutes, the control will default
to the previously saved settings and return to normal
operating mode.
Once the setting of the modulating valve has been
completed, replace the valve cover removed earlier.
Move the field installed manual shut-off valve to the “OFF”
position, remove the manometer, and replace the 1/8&quot; pipe
plug.
After the plug is in place, move the field installed manual
shut-off valve to the “ON” position and recheck the pipe
plug for gas leaks with soap solution.
Proceed to the section &quot;Air Shutter Adjustment&quot;.
LED INDICATOR
Air Shutter Adjustment
Proper operation provides a soft blue flame with a well-defined
inner core. A lack of primary air will reveal soft yellow-tipped
flames. Excess primary air produces short, well-defined flames
with a tendency to lift off the burner ports. For both natural
and propane gas, the air shutters can be adjusted to control
the burner flame height. The air shutters can be accessed by
reaching behind the manifold tee in Figure 21.1. The larger
models may require the removal of the manifold (see Manifold
Assembly Removal).
Adjusting the primary combustion air is achieved by resetting
the primary air shutters (See Figure 51.2). 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.
1. T
o increase primary air, loosen the air shutter set screws and
move the air shutters closer to the manifold until the yellow
tipped flames disappear and a clean blue flame with a well
defined inner cone appears.
2. T
o 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.
3. R
e-tighten set screws after adjustment.
5-594.10
START-UP PROCEDURE
Blower Adjustments
If blower fan speed changes are required, adjust motor sheave
as follows:
1. Refer to pages 39-41 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 20.1 - Motor Sheave Adjustment
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.
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 23.3.
4. Tighten the 5/16&quot; hex head screw on the ball joint.
SET SCREW
MOTOR
SHAFT
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&quot; deflection with about 5 lbs. of force.
Figure 23.3 - Damper Linkage Adjustment
Figure 23.2 - Belt Tension Adjustment
BALL JOINT
CONNECTING ROD
BLADE ARM
DAMPER
BLADE
&ntilde;
3/4&quot; 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.
5-594.10
23
START- UP PROCEDURE
Furnace Control Operating Sequence
IMPORTANT
4.
nce the pilot is lit, the flame sensor proves the pilot and
O
stops the spark igniter from sparking.
5.
he main gas valve is opened and the main burner is
T
controlled as follows:
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.
Furnaces are supplied with intermittent pilot systems with
continuous retry, which both the main burner and pilot burner
are turned off 100% when the thermostat is satisfied.
Gas Control Options (see page 27) could change the listed
sequence of operation based on their function.
The descriptions given are for the basic duct furnace.
a.
Single-Stage Furnaces (Model Digit 12=1): The main
burner is lit to 100% full fire.
b.
wo-Stage Furnaces (Model Digit 12=2): The main
T
burner is lit to 50% fire. If the temperature at the
thermostat continues to fall, the thermostat will call for
high stage heat and the main burner is lit to 100% full
fire.
c.
odulating Room or Duct Thermostat (Model Digit
M
12=4): The main gas valve is opened 100% and the
burner firing rate is modulated between 40% and 100%
full fire. A resistance signal (8000 to 12000 ohms) in the
thermostat is converted by the modulating amplifier to
an inverted DC voltage (between 0VDC for high fire to
12 VDC for low fire) and applied to the modulating gas
valve to control the gas flow to the main burner.
Single Furnace Controls
Single furnace units (Model Digits 4-6=75 through 400) are
offered with different types of gas control:
•
Staged Control (Model Digit 12=1 or 2): These furnaces
utilize a single- or two-stage combination gas valve, an
ignition control, and a low voltage thermostat.
•
Electronic Modulating Control (Model Digit 12=4, 7, or
8): These furnaces utilize a single-stage combination gas
valve, an electronic modulating gas valve, a modulating
amplifier, an ignition control, and one of the following:
•
&raquo;&raquo;
Modulating room thermostat
&raquo;&raquo;
Modulating duct thermostat with remote temperature
set point adjuster
&raquo;&raquo;
uilding Management System (BMS) signal by others
B
(an inverted signal where 0VDC or 4mA is high fire and
10VDC or 20mA is low fire).
Electronic Modulating Control with Modine Control
System (Model Digit 12=9): These furnaces utilize
a single-stage combination gas valve, an electronic
modulating gas valve, a programmable microprocessor
based controller, an ignition control, and different sensors
depending on the application, but most commonly include:
&raquo;&raquo;
A duct temperature sensor
&raquo;&raquo;
A space temperature sensor
&raquo;&raquo;
There is also BMS integration capability for BACnet or
LonWorks protocol systems.
Note: When modulating duct sensing is utilized, a
room override thermostat can be added. When the
room override calls for heat, the burner modulates to
full fire operation until the room override is satisfied.
The unit then reverts back to duct sensing control.
When equipped with both, either the duct sensor or the
room override thermostat can call for heat.
d.
Note: For further information regarding the operation
of any of the electronic modulating system options
above, consult the literature provided with the unit.
e.
The control operating sequence for all furnaces is as follows:
1.
The thermostat calls for heat or is enabled by the BMS.
2.
he power exhauster relay is energized starting the
T
power exhauster motor. Once the motor has reached full
speed, the differential pressure switch closes. The power
exhauster pre-purge time delay relay then closes after 20 to
40 seconds and energizes the gas control circuit.
3.
24
he pilot valve opens and the spark igniter sparks in an
T
attempt to light the pilot. 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.
MS Signal (Model Digit 12=7 or 8): The main gas
B
valve is opened 100% and the burner firing rate is
modulated between 40% and 100% full fire. A BMS
0-10VDC or 4-20mA signal (inverted, such that 0 VDC
or 4 mA is high fire and 10 VDC or 20 mA is low fire)
is converted by the signal conditioner/modulating
amplifier into an inverted DC voltage (between 0VDC
for high fire to 12 VDC for low fire) and applied to the
modulating gas valve to control the gas flow to the
main burner. 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.
odulating with Modine Control System (Model
M
Digit 12=9): The main gas valve is opened 100% and
the burner firing rate is modulated between 40% and
100% full fire. Heating demand is determined by the
Modine Control System through a comparison of the
supply air or space temperature to setpoint and a DC
voltage (between 2VDC for low fire to 10 VDC for high
fire) is applied to the modulating gas valve to control
the gas flow to the main burner.
Note: Typically the temperature control is via supply
air with the space sensor used to reset the supply air
temperature setpoint. For additional information, refer
to the Modine Control System Manual, literature #74510 that shipped with the unit.
6.
If the unit was provided with a time delay relay, the blower
starts after 30 to 45 seconds.
7.
Once the temperature is satisfied, both the main and pilot
valves close 100%. Blower operation may or may not
continue, depending on application.
5-594.10
Multiple Furnace Controls
Extended VAV Airflow Limits
Multiple furnace units are available as two furnace units (Model
Digits 4-6=500 through 800) and three furnace units (Model
Digits 4-6=840 or 960) and with different types of gas control:
•
•
Staged Control (Model Digit 12=1): For control of multiple
staged furnaces, each furnace would be individually
controlled. Refer to the section for Single Furnace
Controls, Staged Control (Model Digit 12=1).
&raquo;&raquo;
Two furnace units would be controlled as 2-stage
(50%/50%).
&raquo;&raquo;
Three furnace units can be controlled as 3-stage
(33%/33%/33%) or 2-stage (33%/67%).
Electronic Modulating Control (Model Digit 12=4): For
control of multiple electronic modulating furnaces, one
furnace is the Primary furnace featuring a modulating
amplifier capable of driving modulating gas valves on
Secondary furnaces. Because all valves are driven by one
amplifier, all valves modulate at the same rate, from 40%
to 100% full fire. Refer to the section for Single Furnace
Controls, Electronic Modulating Gas Controls (Digit 12=4).
•
Electronic Modulating Control (Model Digit 12=7 or 8):
For control of multiple electronic modulation furnaces for
BMS control (0-10VDC or 4-20mA control signal), each
furnace would be individually controlled. Refer to the
section for Single Furnace Controls, Electronic Modulation
Control (Model Digit 12=7 or 8).
•
Modulating with Modine Control System (Model Digit
12=9): For control of multiple furnaces, one furnace
features a modulating gas valve while additional furnaces
are two stage furnaces. The Modine Control system
seamlessly stages furnaces and modulates the primary
furnace based on demand.
If certain conditions are followed, the allowable minimum CFM
of the system can be extended to:
75% of the minimum listed CFM in Table 36.1 for high
air temperature rise units (Model Digit 10=H)
•
66% of the minimum listed CFM in Table 36.1 for low
air temperature rise units (Model Digit 10=L).
Refer to Table 25.1 for a summary of the reduced minimum
airflows, indicated in the column &quot;Extended Range&quot;. To allow
the reduced airflows, the unit must be applied as follows:
1.
The unit has 2-stage or modulating gas controls.
2.
The unit is provided with a discharge air thermostat.
3.
The system does not include a room thermostat.
Exception: See note below for units equipped with the
Modine Control System option (Model Digit 12=9).
The discharge air thermostat will prevent the unit from firing
above the allowable 100&deg;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.
Note for units equipped with the Modine Control System option
(Model Digit 12=9): A space temperature sensor (Carel pAD) is
permitted, as a call for heating from the space results in a reset
of the supply air temperature setpoint that will still maintain a
supply temperature that is at or below the maximum allowable
discharge air temperature.
Table 25.1 - Extended Range VAV Minimum Airflow
Minimum Airflow (CFM)
Input Rating
(Digit 4-6)
75
100
125
150
175
200
225
250
300
Variable Air Volume Applications
Units may be supplied with variable frequency drives for
applications where variable air volume is required. The minimum
air flow may be reduced to as low as 30% of the full speed
air flow, but not lower than the minimum airflow listed in Table
25.1 and 36.1, unless certain conditions are followed. Refer
to the following section titled &quot;Extended VAV Airflow Limits&quot; for
additional information.
350
400
500
600
700
800
840
960
To determine the actual minimum allowable airflow, all unit
selections must be performed with the AccuSpec configuration
software. Within AccuSpec, multiple variable frequency drive
speed control changeover options are available, which include
these common selections:
•
wo speed which may be controlled by a manual
T
high/low switch which may be factory mounted on the
control panel or shipped loose for field installation or by
exhaust fan interlocks.
•
loating building pressure sensing which utilizes a
F
Photohelic pressure controller to adjust the building
pressure by varying the amount of makeup air supplied
to the space.
•
•
uilding management control which allows for an
B
external signal of 0-10VDC of 4-20mA to adjust the unit
airflow.
Additional options are available when the unit is configured with
the Modine Control System option (Model Digit 12=9).
High ATR
(Digit 10=H)
Extended
Standard
Range 
563
422
750
563
938
703
1,125
844
1,313
984
1,500
1,125
1,688
1,266
1,875
1,406
2,250
1,688
2,625
3,000
-
1,969
2,250
-
Low ATR
(Digit 10=H)
Extended
Standard
Range 
938
619
1,250
825
1,563
1,031
1,875
1,238
2,188
1,444
2,500
1,650
2,813
1,856
3,125
2,063
3,750
2,475
4,375
5,000
3,125
3,750
4,375
5,000
6,562
7,500
2,888
3,300
2,063
2,475
2,888
3,300
4,331
4,950
j Extended range minimum can be 75% of standard minimum.
 Extended range minimum can be 66% of standard minimum.
Cooling Coil Operation
1. P
roper 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. F
or chilled fluid coils, fluid velocities should be maintained
within the recommended values of 1 to 8 feet per second (fps)
for Water and 1 to 6 fps for Glycol solutions.
5-594.10
25
COMPONENT LOCATIONS
Figure 26.1 - Factory Mounted Option Locations
1.
Discharge Thermostat (not shown)
2.
Low Gas Pressure Switch
3.
High Gas Pressure Switch
4.
Power Exhauster Assembly
5.
Timed Freeze Protection
6.
Ignition Controller
7.
Differential Pressure Switch
8.
Control Relay
9.
Time Delay Relay
4
2
13
11
9
7
5
12
10
8
6
18
16
14
15
17
19
21
20
22
23
24
25
26
3
27
28
10. Furnace Low Voltage Terminal Strip
11. Power Exhauster Relay
12. Furnace Supply Power Terminal Strip
13. Control Step Down Transformer
14. Control Relay
15. Blower Low Voltage Terminal Strip
50
16. Dead Front Disconnect Switch
17. Step Down Transformer Fuses
52
49
51
46
48
45
47
43
44
18. Step Down Transformer
40
42 41
38
39
36
34
37
35
32
30
33
31
19. Factory Installed Minimum Positioner
20. Extended Grease Line Zerk Fittings
21. Extended Grease Lines
Furnace Control Panel(s) for
Modine Control System Equipped Units (Model Digit 12=9)
22. Return Air Fire Stat
23. Blower Housing
24. Pillow Block Bearings
25. Blower Motor
26. Filters
13
27. Fresh Air Damper
28. Enthalpy Sensor (not pictured)
56
29. Not Used
30. Direct Drive Damper Actuator
31. Enthalpy Controller
32. Damper to Damper Linkage
11
33. Return Air Damper
6
34. Proportional Temp Controller Sensor
35. Motor and Blower Vibration Isolation
58
12
11
12
7
59
6
7
36. Blower Support
37. Convenience Outlet
38. Blower Door Switch
39. Dirty Filter Switch
40. Motor Starter/VFD Control
41. Mild Temperature Thermostat
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
26
50 49 48
10
60
57
Single Furnace Units or
Primary Furnace on Multiple Furnace Units
For Modine Control System Units Only
(Model Digit 12=9):
56. Carel pCOOEM+ Microprocessor Controller
57. Carel pLDPro User Interface Panel
58. Optional Control Relays
59. Optional Unit Enable Relay
60. Wiring Channels
61. Return Air Sensor (not shown)
62. Outside Air Sensor (not shown)
63. Mixed Air Sensor (not shown)
5-594.10
50 49
10
Secondary Furnace(s) on
Multiple Furnace Units
COMPONENT DESCRIPTIONS
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/Sensor – (OPT)
The discharge thermostat or sensor is field installed in the
discharge (supply) air ductwork. For additional information, refer
to the thermostat vendor literature provided in the literature
packet with the unit. 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 Thermostat (Digit 12=1 or 2)
The thermostat capillary is to be field routed/installed
in the ductwork. The thermostat body contains the
setpoint adjuster that must be field set.
SUPPLY
DUCTWORK
(BY OTHERS)
SETPOINT
ADJUSTER
RIGHT
LEFT
CAPILLARY
b.
R
B
W
R
B
W
(3) High Gas Pressure Switch – (OPT)
The switch monitors the gas pressure downstream of all the gas
controls and disables the ignition controller and combination
gas valve if high gas pressure is experienced right before the
manifold. The switch is manual reset so that if the gas pressure
is too high, a service person must check the unit to be sure the
gas controls have not been damaged, then reset the switch to
allow the unit to operate when gas pressure returns below the
maximum setpoint. The switch should be set to insure that the
maximum manifold gas pressure is not exceeded (3.5&quot; W.C. for
natural gas, 10&quot; W.C. for propane gas).
Low or High Gas Pressure Switch
THERMOSTAT BODY
(COVER REMOVED)
Two-Stage Electronic Thermostat (Digit 12=1 or 2)
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.
Note: Second stage
S350 module not shown.
c.
(2) Low Gas Pressure Switch – (OPT)
The switch monitors the gas pressure upstream of all the gas
controls and disables the ignition controller and combination
gas valve if low gas pressure is experienced. The switch is
automatic reset, allowing the unit to operate when gas pressure
returns above the minimum setpoint. The switch should be set
to insure that the minimum inlet gas pressure is available (6&quot;
W.C. for natural gas, 11&quot; W.C. for propane gas).
Electronic Modulating Discharge Sensor (Digit 12=4)
Includes a field installed mixing tube and discharge
air sensor 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 for instructions.
(4) Duct Furnace Power Exhauster – (STD)
The power exhauster is factory installed in the duct furnace
section. On a call for heat, the power exhauster creates a
combustion draft through the duct furnace prior to the pilot being
energized. The draft is proven through a differential pressure
switch that closes when the motor reaches full speed. For
information about venting, refer to &quot;Installation - Venting&quot; section.
(5) Timed Freeze Protection (OPT) (All Except Digit 12=9)
The timed freeze protection system includes a sensor 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 a manual 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
(30&deg;-75&deg;F adjustable) and will shut down the unit.
Timed Freeze Protection Module
d.
Supply Air Sensor (Model Digit 12=9) (not shown)
Used on units with Modine Control System option, the
sensor is field installed in duct work. Refer to Literature
74-541 latest revision for instructions.
For units with the Modine Control System option (Model Digit
12=9), this feature is integral to the control logic and utilizes
existing sensors included with that option. Refer to the latest
revision of the Modine Control System Manual, literature 74-510
for additional information.
5-594.10
27
COMPONENT DESCRIPTIONS
6) Ignition Controller – (STD)
The ignition controller is factory installed in the duct furnace
electrical junction box with the spark ignitor and sensor located
on the burner. 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&shy;imately six minutes with the
combination gas control closed and no spark. After six minutes,
the cycle will begin again. After three cycles, some ignition
controllers lockout for approximately one hour before the cycle
begins again. This will continue indefinitely until the pilot flame is
sensed or power is interrupted to the system.
(7) Differential Pressure Switch - (STD)
The differential pressure switch is factory installed in the duct
furnace electrical junction box. The differential pressure switch
monitors the pressure differential between the duct furnace vent
discharge and the atmosphere and disables the gas controls if
vent pressure measured by the switch is not adequate to close
the switch. This could be caused by a blocked combustion air
inlet vent pipe.
(8) Control Relay – (OPT)
The control relay is factory installed in the duct furnace electrical
junction box. The relay has a 24V coil with double-pole, double
throw (DPDT) contacts. Refer to the unit wiring diagram for the
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 satis&shy;fied to remove
the residual heat from the heat exchanger. For single phase units
below 1-1/2 Hp, the time delay relay controls the motor directly.
For single phase units 1-1/2 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.
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 29.1). When in the “OFF”
position, power is disconnected to all unit wiring electrically
following the switch (See Warning). For servicing the unit,
the disconnect switch can be manually overridden by using a
wrench and turning the disconnect switch shaft 90&deg; clockwise
(See Figure 29.1). 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.
(11) Power Exhauster Relay - (STD)
The control relay is factory installed in the duct furnace electrical
junction box. On a call for heat, the relay coil is energized
resulting in the contacts energizing the power exhauster motor.
28
5-594.10
COMPONENT DESCRIPTIONS
Figure 29.1 - Dead Front Disconnect Switch Assembly
BLOWER SECTION
ELECTRICAL
COMPARTMENT
ACCESS DOOR
DISCONNECT
SWITCH HANDLE
OPERATION
INSTRUCTION
LABEL
DISCONNECT
SWITCH HANDLE
SHOWN IN THE
&quot;ON&quot; POSITION
SUPPLY POWER
WIRING TERMINALS
(SEE WARNING)
(20, 21) Extended Grease Lines – (OPT)
The extended grease lines (21) are factory installed in the
blower section and include Zerk&reg; grease fittings (20) factory
installed on the exterior corner post between the electrical and
blower sections. This option allows the pillow block bearings to
be lubricated with a grease gun without requiring the service
personnel to remove both blower doors to access the bearings.
Refer to Lubrication Recommendations for lubricant
recommendations.
(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.
DISCONNECT
SWITCH HANDLE
SHOWN IN THE
&quot;OFF&quot; POSITION
(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 electrical
section. The transformer is required for power exhausted units
with a supply voltage of 460V/3Ph and 575V/3Ph.
(19) Minimum Positioner – (OPT) (All Except Digit 12=9)
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.
Minimum Positioner
For units with the Modine Control System option (Model Digit
12=9), this feature is available as a damper control when
configured properly and does not require a separate additional
positioner. Refer to the latest revision of the Modine Control
System Manual, literature 74-510 for additional information.
(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.
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 nongreased from the factory and require lubrication before start-up.
For lubrication recommendations, see Lubrication
Recommendations.
(25) Blower Motor – (STD)
The blower motor is factory installed in the blower section. The
blower motor can be provided in a variety of supply voltages,
frame types, and motor horsepowers. Refer to the model
nomenclature to determine the type of motor provided. The
blower motor is supplied with an adjustable sheave that can be
used to increase/decrease the blower RPM. For instructions on
changing the blower RPM, refer to Blower Adjustments.
(26) Filters – (OPT)
When filters are supplied with the unit, a rack and the filters are
factory installed in the blower section. The unit can be supplied
with 2&quot; permanent filters, or 2&quot; pleated throwaway filters in
MERV 8 or 13 ratings. For filter replacement, refer to
Maintenance.
5-594.10
29
COMPONENT DESCRIPTIONS
(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 I
leakage resistance (less than 4 CFM/ft&sup2; at 1&quot; W.C.) dampers
with self-compensating stainless steel side seals and
santoprene and galvanized steel blade seals are used.
Figure 30.1 - Two-Position Damper Actuator Limiter
(28) Enthalpy Sensor – (OPT) (All Except Digit 12=9)
Refer to Option #31.
(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 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 actuator is
provided with Air Control options (Model Digits 20-21=DA
and EA). The actuator provides open/closed operation of
the fresh air damper. When the actuator is energized, the
fresh air damper is opened to 100% outside air in 75
seconds (for outside air percentages lower than 100%, refer
to the following section, &quot;Setting the Damper Limiter&quot;).
Actuators are spring return, so when the damper is
de-energized, the fresh air damper will spring closed.
Actuator include auxiliary switches (one normally open and
one normally closed) that reverse when the damper actuator
is at 85&deg; rotation (adjustable).
Setting the Damper Limiter: The two-position damper limiter
can be factory set to prevent the outside air damper from
opening 100%. Field adjustment of the two-position damper
limiter is accom&shy;plished by the following:
1. Determine the maximum outside air % required.
2. Locate the angle of rotation limiter on the actuator so
that its edge lines up with the degree graduation on the
actuator face corresponding to the required rotation.
(See Figure 30.1 which is shown at 50% rotation limit.)
3. Position the limiter to the desired position, making sure
the locating “teeth” on the limiter are engaged into the
locating holes on the actuator.
4. Fasten the limiter to the actuator using the screw
provided.
5. Test the damper rotation either manually with the
manual crank or apply power. Re-adjust if necessary.
6. If the damper end switch is being used in the control
circuit and needs to be adjusted for the new limit
position, refer to the next section, &quot;Adjusting the
Damper End Switch&quot;.
30
PHILIPS SCREWDRIVER
Adjusting the Damper End Switch
If the damper limiter was adjusted in the previous section, it may
be required to adjust the Damper End Switch as follows:
1. The actuator must be in its fail-safe position.
2. Insert the crank handle into the torx shaped hole located in
the center of the adjustable switch pointer as shown in
Figure 30.2.
3. Gently rotate the crank until the switch pointer is at the
desired switch point in degrees as shown.
Figure 30.2 - Adjusting the Damper End Switch
•
Modulating Damper Actuator: A modulating actuator is
provided with Air Control options (Model Digits 20-21=GA,
GB, GC, GD, GE, GG, GH, and GJ). The actuator provides
incremental operation of the fresh air damper (the return air
damper is controlled by the fresh air damper position). Full
90&deg; rotation of the actuator requires 150 seconds. 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. Actuators are spring return, so
when the damper is de-energized, the fresh air damper will
spring closed.
For units with the Modine Control System option (Model
Digit 12=9), when the damper control is modulating, Model
Digits 20-21 will always be GA and the control will be
integral to the Modine Control System control logic. Refer
to the latest revision of the Modine Control System Manual,
literature 74-510 for additional information.
•
5-594.10
Floating Damper Actuator (All Except Model Digit
12=9): A floating actuator is provided with Air Control
option (Model Digits 20-21=HP). The actuator provides
forward and reversing damper operation in response to
contact closures from the space pressure controller. When
above the desired high pressure setpoint, a contact on
COMPONENT DESCRIPTIONS
the space pressure controller energizes the actuator to
drive the fresh air damper closed. When below the desired
low pressure setpoint, a contact on the space pressure
controller energizes the actuator to drive the fresh air
damper open. When the space pressure is between the
high and low setpoints, the damper remains at the fresh air
percentage that satisfied the space pressure controller. Full
90&deg; rotation of the floating actuator requires 150 seconds.
For additional information on the space pressure controller,
refer to Literature 5-585.
The actuator is designed to “float” and therefore is not
spring return. When the unit is de-energized under normal
operation, the fresh air damper is powered closed. If the
supply power to the unit is interrupted before the damper
actuator can drive closed, the fresh air damper will remain
open.
(31) Enthalpy Controller – (OPT) (All Except Model Digit 12=9)
An enthalpy controller is provided with Air Control option (Model
Digits 20-21=GJ). The purpose of the enthalpy controller is to
use outside air for free cooling, whenever possible, to reduce
compressor operation of the mechanical cooling system.
The economizer functions as a true first stage of cooling and
minimizes energy usage during the cooling cycle.
The components used for the Enthalpy Economizer are:
•
Enthalpy Economizer Controller. The controller is used in
conjunction with the Enthalpy Sensor and a Mixed Air
Temperature sensor. The controller is factory mounted in
the blower control cabinet.
•
Outside Air Enthalpy Sensor. The sensor provides a
signal in relation to enthalpy (temperature and humidity) of
the outside air and is installed in the outside air stream.
•
Mixed Air Temperature Sensor. The sensor is factory
installed in the blower section to sense the mixed air
temperature of the fresh and return air streams.
(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/ft&sup2; at 1&quot; 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 GG or GH (Digits 20 &amp; 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. See
Option #42 for complete description of option.
(35) Motor and Blower Vibration Isolation – (STD)
The motor vibration isolation is factory installed below the
blower support bracket. The four (4) neoprene vibration mount
grommet provides isolation of the blower housing and motor
from the blower support channels. The blower duct connection
is not rigidly mechanically fastened and the 1/4'' thick gasketing
around the duct transition provides vibration isolation.
Blower/Motor Vibration Isolation
BLOWER
SUPPORT
For complete details on the Enthalpy Economizer controller
setup and sequence of operation, please refer to Literature
5-598, latest revision.
BLOWER
SUPPORT
RAIL
Enthalpy Controller
NEOPRENE
VIBRATION
ISOLATOR
(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.
For units with the Modine Control System option (Model Digit
12=9), when the damper control is enthalpy economizer, Model
Digits 20-21 will always be GA and the control will be integral to
the Modine Control System control logic. Refer to the latest
revision of the Modine Control System Manual, literature 74-510
for additional information.
5-594.10
31
COMPONENT DESCRIPTIONS
(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
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 1-1/2 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.
For units with Modine Control System option (Model Digit 12=9),
the switch is wired to a digital input on the unit controller.
Blower Door Switch
OPEN
DOOR CLOSED DOOR
POSITION
POSITION
(39) Dirty Filter Switch – (OPT)
The dirty filter pressure switch is factory installed in the blower
electrical section. The 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
(for units with Modine Control System option (Model Digit 12=9),
the switch is wired to a digital input on the unit controller). The
switch must be field set with ductwork installed and the blower
in operation.
Setting the Dirty Filter Switch
The range of the dirty filter pressure switch is adjustable
between 0.17&quot; to 5.0&quot; W.C.
1. Ensure that the unit filters are 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
below.
3. Turn the set screw of the pressure switch clockwise until
it stops. This will set the pressure at 5.0&quot; W.C. and the
continuity tester should be sensing an open circuit.
4. Begin turning the screw counterclockwise until the
continuity tester senses a closed circuit. This determines
the base pressure of the system.
5. Turn the screw clockwise until the continuity tester senses
an open circuit and then one additional full turn (This is
approx&shy;imately 0.25&quot; W.C.) This will allow for the increase in
static pressure due to dirty filters.
Dirty Filter Pressure Switch and Air Flow Proving Switch
OVERRIDE
POSITION
POSITIVE
PRESSURE
CONNECTION
NEGATIVE
PRESSURE
CONNECTION
C
NO
PRESSURE
ADJUSTMENT
SET SCREW
COM
NC NO
32
5-594.10
COMPONENT DESCRIPTIONS
(40) Motor Starter – (OPT)
The motor starter is factory installed in the blower electrical
section. A motor starter is required for:
•
All three phase motors
•
Single phase motors 1-1/2 Hp and greater
If the factory installed motor starter option was not ordered with
a unit that requires it, a motor starter must be field supplied and
installed. Alternatively for three phase motors, see also the
Variable Frequency Drive option below.
The overload module of the motor starter is designed 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 current set point dial is factory set to the motor full load
amps listed on the motor nameplate.
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 contactor module includes one (1) normally open auxiliary
contact. The contact rating is 10 amps.
Motor Starter
(41) Mild Temperature Stat - (OPT) (All Except Digit 12=9)
The mild temperature thermostat is designed to lockout the
burner during mild weather conditions which prevents the
burner from cycling. The thermostat must be field set to the
desired mild temperature condition. Refer to the latest revision
of Modine publication 75-540, &quot;Installation/Setup Instructions,
Electronic Mild Temperature Thermostat&quot; for additional
instructions.
For units with the Modine Control System option (Model Digit
12=9), this feature is integral to the control logic and utilizes
existing sensors included with that option. Refer to the latest
revision of the Modine Control System Manual, literature 74-510
for additional information.
(42) Proportional Temperature Controller – (OPT) (All
Except Digit 12=9)
A proportional temperature controller is provided with Air Control
options GG or GH (Digits 20 &amp; 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&deg;F). This acts as a dry bulb economizer,
primarily by utilizing warmer outside air as first stage heating to
minimize gas heat energy usage.
Proportional Temperature Controller
A1
1
A2
3
L1
5
L2
13
L3
NO
CONTACTOR
MODULE
CURRENT
SET POINT
DIAL
TRIP
INDICATOR
WINDOW
2
4
T1
6
T2
14
T3
NO
RESET
A2
OVERLOAD
MODULE
A R
E
S
E
T
H
NO
98
2
NC
97
T1
4
95
T2
96
6
T3
(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 (refer to the section &quot;Variable Air Volume
Applications&quot; on page 25 for additional information).
The control changeover options include two speed, building
pressure control, and building management control. For units
with the Modine Control System option (Model Digit 12=9),
additional control options may be available. Refer to the latest
revision of the Modine Control System Manual, literature 74-510
for additional information.
For units with the Modine Control System option (Model Digit
12=9), when the damper control is dry economizer, Model Digits
20-21 will always be GA and the control will be integral to the
Modine Control System control logic. Refer to the latest revision
of the Modine Control System Manual, literature 74-510 for
additional information.
(43) Warm-Up Stat – (OPT)
A warm-up stat can be provided with Air Control options EA,
GG, or GH (Digits 20 &amp; 21) and factory installed in the electrical
section with the sensor in the return air stream. The warmup 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&deg;F or 5&deg;F below the room temperature).
5-594.10
33
COMPONENT DESCRIPTIONS
(44) Blower Supply Power Terminal Strip – (STD)
The terminal strip is labeled to match the electrical wiring
diagram provided with the unit. 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) (All Except Digit 12=9)
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 compo&shy;
nent directly. All switches need to be reset to the “OFF” position
after testing otherwise the components will remain energized.
Service Switches
SYSTEM OVERRIDE SWITCH POSITIONS
DAMPERS ONLY
ON
OFF
OFF
DAMPERS &amp; BLOWER ONLY
ON
ON
OFF
ON
ON
* RESET SWITCHES TO “OFF” POSITION AFTER TESTING
ON
ON
ON
OFF
OFF 5H0756370000 REV B OFF
For units with the Modine Control System option (Model Digit
12=9), this feature is integral to the control logic and provides
service personnel with real-time operating status of the unit
systems. Refer to the latest revision of the Modine Control
System Manual, literature 74-510 for additional information.
(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&shy;ped with Electronic Modulating Gas Controls (Digit 12=4).
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.
(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 (Model Digit 12=4, 7, 8,
or 9). The gas valve modulates the firing rate between 40%
to 100% full fire based on the input signal from the Electronic
Modulation Amplifier (Model Digit 12=4), Signal Conditioner
(Model Digit 12=7 or 8), or Modine Control System controller
(Model Digit 12=9). For additional information, refer to the
Furnace Control Operating Sequence section in this manual.
34
Setting the Air Flow Proving Switch
The range of the switch is adjustable between 0.17&quot; to 5.0&quot; W.C.
1. Set the thermostat or controller so that there is a call for
heat. For units with the Modine Control System option
(Model Digit 12=9), refer to the latest revision of the Modine
Control System Manual, literature 74-510 for additional
information.
2. Turn the set screw of the pressure switch clockwise until it
stops. This will set the pressure at 5.0&quot; 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
The 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. Two types of high limit switches
are offered:
•
Automatic – (STD): The automatic reset high limit will reset
when 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. 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.
DAMPERS, BLOWER &amp; FURNACE ONLY
ON
(48) Air Flow Proving Switch – (OPT) (All Except Digit 12=9)
(STD on units with Digit 12=9)
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 and disables the 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.
(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.
(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.
5-594.10
COMPONENT DESCRIPTIONS
Circuit Analyzer – (OPT) (All Except Digit 12=9)
(Not Shown in Figure 26.1)
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
For Modine Control System Units Only (Model Digit 12=9)
The following items may be included with units configured with
the Modine Control System option:
(56) Carel pCOOEM+ Microprocessor Controller
The Modine Controls System utilizes a Carel pCOOEM+
programmable microprocessor controller that is factory
installed in the duct furnace electrical section.
Circuit Analyzer 
(57) Carel pLDPro User Interface Panel
The interface allows a user to access the Carel controller
for setpoint changes and to view the operational status
of the equipment. The interface features an LED backlit
graphic display and buttons for excellent visibility.
(58) Control Relays - (OPT)
The control relay(s) are 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 switching function of the relay. The two
normally open and two normally closed contacts are rated
for a maximum of 8A @ 230V/1Ph.
(59) Unit Enable Relay and/or Cooling Interlock - (OPT)
The control relay is factory installed in the duct furnace
electrical junction box and is used to enable the unit based
on contact closure from a customer enable circuit. The
closing of that contact will power a 24V relay from the unit
mounted controller and enable the unit in On or Occupied
mode. The relay provides electrical isolation to the
controller for protection.
j Circuit Analyzer tagging will vary based on the unit ordered.
Circuit analyzer shown is for reference only.
not lit, that is the point where failure occurred.
For units with the Modine Control System option (Model Digit
12=9), this feature is integral to the control logic and provides
service personnel with real-time operating status of the unit
systems. Refer to the latest revision of the Modine Control
System Manual, literature 74-510 for additional information.
(60) Wiring Channels with Cover - (STD)
The wiring channels organize and separate high voltage
and low voltage wiring.
(61) Return Air Sensor (not shown) - (OPT)
This sensor is required on all units that have a mixture of
outside and return air. The sensor is field mounted in the
return air ductwork. It may be dry bulb only or enthalpy
(temperature and humidity).
(62) Outside Air Sensor (not shown) - (OPT)
This sensor is required on all units except 100% return air
units and is field installed. Depending on the unit
configuration, the sensor may be duct mounted or remote
mounted. It may be dry bulb only or enthalpy (temperature
and humidity).
(63) Mixed Air Sensor (not shown) - (OPT)
This sensor is required on all units that have a mixture of
outside and return air and is factory mounted in the blower
cabinet. The sensor is dry bulb temperature only.
Refer to the latest revision of the Modine Control System
Manual, literature 74-510 for additional information.
5-594.10
35
GENERAL PERFORMANCE DATA
Table 36.1 - General Performance Data
Model Size
(Digits 4-6)
Btu/Hr
Input j
Btu/Hr
Output j
75
75,000
60,750
100
100,000
81,000
125
125,000
101,250
150
175
200
225
250
300
350
400
500
600
700
800
150,000
175,000
200,000
225,000
250,000
300,000
350,000
400,000
500,000
600,000
700,000
800,000
121,500
141,750
162,000
182,250
202,500
243,000
283,500
324,000
405,000
486,000
567,000
648,000
840
1,050,000
850,500
960
1,200,000
972,000
Blower Style/Size
Temperature Rise (&deg;F)
(Digit 16)
Size
Minimum
CFM k
Maximum
CFM
Maximum
Minimum
A or B
9-7
562
1800
100
31
C or D
9-9
750
2813
75
20
C or D
9-9
750
3000
100
25
E or F
12-12
1500
3750
50
20
C or D
9-9
937
3000
100
31
E or F
12-12
1500
4688
63
20
C or D
9-9
1125
3000
100
38
E or F
12-12
1250
5550
90
20
C or D
9-9
1312
3000
100
44
E or F
12-12
1312
5550
100
24
C or D
9-9
1500
3000
100
50
E or F
12-12
1750
5000
86
30
G or H
15-15
1750
6500
86
23
C or D
9-9
1687
3000
100
56
E or F
12-12
1750
5000
96
34
G or H
15-15
1750
6500
96
26
E or F
12-12
1875
5500
100
34
G or H
15-15
1875
6500
100
29
I, J, or K
18-18
3000
9375
63
20
E or F
12-12
2250
5500
100
41
G or H
15-15
2250
6500
100
35
I, J, or K
18-18
3000
11250
75
20
E or F
12-12
2625
5500
100
48
G or H
15-15
2625
6500
100
40
I, J, or K
18-18
4000
12000
66
22
E or F
12-12
3000
5500
100
55
G or H
15-15
3000
6500
100
46
I, J, or K
18-18
4000
12000
75
25
G or H
15-15
3125
6500
120
58
I, J, or K
18-18
4000
9375
94
40
L
20-18
4000
9375
94
40
G or H
15-15
3750
6500
120
69
I, J, or K
18-18
4000
11250
113
40
L
20-18
5000
11250
90
40
G or H
15-15
4375
6500
120
81
I, J, or K
18-18
4375
13000
120
40
L
20-18
4375
13000
120
40
G or H
15-15
5000
6500
120
92
I, J, or K
18-18
5000
13000
120
46
L
20-18
5000
14500
120
41
I, J, or K
18-18
6562
13000
120
61
L
20-18
6562
13000
120
61
I, J, or K
18-18
7500
13000
120
69
L
20-18
7500
14500
120
62
j Ratings are shown for elevations up to 2,000 feet. For higher elevations, refer to section &quot;Considerations for Elevation&quot; on page 14.
k For Variable Air Movement Applications, see page 25.
36
5-594.10
GENERAL PERFORMANCE DATA
Table 37.1 - Air Temperature Rise jkl
Model Size
Btu/Hr
Input j
Btu/Hr
Output j
Air Temperature Rise Through Unit (&deg;F)
20
40
50
60
70
80
90
100
110
120
75
75,000
60,750
2,813
1,406
1,125
938
804
703
625
562
-
-
100
100,000
81,000
3,750
1,875
1,500
1,250
1,071
938
833
750
-
-
125
125,000
101,250
4,688
2,344
1,875
1,563
1,339
1,172
1,042
937
-
-
150
150,000
121,500
5,500
2,813
2,250
1,875
1,607
1,406
1,250
1,125
-
-
175
175,000
141,750
5,500
3,281
2,625
2,188
1,875
1,641
1,458
1,312
-
-
200
200,000
162,000
6,500
3,750
3,000
2,500
2,143
1,875
1,667
1,500
-
-
225
225,000
182,250
6,500
4,219
3,375
2,813
2,411
2,109
1,875
1,687
-
-
250
250,000
202,500
9,375
4,688
3,750
3,125
2,679
2,344
2,083
1,875
-
-
300
300,000
243,000
11,250
5,625
4,500
3,750
3,214
2,813
2,500
2,250
-
-
350
350,000
283,500
12,000
6,563
5,250
4,375
3,750
3,281
2,917
2,625
-
-
400
400,000
324,000
12,000
7,500
6,000
5,000
4,286
3,750
3,333
3,000
-
-
500
500,000
405,000
-
9,375
7,500
6,250
5,357
4,688
4,167
3,750
3,409
3,125
600
600,000
486,000
-
11,250
9,000
7,500
6,429
5,625
5,000
4,500
4,091
3,750
700
700,000
567,000
-
13,000
10,500
8,750
7,500
6,563
5,833
5,250
4,773
4,375
800
800,000
648,000
-
14,500
12,000
10,000
8,571
7,500
6,667
6,000
5,455
5,000
840
1,050,000
850,500
-
-
-
13,000
11,250
9,844
8,750
7,875
7,159
6,562
960
1,200,000
972,000
-
-
-
14,500
12,857
11,250
10,000
9,000
8,182
7,500
j Ratings are shown for elevations up to 2000 feet. For higher elevations, refer to section &quot;Considerations for Elevation&quot; on page 14.
k Minimum Air Temperature Rise, Maximum Air Temperature Rise, and Maximum Discharge Air Temperature are as follows:
-For Model Sizes 75-400, Min Air Temp Rise is 20&deg;F, Max Air Temp Rise is 100&deg;F, and Max Discharge Air Temp is 150&deg;F.
-For Model Sizes 500-800, Min Air Temp Rise is 40&deg;F, Max Air Temp Rise is 120&deg;F, and Max Discharge Air Temp is 150&deg;F.
-For Model Sizes 840-960, Min Air Temp Rise is 60&deg;F, Max Air Temp Rise is 120&deg;F, and Max Discharge Air Temp is 150&deg;F.
-Note that these are typical limits but may vary by Model Size. Refer to Table 36.1 for actual limits.
l For Variable Air Movement Applications, see page 25.
Air Temperature Limits
The maximum allowable discharge air temperature is 150&deg;F. The maximum allowable air temperature rise per furnace for Low Air
Temperature Rise Units is 60&deg;F. All system units are designed for a maximum allowable total static pressure of 3.0&quot; W.C.
5-594.10
37
OPTION &amp; ACCESSORY PRESSURE DROP DATA
Table 38.1 - Option &amp; Accessory Pressure Drop Tables (in ''W.C.) j
150/175
C,D,E,F
200/225
C,D,E,F,G,H
E,F,G,H
250/300
500/600
I,J,K,L
E,F,G,H
350/400
700/800
840/960
I,J,K,L
38
5-594.10
Evap Cooler
12'' Media
w/Prefilter
Evap Cooler
12'' Media
0.03
0.01
0.05
0.02
0.07
0.03
0.01
0.05
0.02
0.07
0.04
0.02
0.08
0.04
0.12
0.05
0.03
0.11
0.06
0.17
0.06
0.04
0.14
0.08
0.22
0.07
0.06
0.17
0.11
0.29
0.09
0.08
0.21
0.15
0.36
0.10
0.10
0.25
0.19
0.44
0.11
0.12
0.30
0.23
0.53
0.13
0.16
0.37
0.31
0.68
0.16
0.23
0.51
0.45
0.96
0.02
0.01
0.06
0.02
0.08
0.04
0.02
0.08
0.04
0.12
0.07
0.04
0.14
0.08
0.23
0.10
0.08
0.21
0.15
0.36
0.14
0.12
0.30
0.23
0.53
0.19
0.17
0.40
0.34
0.73
0.24
0.23
0.51
0.46
0.97
0.30
0.30
0.63
0.60
1.23
0.374000 Max CFM for Evap
4000 Max CFM Evap
0.39
0.04
0.01
0.07
0.03
0.09
0.05
0.03
0.10
0.05
0.15
0.08
0.04
0.15
0.09
0.24
0.11
0.07
0.20
0.14
0.34
0.15
0.10
0.27
0.20
0.46
0.18
0.14
0.34
0.27
0.61
0.23
0.18
0.41
0.35
0.77
0.27
0.23
0.50
0.45
0.95
0.32
0.28
0.59
0.55
1.15
0.34
0.30
0.63
0.60
1.23
0.385200 Max CFM for Evap
0.03
0.02
0.08
0.04
0.12
0.04
0.03
0.12
0.07
0.19
0.06
0.05
0.17
0.10
0.27
0.08
0.08
0.22
0.15
0.36
0.10
0.10
0.27
0.20
0.47
0.12
0.13
0.33
0.27
0.60
0.15
0.17
0.40
0.34
0.73
0.18
0.21
0.47
0.42
0.89
0.21
0.25
0.55
0.50
1.05
0.25
0.30
0.63
0.60
1.23
0.286000 Max CFM for Evap
0.05
0.02
0.10
0.05
0.15
0.06
0.03
0.11
0.06
0.17
0.09
0.04
0.15
0.09
0.24
0.11
0.06
0.19
0.13
0.32
0.15
0.09
0.24
0.17
0.41
0.18
0.11
0.29
0.23
0.52
0.22
0.15
0.35
0.29
0.64
0.31
0.22
0.48
0.43
0.91
0.42
0.30
0.63
0.60
1.23
0.516500 Max CFM for Evap
0.03
0.01
0.05
0.02
0.08
0.05
0.03
0.10
0.05
0.15
0.09
0.04
0.15
0.09
0.23
0.12
0.07
0.20
0.14
0.34
0.16
0.10
0.26
0.20
0.46
0.21
0.14
0.34
0.27
0.61
0.27
0.18
0.41
0.35
0.77
0.33
0.23
0.50
0.45
0.95
0.42
0.30
0.64
0.60
1.23
0.4710400 Max CFM for Evap
0.04
0.03
0.10
0.05
0.16
0.05
0.04
0.13
0.07
0.20
0.06
0.05
0.16
0.10
0.25
0.08
0.06
0.19
0.13
0.32
0.10
0.08
0.23
0.16
0.39
0.12
0.10
0.27
0.20
0.47
0.14
0.12
0.31
0.24
0.55
0.17
0.15
0.36
0.29
0.64
0.19
0.17
0.40
0.34
0.74
0.22
0.20
0.45
0.39
0.85
0.02
0.02
0.08
0.03
0.11
0.03
0.02
0.09
0.04
0.14
0.04
0.04
0.14
0.08
0.22
0.06
0.06
0.19
0.12
0.31
0.08
0.09
0.25
0.18
0.42
0.11
0.12
0.31
0.24
0.55
0.13
0.16
0.38
0.32
0.70
0.16
0.20
0.46
0.40
0.86
0.19
0.25
0.54
0.50
1.04
0.23
0.31
0.64
0.61
1.24
0.27
11050
Max
CFM
for
Evap
0.31
Evap Cooler
6'' Media
w/Prefilter
0.02
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.10
0.11
0.15
0.02
0.03
0.05
0.07
0.10
0.13
0.16
0.20
0.25
0.26
0.03
0.04
0.06
0.09
0.11
0.14
0.18
0.21
0.25
0.27
0.30
0.03
0.04
0.05
0.07
0.09
0.11
0.13
0.16
0.19
0.22
0.25
0.05
0.05
0.07
0.10
0.12
0.15
0.18
0.25
0.34
0.41
0.03
0.05
0.08
0.11
0.15
0.19
0.24
0.30
0.38
0.43
0.04
0.05
0.06
0.07
0.09
0.10
0.12
0.14
0.16
0.18
0.02
0.02
0.04
0.05
0.07
0.10
0.12
0.15
0.18
0.22
0.26
0.30
Evap Cooler
6'' Media
0.01
0.01
0.01
0.02
0.02
0.03
0.04
0.04
0.05
0.07
0.09
0.02
0.02
0.04
0.06
0.08
0.11
0.13
0.16
0.20
0.21
0.02
0.03
0.04
0.06
0.08
0.11
0.13
0.16
0.19
0.21
0.23
0.02
0.02
0.04
0.05
0.06
0.08
0.10
0.11
0.14
0.16
0.18
0.02
0.03
0.04
0.06
0.08
0.10
0.13
0.19
0.26
0.32
0.01
0.03
0.05
0.08
0.11
0.15
0.20
0.25
0.33
0.38
0.02
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.10
0.11
0.01
0.02
0.03
0.04
0.05
0.07
0.09
0.12
0.14
0.17
0.20
0.24
Discharge
Damper
C,D,E,F
0.01
0.01
0.02
0.02
0.03
0.03
0.04
0.04
0.05
0.06
0.08
0.01
0.02
0.03
0.05
0.07
0.09
0.11
0.14
0.17
0.17
0.01
0.02
0.03
0.05
0.06
0.08
0.11
0.13
0.16
0.17
0.19
0.01
0.01
0.02
0.03
0.03
0.05
0.06
0.07
0.09
0.11
0.13
0.03
0.03
0.04
0.05
0.07
0.08
0.10
0.14
0.19
0.23
0.02
0.03
0.05
0.08
0.11
0.15
0.19
0.24
0.32
0.36
0.02
0.02
0.03
0.03
0.04
0.05
0.06
0.06
0.07
0.08
0.02
0.02
0.03
0.04
0.06
0.07
0.09
0.11
0.13
0.15
0.18
0.20
Rainhood and
Birdscreen
100/125
556
600
800
1000
1200
1400
1600
1800
2000
2300
2778
741
1000
1500
2000
2500
3000
3500
4000
4500
4630
1111
1500
2000
2500
3000
3500
4000
4500
5000
5200
5556
1481
2000
2500
3000
3500
4000
4500
5000
5500
6000
6500
1852
2000
2500
3000
3500
4000
4500
5500
6500
7250
1925
3000
4000
5000
6000
7000
8000
9000
10400
11111
2593
3000
3500
4000
4500
5000
5500
6000
6500
7000
2593
3000
4000
5000
6000
7000
8000
9000
10000
11050
12000
13000
Downturn
Plenum
A,B,C,D
2'' Farr 30/30
Filters
75
CFM
2'' Farr
Aeropleat
Filters
Digit 16
Weatherproof Unit Only
2'' Permanent
Filters
Unit Size
All Units
1'' Permanent
Filters
0.00
0.00
0.01
0.01
0.02
0.03
0.04
0.05
0.06
0.08
0.12
0.00
0.01
0.02
0.04
0.07
0.11
0.15
0.19
0.25
0.26
0.02
0.02
0.04
0.05
0.07
0.10
0.13
0.17
0.21
0.23
0.26
0.02
0.03
0.04
0.06
0.09
0.11
0.14
0.18
0.21
0.26
0.30
0.02
0.02
0.03
0.04
0.06
0.08
0.10
0.15
0.21
0.27
0.02
0.04
0.08
0.12
0.18
0.25
0.33
0.42
0.57
0.66
0.02
0.03
0.04
0.05
0.06
0.07
0.09
0.10
0.12
0.14
0.02
0.03
0.05
0.07
0.10
0.14
0.19
0.24
0.30
0.36
0.43
0.51
0.01
0.01
0.02
0.03
0.03
0.04
0.06
0.07
0.08
0.11
0.15
0.03
0.05
0.07
0.10
0.13
0.16
0.19
0.22
0.25
0.26
0.02
0.03
0.05
0.08
0.10
0.14
0.18
0.22
0.27
0.29
0.33
0.03
0.05
0.08
0.10
0.14
0.18
0.22
0.27
0.32
0.38
0.45
0.07
0.08
0.09
0.12
0.14
0.16
0.19
0.25
0.31
0.37
0.07
0.12
0.16
0.22
0.28
0.35
0.42
0.51
0.64
0.71
0.03
0.04
0.05
0.07
0.09
0.11
0.14
0.17
0.20
0.23
0.03
0.04
0.07
0.11
0.17
0.23
0.30
0.38
0.48
0.58
0.69
0.81
0.00
0.01
0.01
0.01
0.01
0.02
0.02
0.03
0.03
0.04
0.06
0.01
0.01
0.02
0.03
0.04
0.05
0.07
0.09
0.11
0.11
0.01
0.01
0.02
0.02
0.04
0.05
0.06
0.08
0.10
0.11
0.13
0.01
0.01
0.02
0.04
0.05
0.06
0.08
0.10
0.12
0.14
0.16
0.02
0.02
0.03
0.04
0.06
0.07
0.09
0.13
0.18
0.23
0.02
0.04
0.07
0.11
0.16
0.21
0.28
0.35
0.47
0.53
0.01
0.01
0.01
0.01
0.02
0.02
0.03
0.04
0.04
0.05
0.01
0.01
0.01
0.02
0.04
0.05
0.08
0.10
0.14
0.17
0.21
0.26
j Accessory / Option static
pressure losses are
approximate values only.
Please consult the Accuspec
selection software for static
pressure losses at other than
listed CFM.
BLOWER PERFORMANCE DATA
Table 39.1 - Unit Performance Tables jk
Air
Digit Temp.
Unit Size 16
Rise
75
A,B
75
C,D
100/125 C,D
Start 125
100/125
E,F
End 100
150/175 C,D
Start 175
150/175
E,F
200/225 C,D
Start 225
200/225
E,F
200/225
G,H
0.25
0.50
0.75
RPM BHP RPM BHP RPM
CFM BHP
0.09
100&deg;F / - 556
0.14
79&deg;F / - 700
0.18
69&deg;F / - 800
56&deg;F / - 1000 0.29
46&deg;F / - 1200 0.45
40&deg;F / - 1400 0.66
35&deg;F / - 1600 0.93
31&deg;F / - 1800 1.28
69&deg;F / - 800
56&deg;F / - 1000
46&deg;F / - 1200 0.19
40&deg;F / - 1400 0.27
35&deg;F / - 1600 0.37
31&deg;F / - 1800 0.49
28&deg;F / - 2000 0.65
24&deg;F / - 2300 0.94
20&deg;F / - 2778 1.59
100&deg;F / - 741
0.13
80&deg;F/100&deg;F 926
62&deg;F/77&deg;F 1200 0.22
53&deg;F/66&deg;F 1400 0.30
41&deg;F/51&deg;F 1800 0.55
34&deg;F/42&deg;F 2200 0.93
28&deg;F/36&deg;F 2600 1.45
25&deg;F/31&deg;F 3000 2.16
41&deg;F/51&deg;F 1800 0.28
34&deg;F/42&deg;F 2200 0.43
28&deg;F/36&deg;F 2600 0.63
25&deg;F/31&deg;F 3000 0.91
22&deg;F/27&deg;F 3400 1.26
20&deg;F/25&deg;F 3704 1.58
- / 23&deg;F 4100 2.09
- / 20&deg;F 4630 2.93
0.19
100&deg;F/117&deg;F 1111
86&deg;F/100&deg;F 1296 0.27
79&deg;F/93&deg;F 1400 0.32
62&deg;F/72&deg;F 1800 0.59
51&deg;F/59&deg;F 2200 1.00
43&deg;F/50&deg;F 2600 1.58
37&deg;F/43&deg;F 3000 2.35
86&deg;F/100&deg;F 1296
79&deg;F/93&deg;F 1400 0.17
62&deg;F/72&deg;F 1800 0.28
51&deg;F/59&deg;F 2200 0.44
43&deg;F/50&deg;F 2600 0.67
37&deg;F/43&deg;F 3000 0.96
33&deg;F/38&deg;F 3400 1.35
29&deg;F/34&deg;F 3800 1.82
26&deg;F/31&deg;F 4200 2.40
24&deg;F/28&deg;F 4700 3.30
21&deg;F/25&deg;F 5200 4.40
100&deg;F/113&deg;F 1481 0.36
89&deg;F/100&deg;F 1667 0.48
85&deg;F/95&deg;F 1750 0.54
74&deg;F/83&deg;F 2000 0.76
66&deg;F/74&deg;F 2250 1.04
59&deg;F/67&deg;F 2500 1.38
54&deg;F/61&deg;F 2750 1.79
49&deg;F/56&deg;F 3000 2.28
85&deg;F/95&deg;F 1750 0.29
74&deg;F/83&deg;F 2000 0.40
59&deg;F/67&deg;F 2500 0.68
49&deg;F/56&deg;F 3000 1.09
42&deg;F/48&deg;F 3500 1.66
37&deg;F/42&deg;F 4000 2.40
33&deg;F/37&deg;F 4500 3.34
30&deg;F/33&deg;F 5000 4.52
85&deg;F/95&deg;F 1750 0.20
74&deg;F/83&deg;F 2000 0.26
59&deg;F/67&deg;F 2500 0.42
49&deg;F/56&deg;F 3000 0.65
42&deg;F/48&deg;F 3500 0.97
37&deg;F/42&deg;F 4000 1.38
33&deg;F/37&deg;F 4500 1.90
30&deg;F/33&deg;F 5000 2.54
27&deg;F/30&deg;F 5500 3.32
25&deg;F/28&deg;F 6000 4.25
679
747
801
917
1042
1173
1308
1445
705
770
839
912
987
1104
1296
670
758
828
982
1145
1315
1489
497
553
614
680
748
802
873
969
727
793
832
994
1166
1344
1526
474
526
588
657
729
804
880
959
1058
1158
871
943
975
1077
1181
1288
1396
1506
594
642
746
857
972
1091
1211
1332
425
449
507
571
639
710
783
858
933
1009
0.15
0.21
0.26
0.39
0.57
0.80
1.09
1.46
0.15
0.20
0.27
36.00
0.47
0.60
0.77
1.08
1.75
0.15
0.21
0.31
0.41
0.69
1.10
1.65
2.39
0.41
0.58
0.81
1.11
1.48
1.83
2.35
3.23
0.28
0.37
0.42
0.72
1.16
1.76
2.57
0.25
0.28
0.41
0.59
0.83
1.15
1.55
2.05
2.66
3.58
4.71
0.48
0.61
0.68
0.92
1.21
1.57
2.00
2.51
0.43
0.54
0.85
1.29
1.88
2.65
3.62
4.82
0.33
0.40
0.58
0.83
1.17
1.60
2.14
2.81
3.61
4.57
871
924
966
1062
1171
1288
1412
1539
795
822
862
912
968
1030
1095
1200
1377
808
846
916
975
1108
1254
1410
1573
622
662
710
766
825
873
938
1028
884
937
970
1109
1264
1429
1600
609
615
650
697
753
815
881
951
1023
1116
1212
1016
1078
1106
1197
1291
1389
1490
1593
723
759
845
942
1047
1157
1270
1387
546
562
603
654
713
776
842
911
982
1054
0.22
0.29
0.35
0.50
0.69
0.94
1.25
0.21
0.28
0.35
0.45
0.57
0.72
0.90
1.22
1.92
0.23
0.29
0.41
0.53
0.83
1.27
1.85
2.61
0.56
0.75
1.00
1.32
1.72
2.08
2.63
3.53
0.38
0.47
0.54
0.86
1.32
1.95
2.78
0.37
0.40
0.55
0.75
1.01
1.35
1.77
2.29
2.92
3.87
0.60
0.75
0.82
1.08
1.39
1.77
2.22
2.75
0.58
0.71
1.04
1.50
2.12
2.91
3.91
0.48
0.56
0.75
1.02
1.38
1.83
2.40
3.08
3.91
4.89
1031
1074
1109
1192
1289
1395
1509
960
975
1003
1041
1087
1139
1197
1292
1456
962
993
1052
1103
1220
1354
1500
1654
735
762
800
847
899
942
1001
1085
1023
1066
1093
1216
1356
1510
1673
734
737
760
796
842
895
955
1018
1085
1172
1144
1198
1224
1306
1393
1484
1579
1677
838
866
938
1024
1119
1221
1329
653
662
692
732
782
839
899
963
1030
1099
.
Total Static Pressure, ''W.C.
1.00
1.25
1.50
2.00
BHP RPM BHP RPM BHP RPM BHP RPM
0.29
0.37
0.44
0.60
0.82
1.08
1.42
0.36
0.44
0.55
0.68
0.84
1.03
1.37
2.09
0.30
0.38
0.52
0.64
0.98
1.44
2.05
2.84
0.72
0.93
1.20
1.54
1.96
2.34
2.91
3.84
0.48
0.59
0.66
1.00
1.49
2.14
3.00
0.70
0.91
1.19
1.55
2.00
2.53
3.18
4.16
0.73
0.88
0.96
1.24
1.57
1.97
2.44
2.98
0.75
0.88
1.23
1.72
2.36
3.18
4.21
0.74
0.94
1.23
1.60
2.08
2.66
3.37
4.22
-
1170
1206
1237
1310
1397
1495
1601
1112
1131
1161
1199
1244
1295
1380
1532
1093
1121
1173
1218
1325
1449
1585
1731
837
855
885
1731
970
1008
1062
1140
1148
1184
1208
1316
1444
1589
1743
859
887
925
972
1025
1083
1145
1227
1259
1309
1332
1407
1488
1573
1663
1756
944
966
1025
1101
1188
1284
1385
754
774
807
850
899
955
1014
1077
-
0.37
0.46
0.54
0.72
0.94
1.23
0.54
0.66
0.80
0.96
1.16
1.52
2.26
0.38
0.47
0.62
0.76
1.12
1.61
2.25
1.12
1.41
1.77
2.21
2.60
3.20
4.16
0.59
0.71
0.78
1.15
1.66
2.34
0.85
1.09
1.39
1.76
2.23
2.79
3.45
4.46
0.85
1.03
1.11
1.40
1.75
2.17
2.66
0.94
1.08
1.45
1.95
2.61
3.46
4.51
1.16
1.45
1.84
2.34
2.94
3.67
4.54
-
1296
1327
1354
1419
1499
1589
1250
1273
1304
1343
1388
1465
1606
1212
1236
1282
1323
1422
1537
1666
942
965
997
1038
1072
1122
1194
1262
1293
1313
1410
1529
1664
952
972
1004
1044
1092
1146
1204
1281
1366
1411
1433
1502
1577
1658
1743
1042
1058
1108
1176
1255
1345
1441
851
877
914
958
1008
1064
1123
-
0.45
0.55
0.64
0.83
1.08
1.38
0.65
0.77
0.92
1.09
1.30
1.67
2.44
0.47
0.56
0.74
0.89
1.27
1.79
2.46
1.33
1.63
2.01
2.47
2.88
3.49
4.48
0.70
0.83
0.91
1.30
1.84
2.54
1.27
1.59
1.98
2.47
3.04
3.73
4.76
0.99
1.17
1.26
1.57
1.94
2.37
2.88
1.14
1.28
1.67
2.19
2.88
3.75
4.82
1.38
1.69
2.10
2.60
3.23
3.98
4.87
-
1411
1438
1462
1522
1595
1680
1361
1377
1403
1437
1477
1547
1679
1320
1342
1384
1422
1513
1621
1744
1025
1042
1068
1104
1135
1180
1247
1369
1395
1412
1500
1610
1737
1052
1078
1114
1157
1206
1260
1333
1465
1507
1527
1592
1663
1739
1820
1134
1146
1188
1248
1320
1404
1495
925
944
975
1014
1061
1112
1168
-
0.63
0.75
0.84
1.07
1.35
1.00
1.17
1.36
1.59
1.98
2.80
0.60
0.77
0.97
1.15
1.58
2.15
1.35
2.51
3.01
3.45
4.10
0.94
1.09
1.18
1.62
2.20
2.95
1.67
2.02
2.45
2.96
3.58
4.30
1.26
1.47
1.57
1.91
2.31
2.78
1.58
1.74
2.15
2.71
3.43
4.35
2.21
2.64
3.18
3.84
4.62
-
1617
1638
1658
1709
1773
1572
1589
1613
1645
1703
1818
1514
1532
1568
1600
1681
1778
1638
1202
1229
1254
1291
1563
1582
1596
1667
1762
1877
1201
1218
1245
1280
1322
1369
1646
1682
1700
1758
1822
1892
1303
1309
1337
1384
1455
1518
1071
1093
1123
1161
1206
-
2.50
3.00
BHP RPM BHP RPM
0.81
0.95
1.06
1.32
1.44
1.65
1.89
2.31
0.86
0.99
1.22
1.42
1.90
2.52
3.04
3.58
4.04
4.74
1.21
1.37
1.47
1.95
2.57
2.47
2.94
3.49
4.14
4.90
1.54
1.77
1.88
2.26
2.69
2.07
2.23
2.67
3.27
4.03
4.98
3.23
3.80
4.48
-
1800
1818
1832
1879
1760
1777
1802
1850
1686
1702
1733
1762
1834
1923
1328
1347
1367
1398
1738
1752
1763
1823
1906
1348
1368
1396
1431
1472
1808
1842
1857
1910
1969
1458
1458
1475
1511
1563
1628
1202
1226
1258
-
1.01
1.17
1.30
1.72
1.94
2.20
2.65
1.07
1.22
1.48
1.70
2.23
2.90
3.60
4.17
4.67
1.48
1.66
1.78
2.29
2.96
2.96
3.45
4.03
4.72
1.84
2.09
2.21
2.62
2.60
2.78
3.24
3.86
3.86
4.46
-
1968
1982
1996
1920
1931
1950
1990
1840
1856
1884
1910
1976
2057
1446
1459
1474
1899
1909
1917
1967
2041
1469
1483
1505
1535
1958
1988
2003
2051
1600
1595
1604
1632
1307
1324
-
j Total static pressure should include external static pressure and accessory / option static pressure from Table 38.1. Unit internal resistance has been included
in the unit performance tables.
k Brake Horsepower and RPM values are approximate values only. Please consult the AccuSpec selection software for values at other than listed CFM / static pressures.
5-594.10
39
BLOWER PERFORMANCE DATA
Table 40.1 - Unit Performance Tables jk
Air
Digit
Temp.
Unit Size 16
Rise
CFM
0.25
0.50
BHP RPM BHP RPM
532
250/300 E,F 100&deg;F / 120&deg;F 1852M 0.26
0.39
582
83&deg;F / 100&deg;F 2222
Start 300
0.51
625
74&deg;F / 89&deg;F 2500
0.80
706
62&deg;F / 74&deg;F 3000
1.19
793
53&deg;F / 63&deg;F 3500
1.69
882
46&deg;F / 56&deg;F 4000
2.34
974
41&deg;F / 49&deg;F 4500
3.14 1067
37&deg;F / 44&deg;F 5000
4.11 1161
34&deg;F / 40&deg;F 5500
250/300 G,H 100&deg;F / 120&deg;F 1852
Start 300
0.28
424
83&deg;F / 100&deg;F 2222
0.35
447
74&deg;F / 89&deg;F 2500
0.53
492
62&deg;F / 74&deg;F 3000
0.76
542
53&deg;F / 63&deg;F 3500
1.07
594
46&deg;F / 56&deg;F 4000
1.45
649
41&deg;F / 49&deg;F 4500
1.92
706
37&deg;F / 44&deg;F 5000
2.50
767
34&deg;F / 40&deg;F 5500
3.16
822
31&deg;F / 37&deg;F 6000
3.96
881
28&deg;F / 34&deg;F 6500
250/300 I, J, K 46&deg;F / 56&deg;F 4000
37&deg;F / 44&deg;F 5000
1.94
559
31&deg;F / 37&deg;F 6000
2.93
632
26&deg;F / 32&deg;F 7000
4.24
707
23&deg;F / 28&deg;F 8000
6.40
804
20&deg;F / 24&deg;F 9259
End 250
10000 7.97
862
- / 22&deg;F
11111 10.79 949
- / 20&deg;F
2593
0.61
668
100&deg;F / 350/400 E,F
2700
0.67
686
96&deg;F / 0.85
730
87&deg;F / 100&deg;F 2963
Start 400
1.30
826
74&deg;F / 85&deg;F 3500
1.86
918
65&deg;F / 74&deg;F 4000
2.57 1012
58&deg;F / 66&deg;F 4500
3.44 1109
52&deg;F / 59&deg;F 5000
4.50 1206
47&deg;F / 54&deg;F 5500
2593
0.43
479
100&deg;F / 350/400 G,H
0.57
516
87&deg;F / 100&deg;F 2963
Start 400
0.85
574
74&deg;F / 85&deg;F 3500
1.19
631
65&deg;F / 74&deg;F 4000
1.61
690
58&deg;F / 66&deg;F 4500
2.22
767
52&deg;F / 59&deg;F 5000
2.77
813
47&deg;F / 54&deg;F 5500
3.53
876
43&deg;F / 49&deg;F 6000
4.42
939
40&deg;F / 46&deg;F 6500
2593
100&deg;F / 350/400 I,J,K
Start 400
87&deg;F / 100&deg;F 2963
65&deg;F / 74&deg;F 4000
1.37
515
52&deg;F / 59&deg;F 5000
2.20
588
43&deg;F / 49&deg;F 6000
3.34
665
37&deg;F / 42&deg;F 7000
4.84
744
32&deg;F / 37&deg;F 8000
6.75
824
29&deg;F / 33&deg;F 9000
906
26&deg;F / 30&deg;F 10000 9.13
24&deg;F / 27&deg;F 11000 12.01 988
23&deg;F / 26&deg;F 11500 13.66 12.09
0.39
0.54
0.68
0.99
1.41
1.94
2.62
3.44
4.44
0.34
0.43
0.52
0.72
0.98
1.31
1.72
2.22
2.81
3.52
4.34
0.97
1.51
2.29
3.33
4.69
6.91
8.52
11.40
0.80
0.87
1.06
1.54
2.13
2.87
3.78
4.87
0.62
0.79
1.09
1.45
1.91
2.46
3.12
3.91
4.82
1.07
1.69
2.58
3.77
5.33
7.29
9.72
12.66
14.34
665
703
736
803
878
958
1043
1130
1219
519
537
553
588
878
673
721
771
824
878
934
507
560
620
686
755
846
901
985
781
796
834
917
1000
1087
1177
1269
585
614
662
710
762
817
874
933
992
533
590
654
723
796
871
948
1027
1067
0.75
BHP RPM
0.54
0.70
0.85
1.19
1.64
2.20
2.90
3.76
4.78
0.49
0.61
0.71
0.93
1.21
1.57
2.00
2.52
3.14
3.87
4.72
1.25
1.84
2.66
3.75
5.16
7.45
9.09
12.03
1.01
1.08
1.28
1.80
2.42
3.18
4.12
0.84
1.02
1.35
1.74
2.22
2.80
3.49
4.30
0.77
0.89
1.37
2.04
2.97
4.22
5.83
7.85
10.33
13.32
-
782
810
836
893
959
1032
1109
1191
1275
623
634
646
674
707
746
789
834
882
933
984
583
626
679
738
802
887
939
1020
882
895
928
1002
1078
1158
1242
679
702
742
784
830
880
933
987
561
571
609
658
715
778
845
917
990
1065
-
.
Total Static Pressure, ''W.C.
1.00
1.25
1.50
BHP RPM BHP RPM BHP
RPM
0.69
0.87
1.04
1.40
1.87
2.46
3.19
4.08
0.66
0.79
0.90
1.15
1.45
1.83
2.29
2.84
3.49
4.24
1.56
2.19
3.06
4.19
5.64
7.99
9.67
12.66
1.22
1.30
1.52
2.07
2.71
3.51
4.47
1.09
1.28
1.63
2.04
2.55
3.15
3.87
4.70
1.04
1.18
1.69
2.41
3.39
4.68
6.34
8.41
10.95
14.00
-
887
909
930
978
1036
1102
1174
1250
713
721
730
752
780
814
852
894
938
984
654
688
734
788
847
927
977
1054
975
986
1015
1081
1151
1226
1305
764
782
815
853
895
940
989
1040
639
646
679
721
772
830
893
960
1030
1103
-
0.85
1.05
1.23
1.62
2.12
2.73
3.49
4.40
0.85
0.99
1.11
1.38
1.71
2.11
2.59
3.16
3.83
4.61
1.89
2.56
3.46
4.64
6.14
8.55
10.27
13.31
1.45
1.53
1.76
2.34
3.01
3.84
4.84
1.35
1.56
1.93
2.36
2.89
3.52
4.25
1.34
1.49
2.03
2.79
3.82
5.16
6.87
8.99
11.58
14.68
-
985
1000
1016
1058
1109
1170
1236
1308
795
800
806
824
848
878
912
950
991
1035
719
748
787
836
891
966
1014
1087
1061
1071
1097
1157
1221
1291
1366
841
856
885
918
956
998
1042
709
715
742
779
826
879
938
1002
1069
1139
-
1.03
1.24
1.43
1.84
2.36
3.01
3.79
4.73
1.05
1.20
1.33
1.62
1.97
2.39
2.90
3.50
4.19
5.00
2.24
2.95
3.89
5.11
6.65
9.12
10.87
13.97
1.69
1.78
2.02
2.62
3.32
4.18
1.64
1.86
2.25
2.70
3.25
3.90
4.66
1.66
1.81
2.40
3.19
4.26
5.65
7.41
9.58
12.22
-
1074
1085
1099
1133
1179
1234
1296
1364
870
872
877
892
912
939
969
1004
1042
1084
781
804
838
882
933
1004
1050
1121
1142
1151
1174
1228
1288
1353
1142
926
951
980
1014
1053
1095
774
779
802
835
877
927
982
1043
1107
-
2.00
BHP RPM
1.39
1.64
1.85
2.31
2.88
3.58
4.41
1.47
1.65
1.81
2.13
2.52
2.99
3.54
4.18
4.93
3.77
4.79
6.09
7.72
10.30
12.12
2.19
2.29
2.56
3.22
3.97
4.88
2.26
2.50
2.93
3.41
4.00
4.70
2.36
2.54
3.18
4.05
5.20
6.68
8.53
10.80
13.54
-
1239
1242
1250
1275
1312
1358
1412
1005
1005
1006
1016
1031
1052
1077
1107
1140
908
935
971
1015
1079
1120
1290
1297
1316
1362
1414
1472
1046
1053
1072
1096
1124
1157
891
894
910
937
973
1016
1066
1121
1180
-
2.50
BHP RPM
1.79
2.06
2.30
2.81
3.42
4.17
1.94
2.14
2.32
2.68
3.11
3.62
4.22
4.90
4.67
5.75
7.13
8.83
11.52
13.41
2.73
2.84
3.13
3.84
4.65
2.94
3.20
3.66
4.19
4.81
3.14
3.34
4.04
4.98
6.21
7.77
9.70
12.07
14.90
-
1387
1385
1389
1406
1435
1474
1126
1123
1123
1129
1140
1156
1177
1202
1005
1025
1055
1093
1150
1187
1425
1431
1446
1486
1531
1165
1170
1183
1202
1226
995
997
1009
1030
1061
1099
1144
1194
1249
-
3.00
BHP RPM
2.21
2.52
2.78
3.33
3.99
4.78
2.44
2.67
2.87
3.27
3.74
4.28
4.92
6.77
8.22
10.00
12.79
14.74
3.30
3.42
3.74
4.50
3.68
3.96
4.45
4.00
4.20
4.96
5.96
7.26
8.90
10.92
13.37
-
1523
1517
1517
1529
1552
1584
1237
1231
1230
1232
1240
1253
1270
1110
1134
1167
1218
1252
1550
1555
1568
1602
1275
1277
1287
1090
1091
1099
1117
1144
1178
1219
1265
-
j Total static pressure should include external static pressure and accessory / option static pressure from Table 38.1. Unit internal resistance has been included in the
unit performance tables.
k Brake Horsepower and RPM values are approximate values only. Please consult the AccuSpec selection software for values at other than listed CFM / static pressures.
40
5-594.10
BLOWER PERFORMANCE DATA
Table 41.1 - Unit Performance Tables jk
Unit
Size
500/600
Digit 16
G or H
Start 600
500/600
Start 600
I, J, K
End 500
500/600
L
Start 500
700/800
G or H
Start 800
700/800
Start 800
I, J, K
700/800
L
End 700
840/960
I, J, K
End 840
840/960
End 840
L
Air
Temp
Rise
120&deg;F / 106&deg;F / 100&deg;F / 120&deg;F
93&deg;F / 111&deg;F
82&deg;F / 99&deg;F
74&deg;F / 89&deg;F
67&deg;F / 81&deg;F
62&deg;F / 74&deg;F
57&deg;F / 68&deg;F
120&deg;F / 100&deg;F / 120&deg;F
93&deg;F / 111&deg;F
74&deg;F / 89&deg;F
62&deg;F / 74&deg;F
53&deg;F / 63&deg;F
46&deg;F / 56&deg;F
41&deg;F / 49&deg;F
- / 44&deg;F
- / 43&deg;F
- / 40&deg;F
- / 40&deg;F
62&deg;F / 74&deg;F
53&deg;F / 63&deg;F
46&deg;F / 56&deg;F
41&deg;F / 49&deg;F
- / 44&deg;F
- / 43&deg;F
- / 40&deg;F
- / 40&deg;F
120&deg;F / 115&deg;F / 105&deg;F / 120&deg;F
104&deg;F / 119&deg;F
94&deg;F / 108&deg;F
86&deg;F / 99&deg;F
80&deg;F / 91&deg;F
120&deg;F / 104&deg;F / 119&deg;F
86&deg;F / 99&deg;F
65&deg;F / 74&deg;F
58&deg;F / 66&deg;F
52&deg;F / 59&deg;F
47&deg;F / 54&deg;F
43&deg;F / 49&deg;F
40&deg;F / 46&deg;F
65&deg;F / 74&deg;F
58&deg;F / 66&deg;F
52&deg;F / 59&deg;F
47&deg;F / 54&deg;F
47&deg;F / 54&deg;F
43&deg;F / 49&deg;F
40&deg;F / 46&deg;F
- / 42&deg;F
- / 41&deg;F
120&deg;F / 111&deg;F / 105&deg;F / 120&deg;F
97&deg;F / 111&deg;F
86&deg;F / 99&deg;F
78&deg;F / 89&deg;F
70&deg;F / 80&deg;F
65&deg;F / 74&deg;F
62&deg;F / 71&deg;F
60&deg;F / 68&deg;F
86&deg;F / 99&deg;F
78&deg;F / 89&deg;F
70&deg;F / 80&deg;F
65&deg;F / 74&deg;F
60&deg;F / 68&deg;F
- / 63&deg;F
Total Static Pressure Inches &quot;W.C.
0.25
0.50
0.75
1.00
1.25
1.50
2.00
2.50
3.00
CFM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM
3086
3500
3704
4000
4500
5000
5500
6000
6500
3086
3704
4000
5000
6000
7000
8000
9000
10000
10400
11000
11111
6000
7000
8000
9000
10000
10400
11000
11111
4321
4500
4938
5000
5500
6000
6500
4321
5000
6000
8000
9000
10000
11000
12000
13000
8000
9000
10000
11000
11050
12000
13000
14000
14500
6481
7000
7407
8000
9000
10000
11050
12000
12500
13000
9000
10000
11050
12000
13000
14000
0.62 529
0.84 575
0.97 598
1.18 633
1.61 693
2.13 755
2.77 818
3.53 882
4.41 946
0.46 401
0.69 443
0.82 464
1.43 542
2.31 624
3.51 709
5.09 797
7.11 885
9.62 975
10.77 1011
12.66 1065
13.04 1075
1.69 512
2.57 580
3.73 650
5.21 721
7.04 793
7.88 823
9.27 866
9.54 874
1.51 685
1.68 708
2.15 763
2.23 770
2.89 834
3.68 900
4.61 965
0.87 443
1.26 488
2.02 558
4.44 707
6.19 784
8.36 861
11.00 940
14.16 1019
17.88 1098
3.26 566
4.54 626
6.13 687
8.06 749
8.17 752
10.37 811
13.09 873
16.26 936
18.02 968
2.72 630
3.36 672
3.93 705
4.87 754
6.80 837
9.20 921
12.28 1010
15.60 1091
17.58 1134
19.71 1177
5.01 675
6.78 742
9.04 812
11.48 876
14.50 945
18.02 1013
0.82
1.06
1.20
1.43
1.88
2.43
3.10
3.89
4.80
0.69
0.95
1.09
1.75
2.68
3.94
5.57
7.65
10.21
11.38
13.31
13.69
1.97
2.89
4.09
5.60
7.48
8.34
9.75
10.03
1.80
1.98
2.48
2.55
3.25
4.06
1.14
1.55
2.36
4.89
6.69
8.91
11.60
14.81
18.59
3.60
4.92
6.54
8.52
8.62
10.86
13.63
16.83
18.61
3.09
3.76
4.35
5.33
7.31
9.76
12.89
16.27
18.27
5.40
7.21
9.51
12.00
15.05
18.61
620
658
678
709
762
818
876
936
996
496
527
544
609
682
760
842
926
1012
1046
1099
1109
565
626
691
758
827
855
897
905
760
780
89
836
895
956
421
558
619
755
827
901
976
1052
1129
611
667
724
782
785
842
902
963
994
685
723
754
799
878
958
1044
1123
1164
715
778
845
907
973
1039
1.03
1.30
1.45
1.69
2.17
2.75
3.44
4.25
0.95
1.23
1.39
2.09
3.07
4.38
6.07
8.20
10.81
12.01
13.97
14.36
2.26
3.22
4.46
6.01
7.93
8.80
10.24
10.52
2.11
2.30
2.82
2.90
3.62
4.46
1.42
1.87
2.73
5.35
7.20
9.47
12.22
15.48
19.30
3.95
5.30
6.97
8.98
9.09
11.37
14.17
17.41
19.21
3.48
4.17
4.79
5.90
7.83
10.33
13.52
16.95
18.97
5.80
7.64
9.99
12.51
15.62
19.21
703 1.26
736 1.54
753 1.70
779 1.96
827 2.46
878 3.07
932 3.79
988 4.63
580 1.23
604 1.54
618 1.71
673 2.46
738 3.48
809 4.84
886 6.58
965 8.76
1048 11.43
1081 12.64
1132 14.64
1141 15.03
615 2.57
671 3.56
731 4.84
795 6.43
860 8.39
887 9.28
927 10.74
935 11.02
830 2.43
847 2.63
893 3.17
899 3.26
953 4.00
1010 4.87
591 1.72
623 2.20
677 3.10
801 5.82
869 7.72
939 10.04
1011 12.84
1085 16.15
1159
654 4.31
706 5.70
760 7.40
815 9.45
818 9.56
872 11.88
930 14.72
989 18.00
1019 19.82
736 3.88
772 4.60
800 5.23
843 6.27
918 8.36
995 10.91
1078 14.16
1154 17.63
1194 19.69
753 6.21
812 8.09
877 10.48
937 13.04
1000 16.18
1065 19.82
779
807
822
846
889
936
986
1038
657
675
686
733
791
857
928
1001
1083
1115
1164
1174
664
714
770
830
892
918
957
964
896
912
953
959
1009
1062
657
683
731
845
909
976
1045
1117
696
744
794
847
850
902
958
1015
1045
785
818
845
885
956
1030
1110
1184
1224
789
846
908
966
1028
1091
1.50
1.80
1.97
2.24
2.77
3.40
4.15
2.05
2.84
3.91
5.31
7.10
9.33
12.05
13.29
15.32
15.72
2.89
3.92
5.23
6.86
8.85
9.76
11.24
11.53
2.77
2.98
3.54
3.63
4.40
2.04
2.54
3.49
6.30
8.25
10.62
13.47
16.83
4.67
6.10
7.85
9.93
10.04
12.40
15.27
18.59
4.30
5.04
5.69
6.76
8.90
11.50
14.80
18.32
6.62
8.54
10.97
13.57
16.75
-
849
874
887
908
948
991
1038
749
790
842
903
970
1042
1118
1149
1197
1205
710
756
808
864
924
949
986
993
958
973
1011
1016
1063
717
740
782
888
949
1012
1079
1148
736
780
828
879
881
931
986
1041
832
863
888
926
994
1065
1142
1214
825
879
939
994
1054
-
1.75
2.07
2.25
2.53
3.09
3.74
4.51
2.42
3.24
4.35
5.80
7.64
9.92
12.69
13.95
16.01
16.41
3.23
4.29
5.64
7.30
9.33
10.25
11.76
12.05
3.13
3.34
3.93
4.02
4.81
2.37
2.90
3.89
6.79
8.79
11.21
14.11
17.52
5.05
6.52
8.30
10.42
10.53
12.92
15.83
19.19
4.72
5.49
6.16
7.26
9.44
12.10
15.45
19.02
7.05
9.00
11.47
14.11
17.33
-
916
937
949
968
1001
1044
1088
810
844
891
947
1010
1079
1152
1182
1228
1237
755
797
845
898
955
979
1015
1022
1018
1032
1066
1072
1116
774
794
832
930
987
1048
1112
1179
774
816
861
910
912
960
1013
1066
876
905
929
965
1030
1099
1173
1243
859
911
968
1022
1081
-
2.28
2.63
2.83
3.14
3.74
4.44
4.09
5.29
6.82
8.75
11.13
14.00
15.30
17.42
17.83
5.06
6.47
8.21
10.31
11.26
12.81
13.12
3.88
4.11
4.74
4.83
3.08
3.66
4.73
7.81
9.90
12.42
15.41
18.92
5.84
7.37
9.22
11.41
11.53
13.99
16.98
5.60
6.42
7.13
8.28
10.56
13.32
16.77
7.91
9.95
12.50
15.20
18.50
-
1038
1054
1064
1080
1110
1145
946
984
1032
1089
1151
1218
1247
1290
1298
874
916
964
1016
1038
1071
1078
1131
1142
1172
1176
879
894
924
1009
1061
1117
1176
1239
848
885
925
969
972
1016
1065
960
986
1007
1040
1100
1164
1234
925
973
1026
1076
1132
-
2.84 1149
3.23 1162
3.44 1170
3.78 1183
4.43 1208
5.01 1041
6.28 1072
7.90 1113
9.92 1163
12.38 1220
15.35 1283
7.35 984
9.16 1027
11.33 1074
12.31 1095
13.90 1126
14.21 1132
4.69 1236
4.94 1245
3.84 974
4.47 985
5.62 1010
8.87 1085
11.04 1131
13.66 1183
16.74 1238
6.66 918
8.25 950
10.17 987
12.43 1027
12.56 1029
15.08 1070
18.14 1116
6.52 1038
7.38 1061
8.13 1081
9.33 1111
11.71 1166
14.56 1226
8.81 988
10.91 1032
13.54 1081
16.32 1129
19.70 1181
-
3.44
3.86
4.09
4.45
7.33
9.03
11.13
13.69
10.14
12.38
13.38
4.65
5.33
6.55
9.96
12.23
14.93
7.51
9.17
11.15
13.48
13.61
16.20
19.33
7.48
8.39
9.17
10.43
12.90
9.73
11.91
14.61
17.46
-
1252
1262
1268
1279
1155
1191
1235
1287
1088
1131
1150
1063
1071
1091
1156
1199
1246
984
1012
1046
1083
1084
1123
1166
1112
1133
1151
1179
1230
1048
1088
1135
1179
-
j Total static pressure should include external static pressure and accessory / option static pressure from Table 38.1. Unit internal resistance has been included in the unit
performance tables.
k Brake Horsepower and RPM values are approximate values only. Please consult the AccuSpec selection software for values at other than listed CFM / static pressures.
5-594.10
41
BLOWER SHEAVE ASSEMBLY DATA
Adjusting the Blower Drive Sheave Setting
All units include a sheave assembly indicated by Digit 19 of
the model nomenclature. Within that assembly are the fixed
blower sheave, adjustable motor sheave, and belt(s) to provide
a method of adjusting the blower speed to balance the airflow
based on actual external static pressure for the installation.
The motor sheave is adjusted at the factory for external
static conditions indicated on the order detail, however actual
external static often varies from design, resulting in a need to
adjust the equipment to provide correct design airflow.
To determine how many turns open the motor sheave should
be set for:
1.
2.
3.
4.
Locate the unit Model Identification Plate and identify the
following model number digits:
a. Digits 4-6 = Model Size
b. Digit 16 = Blower Size
c. Digit 19 = Sheave Arrangement
Use Table 38.1 to determine the individual static pressure
drops for any features included on the unit for the design
airflow. Add those and the design external static pressure
to calculate the total static pressure.
Use Tables 39.1 through 41.1 to determine the blower
speed (RPM) required to meet the job requirements.
Use Table 43.1 to determine the RPM range and
approximately blower speeds for each 1/2 turn open of the
adjustable motor sheave. Find the RPM that is closest
to one value shown to determine the turns open and set
the motor sheave as described in the section &quot;Blower
Adjustments&quot; on page 23.
Example:
Determine motor sheave turns open for a unit operating at
4000 CFM with a design external static pressure (ESP) of
0.60&quot;W.C. as follows:
1.
2.
3.
4.
From the Model Nomenclature:
a. Model size (Model Digit 4-6) = 400
b. Blower size (Model Digit 16) = E
c. Sheave arrangement (Model Digit 19) = J
From Table 38.1, the unit includes 2&quot; Farr 30/30
Filters (0.08&quot;W.C. static) and Rainhood &amp; Birdscreen
(0.07&quot;W.C. static). Total static pressure is
0.08+0.07+0.60=0.75&quot;W.C.
From Table 40.1, the blower speed is 1078 RPM.
From Table 43.1, the blower range is 1029-1332 RPM.
The closest value to 1078 RPM in the row of Blower
RPM by Sheave Turns Open is 1090 RPM, which
corresponds to 4.0 turns open.
If actual job ESP after installation was measured at
0.75&quot;W.C., the process above would be repeated with the
new TSP of 0.90&quot;W.C.
Figure 42.1 - Blower Section
EXTENDED GREASE
LINE ZERK FITTINGS
(OPTION)
ADJUSTABLE
MOTOR SHEAVE
ON MOTOR
EXTENDED
GREASE LINES
(OPTION)
1/4&quot; PERIMETER
GASKETED BLOWER
CONNECTION
FILTER RACK
BOTTOM SUPPORTED
BLOWER AND MOTOR
DIRECT DRIVE
DAMPER ACTUATOR
CONVENIENCE
OUTLET (OPTION)
BLOWER DOOR
SAFETY SWITCH
(OPTION)
42
5-594.10
BLOWER SHEAVE ASSEMBLY DATA
Table 43.1 - Sheave Assembly Data
Blower Type
Digit 16
A or B
(9-7 Blower)
C or D
(9-9 Blower)
Sheave
Digit 19
A, B
C, D, E
F, G
H, I
J, K
A, B
C, D, E
F, G, H
I, J, K
L,M,N
A, B
C, D, E
E or F
(12-12 Blower)
F, G, H
I, J, K, Q
L,M,N
O, P
A, B, C
G or H
(15-15 Blower)
D, E, F
G, H, I
J, K, L, O
M, N
A, B, C
I or J
(18-18 Blower with
Under 15 HP Motor)
K
(18-18 Blower with
15 HP Motor &amp; Up)
D, E, F, G
H, I, J
K, L, M, N
O, P, Q, R
S, T, U
A, B, G, H
C, D, I, J
E, F, K, L
M, N
A, B
C, D, E
L
(20-18 Blower)
F, G, H, I, J, K
L, M, N, O, P, Q
R, S, T, U, V
W, X, Y, Z
Blower RPM by Sheave Turns Open Setting (Approx.)
RPM Range
656-1001
978-1265
1150-1561
1526-1858
1763-2147
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
1001
1265
1561
1858
2147
967
1236
1520
1825
2109
932
1208
1479
1792
2070
898
1179
1438
1758
2032
863
1150
1397
1725
1993
829
1122
1356
1692
1955
794
1093
1314
1659
1917
760
1064
1273
1626
1878
725
1035
1232
1592
1840
691
1007
1191
1559
1801
656
978
1150
1526
1763
656-1001
978-1265
1150-1561
1526-1858
1763-2147
1001
1265
1561
1858
2147
967
1236
1520
1825
2109
932
1208
1479
1792
2070
898
1179
1438
1758
2032
863
1150
1397
1725
1993
829
1122
1356
1692
1955
794
1093
1314
1659
1917
760
1064
1273
1626
1878
725
1035
1232
1592
1840
691
1007
1191
1559
1801
656
978
1150
1526
1763
468-715
644-874
863-1078
1029-1332
1150-1438
1327-1659
715
874
1078
1332
1438
1659
690
851
1057
1302
1409
1626
666
828
1035
1271
1380
1593
641
805
1014
1241
1352
1559
616
782
992
1211
1323
1526
592
759
971
1181
1294
1493
567
736
949
1150
1265
1460
542
713
928
1120
1236
1427
517
690
906
1090
1208
1393
493
667
885
1059
1179
1360
468
644
863
1029
1150
1327
410-625
568-771
767-958
934-1136
1136-1380
625
771
958
1136
1380
604
751
939
1116
1356
582
730
920
1096
1331
561
710
901
1075
1307
539
690
882
1055
1282
518
670
863
1035
1258
496
649
843
1015
1234
475
629
824
995
1209
453
609
805
974
1185
432
588
786
954
1160
410
568
767
934
1136
491-649
586-744
682-821
821-1009
995-1161
1101-1285
649
744
821
1009
1161
1285
633
728
807
990
1144
1267
617
712
793
971
1128
1248
602
697
779
953
1111
1230
586
681
765
934
1095
1211
570
665
752
915
1078
1193
554
649
738
896
1061
1175
538
633
724
877
1045
1156
523
618
710
859
1028
1138
507
602
696
840
1012
1119
491
586
682
821
995
1101
826-1009
995-1161
1101-1285
1232-1438
1009
1161
1285
1438
991
1144
1267
1417
972
1128
1248
1397
954
1111
1230
1376
936
1095
1211
1356
918
1078
1193
1335
899
1061
1175
1314
881
1045
1156
1294
863
1028
1138
1273
844
1012
1119
1253
826
995
1101
1232
491-649
626-765
765-901
901-1059
995-1161
1101-1285
649
765
901
1059
1161
1285
633
751
887
1043
1144
1267
617
737
874
1027
1128
1248
602
723
860
1012
1111
1230
586
709
847
996
1095
1211
570
696
833
980
1078
1193
554
682
819
964
1061
1175
538
668
806
948
1045
1156
523
654
792
933
1028
1138
507
640
779
917
1012
1119
491
626
765
901
995
1101
5-594.10
43
DIMENSIONS - UNIT
Figure 44.1 - DBS Separated Combustion Blower Package Unit Dimensions
Qty (4) Drill Locator
Dimples for Field
Drilled Electrical
Conduit Entry Holes
(spaced 2.0&quot; apart)
500 - 800 Model Shown
Figure 44.2 - DCS Separated Combustion Cooling Package Unit Dimensions
108.94
33.84
23.95
2.00
20.00
Outlet Air
Duct
Connection
F (Height)
X
E (Width)
(Inside)
4.50
51.15
Qty (4) Drill Locator
Dimples for Field
Drilled Electrical
Conduit Entry Holes
(spaced 2.0&quot; apart)
J
(Over Roof)
2.20
34.25
1.90
&Oslash;N
5
Exhaust
&Oslash; P Combustion
5
Air Inlet
19.23
D
A
24.00
(Inside)
G
(Inside)
24.00
(Inside)
L
4.24
7.30
K
M
2
1
10.26
7.65
9.21
24.00
4.35
(Inside)
Return Air Duct Connection
24.92
6.38
5.29
H
6.38 9.21
5.29
1
2
3
4
3.00
1.50
111.68
Table 44.1 - Indoor Separated Combustion Unit Dimensions (All dimensions in inches)
Dimensions
Model Blower Type Qty. of
Gas
Size
(Digit 16) Furnaces A
B
C
D
E
F
G
H
J
K
L
M
Nn Pn
S
Y Conn.
75
All
100/125
All
150/175
All
200/225
All
250/300 E, F, G, or H
350/400 E, F, G, or H
500/600
G or H
700/800
G or H
1
1
1
1
1
1
2
2
33.75 18.90 15.18 28.75 18.00 25.00
33.75 18.90 17.67 28.75 21.00 25.00
33.75 18.90 21.95 28.75 24.00 25.00
37.75 22.90 24.05 32.75 27.00 28.00
37.75 22.90 27.05 32.75 30.00 28.00
37.75 22.90 38.60 32.75 42.00 28.00
37.75 22.90 27.05 32.75 n/a
n/a
37.75 22.90 38.60 32.75 n/a
n/a
20.02
20.02
23.99
23.99
29.96
41.90
29.96
41.90
39.23 32.06 10.26 23.08 18.19
39.23 34.56 10.26 23.08 18.19
39.23 38.82 10.26 23.08 18.19
43.23 40.94 9.60 26.43 19.21
43.23 44.05 9.60 26.43 19.21
43.23 55.57 9.60 26.43 19.21
43.23 44.05 9.60 26.43 19.21
43.23 55.57 9.60 26.43 19.21
3.86
3.86
3.86
5.86
5.86
5.86
5.86
5.86
4.17 87.77 85.69
4.17 87.77 85.69
4.17 87.77 85.69
6.18 87.77 85.69
6.18 87.77 85.69
6.18 87.77 85.69
6.18 128.77 126.78
6.18 128.77 126.78
j For Right Hand Access Units - Location of drill locator dimples for field drilled gas connection entry holes - one side of unit and one on bottom.
k For Left Hand Access Units - Location of drill locator dimples for field drilled gas connection entry holes - one side of unit and one on bottom.
l For Right Hand Access Units - Location of drill locator dimples for field drilled electrical connection entry holes - identical sizes as side electrical connections.
m For Left Hand Access Units - Location of drill locator dimples for field drilled electrical connection entry holes - identical sizes as side electrical connections.
n Nominal vent pipe size is 4&quot; (Models 75-175) and 6&quot; (Models 200-800). Exhaust pipe installed over collar. Combustion air pipe installed collar.
44
5-594.10
1/2
1/2
1/2
1/2
3/4
3/4
3/4
3/4
DIMENSIONS - UNIT
Figure 45.1 - DBS Separated Combustion Blower Package Unit Dimensions with Blower Type I, J, K, or L
500 - 800 Model Shown
Figure 45.2 - DCS Separated Combustion Cooling Package Unit Dimensions with Blower Type I, J, or K
Table 45.1 - Indoor Separated Combustion Unit Dimensions with Blower I, J, K, or L (All dimensions in inches)
Dimensions
Model Blower Type Qty. of
Size
(Digit 16) Furnaces C
E
G
J
S
Uo Wo Xo
Y
Gas
Conn.
250/300
I, J, or K
1
27.05 30.00 29.96 44.05 123.63
n/a
n/a
n/a
121.53
3/4
350/400
I, J, or K
1
38.60 42.00 41.90 55.57 123.63
n/a
n/a
n/a
121.53
3/4
500/600
I, J, K, or L
2
27.05
n/a
29.96 44.05 164.63 29.74 6.50 41.62 162.63
3/4
700/800
I, J, K, or L
2
38.60
n/a
41.90 55.57 164.63 29.74 6.50 41.62 162.63
3/4
840/960
I, J, K, or L
3
38.60
n/a
41.90 55.57 205.77 29.74 6.50 41.62 203.72
3/4
j For Right Hand Access Units - Location of drill locator dimples for field drilled gas connection entry holes - one side of unit and one on bottom.
k For Left Hand Access Units - Location of drill locator dimples for field drilled gas connection entry holes - one side of unit and one on bottom.
l For Right Hand Access Units - Location of drill locator dimples for field drilled electrical connection entry holes - identical sizes as side electrical connections.
m For Left Hand Access Units - Location of drill locator dimples for field drilled electrical connection entry holes - identical sizes as side electrical connections.
n Nominal vent pipe size is 4&quot; (Models 75-175) and 6&quot; (Models 200-800). Exhaust pipe installed over collar. Combustion air pipe installed collar.
o Applies to units with Digit 16 = L only.
5-594.10
45
DIMENSIONS - UNIT
Figure 46.1 - Unit Base Dimensions
A
0.63
2.36
C
(TO END OF UNIT)
M
0.75&quot; SUSPENSION
HANGING LOCATIONS
(TYPICAL 4 CORNERS)
RETURN
AIR
OPENING
(OPTIONAL)
B
J
E
(Inside)
SUSPENSION
POINT
24.00
(Inside)
Suspension
SUSPENSION
PointPOINT
LIFTING
POINTt
LIFTING
POINTt
D
K
M
4.35
1.45
L
N
Table 46.1 - Indoor Separated Combustion Blower Package Units (All dimensions in inches)
Model
Blower Type
Size
(Digit 16)
A
B
C
75
100/125
150/175
200/225
250/300
250/300
350/400
350/400
500/600
500/600
700/800
700/800
840/960
All
All
All
All
E,F,G, or H
I, J, or K
E,F,G, or H
I, J, or K
G, or H
I, J, K, or L
G, or H
I, J, K, or L
I, J, K, or L
87.77
87.77
87.77
87.77
87.77
123.62
87.77
123.62
128.77
164.63
128.77
164.63
205.77
34.85
37.36
41.61
43.71
46.75
46.75
58.27
58.27
46.75
46.75
58.27
58.27
58.27
D
84.73
84.73
84.73
84.73
84.73
120.57
84.73
120.57
119.54
42.00
155.41
42.00
119.54
42.00
155.41
42.00
196.52
48.58
Dimensions
E
F
G
19.52
19.52
23.49
23.49
29.46
29.46
41.40
41.40
29.46
29.46
41.40
41.40
41.40
81.88
81.88
81.88
81.88
81.88
117.73
81.88
117.73
81.88
117.73
81.88
117.73
117.73
N
K
L
56.96
56.96
56.96
56.96
56.96
92.81
56.96
92.81
56.96
97.03
42.00
92.81 125.70 90.15
56.96
97.03
42.00
92.81 125.70 90.15
92.81 166.84 82.94 166.84
Table 46.2 - Indoor Separated Combustion Cooling Package Units (All dimensions in inches)
Dimensions
Model
Blower Type
Size
(Digit 16)
A
B
C
E
F
G
J
M
75
100/125
150/175
200/225
250/300
250/300
350/400
350/400
All
All
All
All
E, F, G, or H
I, J, or K
E, F, G, or H
I, J, or K
111.75
111.75
111.75
111.75
111.75
147.60
111.75
147.60
34.85
37.36
41.61
43.71
46.75
46.75
58.27
58.27
108.75
108.75
108.75
108.75
108.75
144.60
108.75
144.60
19.52
19.52
23.49
23.49
29.46
29.46
41.40
41.40
81.88
81.88
81.88
81.88
81.88
117.73
81.88
117.73
56.96
56.96
56.96
56.96
56.96
92.81
56.96
92.81
32.00
34.50
38.75
40.85
43.89
43.89
55.41
55.41
6.23
7.49
7.63
8.69
7.21
7.21
7.00
7.00
j Gas connection for 1st furnace. For Models 500-800 add 41.09&quot; for second furnace gas connection.
For Model 840-960 add 41.09&quot; and 82.19&quot; for second and third furnace gas connections.
46
5-594.10
J
M
32.00
34.50
38.75
40.85
43.89
43.89
55.41
55.41
43.89
43.89
55.41
55.41
55.41
6.23
7.49
7.63
8.69
7.21
7.21
7.00
7.00
7.21
7.21
7.00
7.00
7.00
DIMENSIONS - COOLING COILS
Figure 47.1 - DX Coil Drawing - (All dimensions in inches)
Rows 2
W
7.5
Airflow Direction
3
6
4
7.5
6
10
TOP VIEW
L
1.5
1.5
Coil for Right Hand Units
(Digit 9 = R)
Headers on opposite
side for Left Hand Units
W
Distributor Inlet (Liquid
Line) Connection(s)
(Second Inlet on Dual
Circuit Coils)
S
FL
FRONT VIEW
H
SIDE VIEW
FH
Airflow
Direction
1.5
Suction Line Connections in direction
of airflow
(Second Inlet on Dual Circuit Coils)
I
Table 47.1 - DX Coil Dimensions
DX - Single Circuit j
DX - Dual Circuit k
Model Size
Cooling MBH
FH
H
S
FL
I
L
FL
I
L
75
All
27.5
30.5
1.5
18
25
21
16.25
26.5
19.25
100/125
All
27.5
30.5
1.5
21
28
24
19.5
29.75
22.5
150/175
All
27.5
30.5
1.5
24
31
27
23
33.25
28.5
Below 185 MBH
32.5
34.5
0.5
27
34
30
185 MBH &amp; Up
32.5
34.5
0.5
27
34.5
30
25.5
35.75
28.5
Below 185 MBH
32.5
34.5
0.5
30
37
33
185 MBH &amp; Up
32.5
34.5
0.5
30
37.5
33
28.5
38.75
31.5
Below 185 MBH
32.5
34.5
0.5
42
49
45
185 MBH &amp; Up
32.5
34.5
0.5
42
49.5
45
40.25
50.5
43.25
200/225
250/300
350/400
j Single Circuit DX coils have 1 each Suction Line and Liquid Lines. Refer to AccuSpec for line size diameters.
k Dual Circuit DX coils have 2 each Suction Line and Liquid Lines. Refer to AccuSpec for line size diameters.
Figure 47.2 - Chilled Water Coil Drawing (All dimensions in inches)
Rows 4
W
7.5
Airflow Direction
6
10
TOP VIEW
W
L
1.5
1.5
Coil for Right Hand Units (Digit
9 = R)
Headers on opposite side for
Left Hand Units
1.8
S
2.25
FL
FRONT VIEW
H
Return Water Line
Connection turned 90&deg; in
direction of airflow
Airflow
Direction
SIDE VIEW
FH
V
Supply Water Line
Connection turned 90&deg; in
direction of airflow
2.25
I
1.8
Table 47.2 - Chilled Water Coil Dimensions
Model Size
FH
H
S
V
FL
I
L
Supply Line
Return Line
75
100/125
150/175
200/225
250/300
350/400
27
27
27
33
33
33
30
30
30
34.5
34.5
34.5
1.5
1.5
1.5
0.5
0.5
0.5
1.5
1.5
1.5
1
1
1
16.25
19.50
23.00
25.50
28.50
40.25
25.50
28.75
32.25
34.75
37.75
49.50
19.25
22.50
26.00
28.50
31.50
43.25
1.50 MPT
1.50 MPT
1.50 MPT
1.50 MPT
1.50 MPT
1.50 MPT
1.50 MPT
1.50 MPT
1.50 MPT
1.50 MPT
1.50 MPT
1.50 MPT
5-594.10
47
WEIGHTS
Table 48.1 - Unit Weights j
Base Unit
Model Blower Type
Size
(Digit 16)
Dampers
Digit 2
B
C
Motor Filters
Insulation
Double Wall Liners
Digit 2
Digit 2
Fresh Air
Fresh &amp;
Only
Return Air
B
C
B
C
75
All
373
480
6
26
46
5
10
38
72
100/125
All
409
519
6
26
46
5
10
38
72
150/175
All
441
556
6
29
52
5
10
43
77
200/225
All
515
641
6
29
52
7
12
46
85
250/300 E,F,G, or H
568
698
250/300
I, J, or K
817
947
350/400 E,F,G, or H
652
801
350/400
I, J, or K
933
1082
500/600
G or H
843
n/a
500/600
I, J, K, or L
1092
700/800
G or H
981
700/800
I, J, K, or L
840/960
I, J, K, or L
33
60
7
12
46
87
33
60
14
19
93
134
12
38
70
7
12
53
101
17
38
70
14
19
96
144
8
33
60
7
n/a
46
n/a
n/a
15
33
60
14
n/a
93
n/a
n/a
12
38
70
7
n/a
53
n/a
1262
n/a
17
38
70
14
n/a
96
n/a
1591
n/a
17
38
70
14
n/a
96
n/a
See Motor Data
8
15
Table 48.2 - Motor Weights j
Supply Voltage Motor Type
(Digit 14)
(Digit 18)
A - 115/60/1ph
B - 208/60/1ph
C - 230/60/1ph
D - 208/60/3ph
E - 230/60/3ph
F - 460/60/3ph
G - 575/60/3ph
Motor Size (Digit 17)
A or L B or M C or N D or P E or Q F or R G or S H or T I or W J or X K or Y V or Z
1/3
1/2
3/4
1
1-1/2
2
3
5
7-1/2
10
15
20
1 - ODP
25
23
25
32
40
49
81
-
-
-
-
-
5 - TE
25
28
30
37
45
49
83
-
-
-
-
-
1 - ODP
-
23
25
32
40
49
81
87
-
-
-
-
5 - TE
-
28
30
37
45
49
83
86
-
-
-
-
1 - ODP
25
23
25
32
40
49
81
87
-
-
-
-
5 - TE
25
28
30
37
45
49
83
86
-
-
-
-
1 - ODP
17
18
21
-
-
-
-
-
-
-
-
-
2 - ODP HE
-
-
-
83
94
99
83
94
141
126
220
250
5 - TE
15
23
26
-
-
-
-
-
-
-
-
-
6 - TE HE
-
-
-
68
66
66
92
99
158
200
259
368
1 - ODP
17
18
21
-
-
-
-
-
-
-
-
-
2 - ODP HE
-
-
-
40
46
54
87
94
130
126
217
250
5 - TEFC
15
23
30
-
-
-
-
-
-
-
-
-
6 - TEFC HE
-
-
-
53
66
67
92
117
194
213
322
368
1 - ODP
17
18
21
-
-
-
-
-
-
-
-
-
2 - ODP HE
-
-
-
40
46
54
87
94
130
126
217
250
5 - TE
15
23
30
-
-
-
-
-
-
-
-
-
6 - TE HE
-
-
-
53
66
66
92
117
194
213
322
368
1 - ODP
-
25
28
-
-
-
-
-
-
-
-
-
2 - ODP HE
-
-
-
35
40
45
76
89
90
220
310
360
5 - TE
-
24
33
-
-
-
-
-
-
-
-
-
6 - TE HE
-
-
-
68
40
67
100
125
192
200
326
368
j All weights in pounds and are approximate.
48
5-594.10
MAINTENANCE
Filters
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
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 owner’s risk.
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 49.1 - Filter Replacement Arrangement for
STANDARD Blower Size (Model Digit 16=A through H)
FILTER
SPACER
CAUTION
B
Do not attempt to reuse any mechanical or electrical
controllers which have been wet. Replace defective controller.
B
IMPORTANT
B
C
B
C
FILTER
SPACER
B
B
B
B
A
150/175
100/125
75
A
FILTER
SPACER
To check most of the Possible Remedies in the troubleshooting
guide listed in Table 52.1 to 53.1, refer to the applicable
sections of the manual.
A
A
A
C
A
A
A
A
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.
A
A
A
A
C
A
350/400
700/800
250/300
500/600
200/225
A = 20'' x 25''
B = 16” x 25”
C = 15” x 25”
FILTER SPACER TO BE INSERTED
ON NON-ACCESS SIDE OF UNIT
Figure 49.2 - Filter Replacement Arrangement for
EXTENDED Blower Size (Model Digit 16 = I, J, K, or L)
Electrical Wiring
The electrical wiring should be checked annually for loose
connections or deteriorated insulation.
A
A
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.
A
D
NON-ACCESS
SIDE
NON-ACCESS
SIDE
FILTER
SPACER
A
FILTER
SPACER
A
A
A
C
5-594.10
A
C
250/300
500/600
A
C
D
A = 20'' x 25''
B = 16” x 25”
C = 20” x 16”
D = 15” x 25”
A
A
B
B
350/400
700/800
840/960
49
MAINTENANCE
Cooling Coil Maintenance
1. Periodically, inspect the coil for signs of corrosion and leaks.
Repair and replacement of the coil and the connecting piping,
valves, etc., must be performed as needed by a qualified
technician.
2. 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. Cleaning solutions must not
be corrosive or cause damage to copper tube/aluminum fin
coils. 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.
3. For DX coils, replace the filter dryer(s) as needed.
4. For chilled fluid coils:
a. M
aintain the circulated fluid free of sediment, corrosive
products and biological contaminants.
b. Freeze
Protection - During the winter, chilled water coils
need to be protected against freezing. Two common
methods are 1) blowing out the coils with air, or 2)
flushing coils with inhibited glycol designed for corrosion
protection in HVAC applications. Select an inhibited glycol
solution that will protect the coil from the lowest possible
temperatures that can occur at that locality.
Cooling Coil Drain Pan and Drain System
The drain pan, trap, and drain pipe must be cleaned regularly to
avoid blockage that can reduce or stop water flow as follows:
1. At the beginning of the cooling season, inspect and clean
the entire cooling coil cabinet and condensate drain pan to
remove contaminants.
2. Inspect and clean the condensate drain trap and piping. The
use of a cleanout opening at the top of the trap can help
facilitate this maintenance.
3. Fill the trap with water to ensure proper operation and replace
the cap on the cleanout opening to close the system.
4. During the end of cooling season shutdown of the system,
disconnect and remove all water from the trap and drain to
prevent freeze damage. If local building codes permit, the trap
may be filled with an antifreeze solution.
5. If the unit is used year round, regularly inspect and clean the
cooling coil cabinet, condensate drain pan, and trap/drain
system to ensure proper function.
6. Depending on climate, freeze protection of the trap may be
required during non-cooling days.
50
Duct Furnace
When providing annual maintenance for the duct furnace, keep
the unit free from dust, dirt, grease and foreign matter. Pay
particular attention to:
1. The power exhauster discharge opening and the
combustion air inlet louvers.
2. The burner ports and pilot burner orifices (avoid the use of
hard, sharp instruments capable of damaging surfaces for
cleaning these ports). To check the burner port and pilot
burner orifice, see Burner and Pilot Assembly Removal.
3. The air shutters and main burner orifices (avoid the use of
hard, sharp instruments capable of damaging surfaces for
cleaning these orifices). To check the air shutters and main
burner orifices, see for Manifold Assembly Removal.
The heat exchanger should be checked annually for cracks
and discoloration of the tubes. If a crack is detected, the heat
exchanger should be replaced before the unit is put back into
service. If the tubes are dark gray, airflow across the heat
exchanger should be checked to insure that a blockage has not
occurred or the blower is operating properly.
Gas Piping &amp; Controls
The gas valves and piping should be checked annually for
general cleanliness and tightness.
The gas controls should be checked to insure that the unit is
operating properly.
(continued next page)
5-594.10
MAINTENANCE
Manifold Assembly Removal
Burner and Pilot Assembly Removal
1.
2.
3.
1.
2.
3.
To remove the manifold (Refer to Figure 51.1)
4.
5.
6.
7.
8.
Shut off gas and electric supply.
Disconnect gas manifold at ground union joint.
Remove the two screws holding the manifold to the heat
exchanger support.
Slide the manifold through the manifold bracket.
Clean the orifices and adjust the air shutters as necessary.
Follow steps 3-6 in reverse order to install the manifold
assembly.
Turn on the electric and gas supply.
Check the ground union joint for leaks with a soap solution.
Tighten if necessary.
To remove the burner (Refer to Figure 51.2)
Shut off gas and electric supply.
Disconnect the pilot supply line from the gas valve.
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.
Remove the screws holding the burner side access panel.
Attached to the panel are the burner retaining pins that
align the burner.
Slide the burner assembly out. The pilot is attached to the
burner assembly.
Examine the burner and pilot assembly for cleanliness
and/or obstructions as necessary (see Duct Furnace for
cleaning instructions).
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.
Reconnect the ignition cable and pilot gas supply line.
Turn on the electric and gas supply.
4.
5.
6.
Figure 51.1 - Manifold Assembly Removal
ELECTRICAL
JUNCTION BOX
SERIAL PLATE ON
OUTSIDE OF DOOR
(NOT SHOWN)
7.
8.
9.
Figure 51.2 - Burner and Pilot Assembly Removal
BURNER SIDE
ACCESS PANEL
HEAT EXCHANGER
SUPPORT
MANIFOLD
GROUND
JOINT UNION
PILOT
IGNITION
ASSEMBLY
CABLE
5-594.10
PILOT
SUPPLY
LINE
HEAT
EXCHANGER
SUPPORT
AIR SHUTTERS
LOCATED ON THE
MANIFOLD
(NOT SHOWN)
51
SERVICE &amp; TROUBLESHOOTING
WARNING
When servicing or repairing this equipment, use only
factory-approved service replacement parts. A complete
replacement parts list may be obtained by contacting Modine
Manufacturing Company. Refer to the rating plate on the unit
for complete unit model number, serial number, and company
address. Any substitution of parts or controls not approved by
the factory will be at the owner’s risk.
CAUTION
Do not reuse any mechanical or electrical component which
has been wet. Such component must be replaced.
IMPORTANT
To check most of the Possible Remedies in the troubleshooting
guide listed in Tables 52.1 and 53.1, refer to the applicable
sections of the manual.
Table 52.1 - 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.
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.
Gas pressure out of proper range.
5.
6.
6.
8.
Pilot valve does not open.
a. Defective ignition controller.
b. Defective gas valve.
No Spark at ignitor.
a. Loose wire connections.
b. Pilot sensor is grounded.
c. Defective ignition controller.
Safety device has cut power.
1.
2.
3.
4.
5.
1.
2.
3.
Defective valve.
Loose wiring.
Defective pilot sensor
Defective ignition controller.
Improper thermostat wiring.
Too much primary air.
Main pressure set too high.
Orifice too large.
1.
2.
3.
4.
5.
1.
2.
3.
1.
2.
Insufficient primary air.
Dirty orifice.
1.
2.
3.
1.
2.
3.
Misaligned orifice.
Too much primary air.
Main pressure set too high.
Orifice too large.
3.
1.
2.
3.
7.
Main burners do not light (Pilot is lit)
Lifting Flames (See Figure 52.1)
Yellow Tipping
(With propane gas, some yellow tipping is
always present.)
Flashback
(Continued next page)
Figure 52.1 - Lifting Flame Condition
52
5-594.10
Adjust to a minimum for Natural Gas - 6”
W.C. Minimum for Propane Gas - 11”
W.C. Maximum 14” W.C.
Check wiring for 24 volts to valve.
a. Replace ignition controller.
b. Replace gas valve.
7
8.
a. Check all ignition controller wiring.
b. Replace sensor if cracked or worn
c. Replace ignition controller.
Check all safety devices (High limit, air
flow proving switch, power exhauster
centrifugal switch, gas pressure switches,
etc.) Determine and correct problem.
Reset if necessary.
Replace valve.
Check wiring to gas valve.
Replace pilot sensor.
Replace ignition controller.
Verify wiring compared to wiring diagram.
Reduce primary air.
Adjust to a maximum of 14” W.C.
Check orifice size with those listed on the
serial plate.
Increase primary air.
Check orifices and clean with compressed
air if necessary.
Check manifold, replace if necessary.
Reduce primary air.
Adjust to a maximum of 14” W.C.
Check orifice size with those listed on the
serial plate.
SERVICE &amp; TROUBLESHOOTING (CONTINUED)
Table 53.1 - Troubleshooting (Continued)
Trouble
Floating Flames (See Figure 53.1)
Flame Rollout (See Figure 53.2)
Not Enough Heat
Possible Cause
1. Insufficient primary air.
2. Main pressure set too high.
3. Orifice too large.
4.
1.
2.
Blocked vent cap.
Main pressure set too high.
Orifice too large.
3.
Blocked vent cap.
1.
Unit cycling on high limit. j
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.
Too Much Heat
Power Exhauster Motor Will Not Start
Possible Remedy
1. Increase primary air.
2. Adjust to a maximum of 14” W.C.
3. Check orifice size with those listed on the
serial plate.
4. Clean louvers in vent cap.
1. Adjust to a maximum of 14” W.C.
2. Check orifice size with those listed on the
serial plate.
3. Clean louvers in vent cap.
1.
a. Clean/correct duct system.
b. Adjust to a maximum of 14” W.C.
c. Check that 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 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).
2.
f. Blocked/damaged venting system.
g. Defective high limit switch.
Main pressure set too low.
3.
Too much outside air.
4.
5.
Thermostat malfunction.
Gas controls wired incorrectly.
4.
5.
6.
Unit undersized.
6.
1.
2.
Thermostat malfunction.
Gas controls do not shut-off.
a. Gas controls wired incorrectly.
1.
2.
3.
4.
1.
2.
3.
4.
5.
b. Short circuit.
Main gas pressure set too high.
Defective gas valve.
Power supply is off.
No 24V power to thermostat.
Thermostat malfunction.
Defective power exhauster relay.
Defective power exhauster motor.
3.
4.
1.
2.
3.
4.
5.
Check/replace thermostat.
Check unit wiring against the wiring
diagram.
Check design conditions. If unit is undersized, an additional unit(s) or other heat
source must be added.
Check/replace thermostat.
a. Check unit wiring against the wiring
diagram.
b. Check for loose or worn wires.
Adjust to a maximum of 14” W.C.
Replace gas valve.
Turn on main power.
Check control transformer.
Check/replace thermostat.
Replace power exhauster relay.
Replace power exhauster motor.
j 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 26.1, 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 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 Table 53.1.
Figure 53.1 - Floating Flame Condition
Figure 53.2 - Flame Rollout Appearance
5-594.10
53
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54
5-594.10
START-UP CHECKLIST
START-UP CHECKLIST
INDIRECT GAS-FIRED HEATING EQUIPMENT
Job Name:
Date:
Address:
Model No.:
City &amp; 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?
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: ______ &quot; 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
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
Low Fire: Does entire burner light off?
Hi Fire: Burner pressure reading? ______ &quot; 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?
27. Has wiring been verified to match the unit wiring diagram?
28. Have all the modes of the sequence of operation been verified and tested?
29. What optional and/or accessory control devices have been set?
Device: _______________ Setting: ___________ (&deg;F/psi/Inches W.C./etc.)
Device: _______________ Setting: ___________ (&deg;F/psi/Inches W.C./etc.)
Device: _______________ Setting: ___________ (&deg;F/psi/Inches W.C./etc.)
_____ Yes
_____ Yes
_____ Yes
_____ Yes
_____ Yes
_____ Yes
_____ Yes
_____ Yes
____
____
____
____
____
____
____
____
No
No
No
No
No
No
No
No
_____ Yes
_____ Yes
_____ Yes
_____ Yes
_____ Yes
____
____
____
____
____
No
No
No
No
No
_____ Yes
_____ Yes
____ No
____ No
_____ Yes
____ No
_____ Yes
____ No
_____ Yes
____ No
_____ Yes
_____ Yes
_____ Yes
____ No
____ No
____ No
_____ Yes
_____ Yes
_____ Yes
____ No
____ No
____ No
_____ Yes
_____ Yes
_____ Yes
____ No
____ No
____ 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: _________________
5-594.10
55
MODEL DESIGNATIONS
Model Identification
Modine weatherproof duct furnace/make-up air units contain
an ETL/ETL Canada certified weatherproof duct furnace. This
duct furnace is combined with either a blower section, or a
blower and/or cooling and/or downturn sections 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, cooling, and/or downturn sections.
Figure 56.1 - Serial Plate and Model Identification
Plate Locations
Replacement Parts Ordering
MODEL
IDENTIFICATION
PLATE
When servicing, repairing or replacing parts on these units,
locate the model identification plate of the unit and always
give the complete Model Number and Serial Number from
the model identification plate. The model identification plate is
located on the door of the electrical control box (See Figure
56.1). For a complete description of the model number, see
Model Identification.
Figure 56.2 - Serial Plate (sample shown, actual data may vary)
Figure 56.3 - Model ID Plate Example
DBS960SMRHN20F2IQ5DBA00
56
SERIAL
PLATE
5-594.10
MODEL NOMENCLATURE FOR SYSTEM UNITS
Model Nomenclature
1
2
3
456
7
8
9
10
11
12
13
14
15
16
17
18
19
20 21
22
23
PT
UC
V
MBH
HE
DS
AS
ATR
GT
GV
SS
SV
TR
BB
HP
MT
SA
AC
EC
CC
1 - Product Type (PT)
D or I - Indoor Indirect Fired Heating &amp; Make-Up Air Unit
2 - Unit Configuration (UC)
B - Blower Package - Furnace &amp; Blower
C - Cooling Package - Furnace, Blower, &amp; Cooling Cabinet
3 - Venting (V)
S - Separated Combustion
4,5,6 - Furnace Input Rating (MBH) (Except for 840 &amp; 960)
75 - 75,000 Btu/Hr Input
350- 350,000 Btu/Hr Input
100 - 100,000 Btu/Hr Input
400 - 400,000 Btu/Hr Input
125 - 125,000 Btu/Hr Input
500 - 500,000 Btu/Hr Input
150 - 150,000 Btu/Hr Input
600 - 600,000 Btu/Hr Input
175 - 175,000 Btu/Hr Input
700 - 700,000 Btu/Hr Input
200 - 200,000 Btu/Hr Input
800 - 800,000 Btu/Hr Input
225 - 225,000 Btu/Hr Input
840 - 1,050,000 Btu/Hr Input
250 - 250,000 Btu/Hr Input
960 - 1,200,000 Btu/Hr Input
300 - 300,000 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
4 - 250 VA
0 - None
16 - Blower Size &amp; Bearing Type (BB)
A - 9-7 Spider Bearings
G - 15-15 Spider Bearings
B - 9-7 Pillow Block Bearings
H - 15-15 Pillow Block Bearings
C - 9-9 Spider Bearings
I - 18-18 Spider Bearings under 15 Hp
D - 9-9 Pillow Block Bearings
J - 18-18 Pillow Block Bearings under 15 Hp
E - 12-12 Spider Bearings
K - 18-18 Pillow Block Bearings for 15 Hp &amp; 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
H - 5 Hp
I - 7-1/2 Hp
J - 10 Hp
K - 15 Hp
V - 20 Hp
L - 1/3 Hp with Motor Starter
M - 1/2 Hp with Motor Starter
N - 3/4 Hp with Motor Starter
P - 1 Hp with Motor Starter
Q - 1-1/2 Hp with Motor Starter
R - 2 Hp Hp with Motor Starter
S - 3 Hp with Motor Starter
T - 5 Hp with Motor Starter
W - 7-1/2 Hp with Motor Starter
X - 10 Hp with Motor Starter
Y - 15 Hp with Motor Starter
Z - 20 Hp with Motor Starter
18 - Motor Type (MT)
1 - ODP
2 - ODP - High Eff.
5 - TE
6 - TE - High Eff.
19 - Sheave Arrangement (SA)
A - (See Sheave Tables)
10 - Air Temperature Rise (ATR)
H - High 60&deg;-100&deg;F
L - Low 20&deg;-60&deg;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
7 - Electronic Modulation 0-10 Vdc External Input
8 - Electronic Modulation 4-20 mA External Input
9 - Electronic Modulation with Modine Control System
13 - Additional Safety Switches (SS)
0 - No Switches (Standard)
1 - Low Gas Pressure Switch (Premium)
2 - High Gas Pressure Switch (Premium)
3 - High and Low Gas Pressure Switch (Premium)
14 - Supply Voltage (SV)
A - 115/60/1
B - 208/60/1
C - 230/60/1
D - 208/60/3
15 - Transformer (TR)
1 - 40 VA
2 - 75 VA
3 - 150 VA
E - 230/60/3
F - 460/60/3
G - 575/60/3
20,21 - Air Control (AC)
AA - RA Opening
BA - FA Opening
CA - FA &amp; RA Openings
DA - FA Dampers w/2 pos motor (No RA)
EA - FA &amp; RA Dampers w/2 pos motor
GA - FA &amp; RA Mod motor w/0-10 Vdc External Input
GB - FA &amp; RA Mod motor w/4-20 mA External Input
GC - FA &amp; RA Mod motor w/Minimum Position (Factory Mounted)
GD - FA &amp; RA Mod motor w/Remote Position
GE - FA &amp; RA Mod motor w/3 pos. damper (100% RA, Variable, 100% OA)
GG - FA &amp; RA Mod motor w/Min Position &amp; Proportional Temp Controller
GH - FA &amp; RA Mod motor w/Remote Position &amp; Prop. Temp Controller
GJ - FA &amp; RA Mod motor w/FA Enthalpy Controller
HP - FA &amp; RA Floating motor w/Space Pressure Controller
JA - Manual FA &amp; RA Dampers
22 - Evaporative Cooling (EC)
0 - None
23 - Cooling Coil (CC)
0 - None
1 - Factory Installed Coil
5-594.10
57
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58
5-594.10
PAGE INTENTIONALLY LEFT BLANK
5-594.10
59
COMMERCIAL WARRANTY
Seller warrants its products to be free from defects in material and
workmanship, EXCLUSIVE, HOWEVER, of failures attributable to the use
of materials substituted under emergency conditions for materials normally
employed. This warranty covers replacement of any parts furnished from the
factory of Seller, but does not cover labor of any kind and materials not
furnished by Seller, or any charges for any such labor or materials, whether
such labor, materials or charges thereon are due to replacement of parts,
adjustments, repairs, or any other work done. This warranty does not apply to
any equipment which shall have been repaired or altered outside the factory of
Seller in any way so as, in the judgment of Seller, to affect its stability, nor
which has been subjected to misuse, negligence, or operating conditions in
excess of those for which such equipment was designed. This warranty does
not cover the effects of physical or chemical properties of water or steam or
other liquids or gases used in the equipment.
BUYER AGREES THAT SELLER’S WARRANTY OF ITS PRODUCTS TO BE
FREE FROM DEFECT IN MATERIAL AND WORKMANSHIP, AS LIMITED
HEREIN, SHALL BE IN LIEU OF AND EXCLUSIVE OF ALL OTHER
WARRANTIES, EITHER EXPRESS OR IMPLIED, WHETHER ARISING
FROM LAW, COURSE OF DEALING, USAGE OF TRADE, OR OTHERWISE,
THERE ARE NO OTHER WARRANTIES, INCLUDING WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PURPOSE, WHICH EXTEND
BEYOND THE PRODUCT DESCRIPTION CONFIRMED BY BUYER AND
SELLER AS OF THE DATE OF FINAL AGREEMENT.
This warranty is void if the input to the product exceeds the rated input as
indicated on the product serial plate by more than 5% on gas-fired and oil-fired
units, or if the product in the judgment of SELLER has been installed in a
corrosive atmosphere, or subjected to corrosive fluids or gases, been subjected
to misuse, negligence, accident, excessive thermal shock, excessive humidity,
physical damage, impact, abrasion, unauthorized alterations, or operation
contrary to SELLER’S printed instructions, or if the serial number has been
altered, defaced or removed.
BUYER AGREES THAT IN NO EVENT WILL SELLER BE LIABLE FOR
COSTS OF PROCESSING, LOST PROFITS, INJURY TO GOODWILL, OR
ANY OTHER CONSEQUENTIAL OR INCIDENTAL DAMAGES OF ANY KIND
RESULTING FROM THE ORDER OR USE OF ITS PRODUCT, WHETHER
ARISING FROM BREACH OF WARRANTY, NONCONFORMITY TO
ORDERED SPECIFICATIONS, DELAY IN DELIVERY, OR ANY LOSS
SUSTAINED BY THE BUYER.
Component
Applicable Models
Heat Exchangers
Gas-Fired Unit Heaters, Gas Heat Option on MPR
Models
Heat Exchangers
Low Intensity Infrared Units
Compressors
Condensing Units for Cassettes
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
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 &amp; CONDITIONS BEYOND SELLER’S
CONTROL
This 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”
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
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
Burners
Low Intensity Infrared Units
Compressors and Electric Heat Elements
MPR Models, ERM Models
Other
Components excluding Heat Exchangers, Coils,
Condensers, Burners, Sheet Metal
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,
Steam/Hot Water Units, Oil-Fired Units, Electric Units,
Cassettes, Vertical Unit Ventilators
Compressors
Vertical Unit Ventilators
Burners
High Intensity Infrared Units
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
Sheet Metal Parts
All Products
As Modine Manufacturing Company has a continuous product improvement program, it reserves the right to change design and specifications without notice.
Modine Manufacturing Company
1500 DeKoven Avenue
Racine, WI 53403
Phone: 1.800.828.4328 (HEAT)
www.modinehvac.com
&copy; Modine Manufacturing Company 2020
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