Airedale Indirect-Fired Outdoor Make-Up Air Service Manual

5-572.11
5H0762330001
December, 2023
INSTALLATION AND SERVICE MANUAL
indirect gas-fired weatherproof make-up air units
models HBP/HCP/HDP/HPP
OBP/OCP/ODP/OPP
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. 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.
AVERTISSEMENT
1. Une installation, un réglage, une altération,
une réparation ou une maintenance
impropre risque de causer des dommages,
des blessures ou la mort, et d’engendrer
une exposition à des substances dont
certains États ont déterminé qu’elles
étaient cancérogènes ou pouvaient causer
des malformations à la naissance et des
problèmes de reproduction. Lisez bien les
instructions d’installation, d’utilisation et de
maintenance avant d’installer ou de réparer
cet appareil.
2. Pour éviter la panne prématurée de
l’échangeur thermique, ne placez AUCUN
appareil à gaz à des endroits où les vapeurs
corrosives (chlorées, halogénées ou acides)
sont présentes dans l’atmosphère.
All models approved for use in California by the CEC.
FOR YOUR SAFETY
IF YOU SMELL GAS:
1. Open windows.
2. Do not try to light any appliance.
3. Don’t touch electrical switches.
4. Extinguish any open flame.
5. Immediately call your gas supplier.
POUR VOTRE SÉCURITÉ
SI VOUS SENTEZ UNE ODEUR DE GAZ:
1. Ouvrez les fenêtres.
2. Ne tentez d'allumer aucun autre appareil.
3. Ne touchez pas aux interrupteurs
électriques.
4. Éteignez toute flamme nue.
5. Appelez immédiatement votre compagnie de
gaz.
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.
POUR VOTRE SÉCURITÉ
L'utilisation et le stockage d'essence ou
d'autres vapeurs et liquides inflammables
dans des récipients ouverts à proximité de cet
appareil sont dangereux.
THIS MANUAL IS THE PROPERTY OF THE OWNER.
PLEASE BE SURE TO LEAVE IT WITH THE OWNER WHEN YOU LEAVE THE JOB.
TABLE OF CONTENTS
TABLE OF CONTENTS
IMPORTANT
1. The use of this manual is specifically
intended for a qualified installation and
service agency. A qualified installation and
service agency must perform all installation
and service of these appliances.
2. This appliance is not intended for use by
persons (including children) with reduced
physical, sensory, or mental capabilities,
or lack of experience and knowledge,
unless they have been given supervision or
instruction concerning use of the appliance
by a person responsible for their safety.
3. Children should be supervised to ensure
that they do not play with the appliance.
IMPORTANT
1. Ce manuel est spécifiquement destiné
au personnel d’une entreprise qualifiée
d’installation et d’entretien. Toutes les
opérations d’installation et d’entretien
doivent être confiées à une entreprise
qualifiée.
2. Cet appareil n’est pas conçu pour être
utilisé ou entretenu par des personnes (y
compris des enfants) dont les capacités
physiques, sensorielles ou mentales sont
réduites, ou qui n’ont pas l’expérience et les
connaissances suffisantes, à moins d’être
supervisées ou d’avoir obtenu des directives
concernant l’utilisation de l’appareil par une
personne responsable de leur sécurité.
3. Les enfants doivent être supervisés
pour s’assurer qu’ils ne jouent pas avec
l’appareil.
INSPECTION ON ARRIVAL
1.
2.
3.
2
Inspect unit upon arrival. In case of damage, report it
immediately to transportation company and your local
factory sales representative.
Check rating plate on unit to verify that power supply meets
available electric power at the point of installation.
Inspect unit upon arrival for conformance with description
of product ordered (including specifications where
applicable).
Inspection On Arrival .............................................................2
Special Precautions ..............................................................3
Hazard Intensity Levels ........................................................3
Special Design Requests / Unit Location ..............................6
Special Design Requests ................................................6
Unit Location ...................................................................6
Location Recommendations ...........................................6
Sound Attenuation / Roof Curb Installation ...........................8
Sound and Vibration Levels ............................................8
Curb or Sub-Base Mounted Sites ...................................8
Slab Mount Installation / Rigging Instructions .....................10
Slab Mounted Units .......................................................10
General Rigging Instructions .........................................11
Duct Installation / Utility Connections .................................12
Duct Installation ............................................................12
Utility Connections ........................................................12
Unit Installation ...................................................................14
Gas Connections ..........................................................14
Considerations for Elevation .........................................17
Manifold Pressure Adjustment ......................................17
Electrical Connections ..................................................18
Cooling Coil Units .........................................................20
Start-Up Procedure .............................................................22
Start-Up Procedure .......................................................22
Pilot Burner Adjustment ................................................23
Furnace Control Operating Sequence ..........................26
Cooling Coil Operation ..................................................28
Component/Option Locations .............................................29
Component Descriptions ....................................................30
General Performance Data .................................................37
General Performance Data .................................................38
Option & Accessory Pressure Drop Data ............................39
Blower Performance Data ...................................................40
General Performance Data .................................................42
Blower Sheave Assembly Data ...........................................43
Dimensions - Unit ...............................................................45
Dimensions - Unit Base ......................................................49
Dimensions - Roof Curbs ....................................................50
Dimensions - Cooling Coils .................................................51
Dimensions Rainhood, Remote Panel & Evaporative Cooler .................52
Weights ...............................................................................53
Maintenance .......................................................................54
Electrical Wiring ............................................................54
Cooling Coil Maintenance .............................................55
Cooling Coil Drain Pan and Drain System ....................55
Duct Furnace ................................................................55
Gas Piping & Controls ...................................................55
Manifold Assembly Removal .........................................56
Burner and Pilot Assembly Removal .............................56
Service & Troubleshooting ..................................................58
Start-Up Checklist ...............................................................60
Model Designations ............................................................61
Model Identification .......................................................61
Replacement Parts Ordering ........................................61
Model Nomenclature For System Units ..............................62
Weatherproof Model Nomenclature ..............................62
5-572.11
SPECIAL PRECAUTIONS
WARNING
SPECIAL PRECAUTIONS
THE INSTALLATION AND MAINTENANCE INSTRUCTIONS
IN THIS MANUAL MUST BE FOLLOWED TO PROVIDE
SAFE, EFFICIENT, AND TROUBLE-FREE OPERATION. IN
ADDITION, PARTICULAR CARE MUST BE EXERCISED
REGARDING THE SPECIAL PRECAUTIONS LISTED BELOW.
FAILURE TO PROPERLY ADDRESS THESE CRITICAL
AREAS COULD RESULT IN PROPERTY DAMAGE OR LOSS,
PERSONAL INJURY, OR DEATH. THESE INSTRUCTIONS
ARE SUBJECT TO ANY MORE RESTRICTIVE LOCAL OR
NATIONAL CODES.
HAZARD INTENSITY LEVELS
1.
2.
3.
4.
DANGER: Indicates an imminently hazardous situation
which, if not avoided, WILL result in death or serious injury.
WARNING: Indicates a potentially hazardous situation
which, if not avoided, COULD result in death or serious
injury.
CAUTION: Indicates a potentially hazardous situation
which, if not avoided, MAY result in minor or moderate
injury.
IMPORTANT: Indicates a situation which, if not avoided,
MAY result in a potential safety concern.
PRÉCAUTIONS PARTICULIÈRES
LES INSTRUCTIONS D'INSTALLATION ET D'ENTRETIEN DE
CE MANUEL DOIVENT ÊTRE OBSERVÉES POUR ASSURER
UN FONCTIONNEMENT SÉCURITAIRE, EFFICACE ET
FIABLE. DE PLUS, LES PRÉCAUTIONS PARTICULIÈRES CIAPRÈS DOIVENT ÊTRE RIGOUREUSEMENT RESPECTÉES.
SINON, IL Y AURAIT RISQUE DE DÉGÂTS MATÉRIELS
OU DE PERTE, DE BLESSURE PERSONNELLE OU DE
MORT D'HOMME. CES INSTRUCTIONS SONT SUJETTES
À TOUTE DISPOSITION PLUS RESTRICTIVE DES CODES
PROVINCIAL OU NATIONAL.
HIÉRARCHIE DES NIVEAUX DE RISQUES
1.
2.
3.
4.
DANGER : Indique un danger imminent qui, s'il n'est pas
évité, entraînera INÉVITABLEMENT des blessures graves,
voire mortelles.
AVERTISSEMENT : Indique un danger potentiel qui, s'il
n'est pas évité, RISQUE d'entraîner des blessures graves,
voire mortelles.
ATTENTION : Indique un danger potentiel qui, s'il n'est
pas évité, PEUT entraîner des blessures mineures ou
modérées.
IMPORTANT : Indique une situation qui, si elle se
matérialise, PEUT entraîner des risques pour la sécurité
des personnes.
1. To prevent premature heat exchanger failure, do not locate
ANY gas-fired appliances in areas where corrosive vapors
(i.e. chlorinated, halogenated or acid) are present in the
atmosphere.
2. 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. Never lift in high winds.
3. All field gas piping must be pressure/leak tested prior to
operation. Never use an open flame. Use a soap solution
or equivalent for testing.
4. Gas pressure to appliance controls must never exceed 3.4
kPa (14" W.C. or 1/2 psi).
5. 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.
6. All appliances must be wired strictly in accordance with
wiring diagram furnished with the appliance. Any wiring
different from the wiring diagram could result in a hazard to
persons and property.
7. Any original factory wiring that requires replacement must
be replaced with wiring material having a temperature
rating of at least 105°C.
8. To reduce the opportunity for condensation, the minimum
sea level input to the appliance, as indicated on the serial
plate, must not be less than 5% below the rated input, or
5% below the minimum rated input of dual rated units.
9. Ensure that the supply voltage to the appliance, as
indicated on the serial plate, is not 5% greater than the
rated voltage.
10. When servicing or repairing this equipment, use only
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 appliance for complete appliance model number,
serial number, and company address. Any substitution of
parts or controls not approved by the factory will be at the
owners risk.
DANGER
Appliances must not be installed where they may be exposed
to potentially explosive or flammable atmosphere.
DANGER
Les appareils ne doivent pas être installés à un endroit où ils
risquent d’être exposés à une atmosphère potentiellement
explosive ou inflammable.
5-572.11
3
SPECIAL PRECAUTIONS
CAUTION
AVERTISSEMENT
1. Pour éviter la panne prématurée de l’échangeur thermique,
ne placez AUCUN appareil à gaz à des endroits où les
vapeurs corrosives (chlorées, halogénées ou acides) sont
présentes dans l’atmosphère.
2. Le non-respect d’une bonne procédure de levage et des
procédures de sécurité qui s’appliquent pourrait mener à
des dommages matériels ou à des blessures graves, voire
mortelles. Le levage doit être effectué uniquement par une
entreprise spécialisée dans le gréage. Utilisez TOUS les
points de levage. Testez le levage pour assurer un bon
équilibre et un bon gréage. Ne procédez jamais au levage
de l’appareil par vents forts.
3. Toutes les canalisations de gaz sur site doivent être
testées (pression/fuites) avant usage. Ne recherchez
jamais les fuites avec une flamme nue. Utilisez plutôt de
l’eau savonneuse ou un produit équivalent.
4. La pression de gaz aux commandes de l’appareil ne doit
jamais dépasser 3.4 kPa (35,5 cm C.E. ou 1/2 psi).
5. Débranchez l’alimentation électrique avant d’effectuer
des connexions ou de travailler sur l’appareil. Respectez
toutes les procédures de sécurité qui s’appliquent pour
éviter toute mise en marche accidentelle. Le non-respect
de cette directive peut entraîner des blessures ou la mort
causées par un choc électrique ou des pièces mobiles, en
plus d’endommager l’appareil.
6. Tous les appareils doivent être branchés de manière
strictement conforme au diagramme fourni. Tout câblage
différent de celui du schéma peut créer des risques de
dommages matériels ou de blessures.
7. Tout câblage usine d’origine exigeant un remplacement
doit être remplacé par un câble d’indice thermique nominal
de 105 °C.
8. Pour réduire le risque de condensation, l’entrée minimum
dans l’appareil au niveau de la mer, telle qu’indiquée sur la
plaque de série, ne doit pas être moins de 5 % inférieure à
la valeur d’entrée nominale des appareils à double valeur
nominale.
9. Assurez-vous que la tension d’alimentation de l’appareil,
comme indiqué sur la plaque de série, n’est pas de 5 %
supérieure à la tension nominale.
10. Pour l’entretien et les réparations de cet appareil, utilisez
uniquement des pièces d’origine certifiées. Pour la liste
complete des pièces de rechange, consultez Modine
Manufacturing Company. Le numéro de modèle complet,
le numéro de série et l’adresse du fabricant figurent sur la
plaque signalétique fixée à l’appareil. Toute substitution de
pièce ou decommande non approuvée par le fabricant sera
aux risques du propriétaire.
4
1. Appliances are designed for outdoor installation only.
DO NOT LOCATE APPLIANCES INDOORS.
2. Purging of air from gas lines should be performed as
described in ANSI Z223.1 - latest edition “National Fuel
Gas Code”, or in Canada in CAN/CGA-B149 codes.
3. Ensure that the supply voltage to the appliance, as
indicated on the serial plate, is not 5% less than the rated
voltage.
4. Do not attempt to reuse any mechanical or electrical
component which has been wet. Such component must be
replaced.
ATTENTION
1. Ces appareils sont conçus pour une installation à
l’extérieur seulement. NE PLACEZ PAS LES APPAREILS
À L’INTÉRIEUR.
2. La purge de l’air des tuyauteries de gaz doit se faire selon
la procédure ANSI Z223.1 de la dernière édition du «
National Fuel Gas Code » ou des codes CAN/CGA-B149
du Canada.
3. Vérifiez que la tension d’alimentation de l’appareil n’est pas
inférieure de plus de 5 % à la tension nominale inscrite sur
la plaque de série.
4. Ne tentez pas de réutiliser un composant mécanique ou
électrique qui a été mouillé. Ces composants doivent être
remplacés.
5-572.11
SPECIAL PRECAUTIONS
Table 5.1 - SI (Metric) Conversion Factors
IMPORTANT
To Convert
Multiply By
To
Obtain
To
Convert
Multiply
By
To
Obtain
"W.C.
0.24
kPa
CFH
1.699
m3/min
psig
6.893
kPa
Btu/ft3
0.0374
mJ/m3
°F
(°F-32) x
0.555
°C
pound
0.453
kg
inches
25.4
mm
Btu/hr
0.000293
kW
feet
0.305
meters
gallons
3.785
liters
CFM
0.028
m3/min
psig
27.7
"W.C.
1. For installation only in locations not accessible to the
general public.
2. Unit can be operated up to a maximum of 10,000 feet
(3048 m).
3. 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%.
4. 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
or the unit access doors where viewing the heat exchanger
is possible. 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 26 for Blower Adjustments.
5. Start up and adjustment procedures, installation, and
service of these appliances must be performed by a
qualified installation and service agency.
6. 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.
7. To check most of the Possible Remedies in the
troubleshooting guide listed in Table 58.1, and refer to the
applicable sections of the manual.
IMPORTANT
1. À installer uniquement dans des endroits non accessibles
au grand public.
2. L’unité peut être utilisée jusqu’à un maximum de 3048 m
(10,000 ft).
3. Pour éviter une défaillance prématurée de l’échangeur de
chaleur, le pouvoir calorifique du gaz utilisé ne doit pas
excéder de plus de 5 % la valeur nominale inscrite sur la
plaque signalétique de l’appareil.
4. Pour éviter la défaillance prématurée de l’échangeur de
chaleur, examinez les tubes de l’échangeur de chaleur en
le regardant à travers les ouvertures d’accès installées
sur les lieux lors de la connexion des tuyaux ou les portes
d’accès à l’unité où il est possible de voir l’échangeur
de chaleur. Si le bas des tubes devient rouge lorsque
la soufflante et la chaudière canalisée sont en marche,
vérifiez que le régime de la soufflante est approprié pour
l’application. Pour le réglage de la soufflante, reportezvous à la page 26.
5. Les procédures de démarrage et de réglage, l’installation
et le service de ces appareils doivent être confiés à un
centre d’installation et de service qualifié.
6. Pour éviter une panne prématurée de l'échangeur de
chaleur, avec tous les systèmes de commande, un
mécanisme de démarrage du ventilateur doit être fourni
de manière à ce que le ventilateur soit en marche ou sous
tension 45 secondes de l'opération de contrôle du gaz
7. Pour essayer la plupart des solutions possibles suggérées
dans le guide de dépannage du Tableau 58.1 reportezvous aux sections correspondantes du manuel.
5-572.11
5
SPECIAL DESIGN REQUESTS / UNIT LOCATION
Special Design Requests
IMPORTANT
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
1. Pour installation uniquement dans des endroits non
accessibles au public.
2. L’unité peut être utilisée jusqu’à un maximum de 3048 m
(10,000 ft).
STORAGE PRIOR TO INSTALLATION
Location Recommendations
If the unit is stored outside prior to installation, the unit should
be covered.
1.
Unit Location
2.
DANGER
3.
Appliances must not be installed where they may be exposed
to potentially explosive or flammable atmosphere.
DANGER
Les appareils ne doivent pas être installés à un endroit où ils
risquent d’être exposés à une atmosphère potentiellement
explosive ou inflammable.
4.
5.
WARNING
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.
AVERTISSEMENT
Pour éviter la panne prématurée de l’échangeur thermique,
ne placez AUCUN appareil à gaz à des endroits où les
vapeurs corrosives (chlorées, halogénées ou acides) sont
présentes dans l’atmosphère.
CAUTION
6.
7.
When locating the furnace, consider general space and
heating requirements and availability of gas and electrical
supply.
Unit must be installed on the positive pressure side of the
circulating blower.
Be sure the structural support at the unit location site is
adequate to support the weight of the unit and any other
required support structure. For proper operation the unit
must be installed in a level horizontal position.
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.
Be sure that the minimum clearances to combustible
materials and recommended service clearances are
maintained. Be sure clearances are maintained to
the combustion air inlet louvers and power exhauster
discharge cover. Units are designed for installation on
non-combustible surfaces or combustible surfaces with the
minimum clearances shown in Figure 6.1 and Table 7.1.
On units that have fresh air openings, a method should be
provided to prevent water and debris from entering the unit
such as a rainhood and bird screen, evaporative cooler,
etc.
On horizontal discharge units (Model Digit 2=B or C),
adequate space must be provided to install the discharge
duct as shown in Figure 12.1. to insure even air flow
across the heat exchanger.
Figure 6.1 Combustible Material & Service Clearances j
Appliances are designed for outdoor installation only.
DO NOT LOCATE APPLIANCES INDOORS.
ATTENTION
B
B
Ces appareils sont conçus pour une installation à
l’extérieur seulement. NE PLACEZ PAS LES APPAREILS À
L’INTÉRIEUR.
SIDE VIEW
IMPORTANT
1" (2.5 cm)
1. For installation only in locations not accessible to the
general public.
2. Unit can be operated up to a maximum of 10,000 feet
(3048 m).
36" (91 cm)
ACCESS
SIDE
A
C
FRONT VIEW
j Minimum clearance to combustible materials is 1" (2.5 cm) from rooftop.
6
5-572.11
UNIT LOCATION
Figure 7.1 Matériaux combustibles et dégagemen j
Tableau 7.1 Matériaux combustibles et dégagements
Dégagements
Dégagements minimaux
recommandés
jusqu’au matériau combustible pour l'entretien
B
Côté
Côté op- Côté opposé
Côté porte Avant et posé à
porte
à la
Taille de
d'accès
arrière la porte d'accès porte
modèle
(A)
(B)
(C)
(A)
(C)
B
Vue latérale
2,5 cm (1”)
91 cm (36”)
Côté porte
d'accès
A
C
Vue de face
j Le dégagement minimal jusqu’au matériau combustible est de
2,5 cm (1 in) à partir du toit.
100/125
20”
(51 cm)
3”
(8 cm )
0”
36”
(91 cm)
150/175
25”
(64 cm)
3”
(8 cm )
0”
42”
(107 cm)
200/225
27”
(69 cm)
4”
(10 cm)
0”
42”
(107 cm)
250/300
30”
(76 cm)
5”
(13 cm)
0”
48”
(123 cm)
350/400
41”
(104 cm)
11”
(28 cm)
0”
6”
(15 cm)
60”
(152 cm)
500/600
30”
(76 cm)
5”
(13 cm)
0”
48”
(123 cm)
700/800
41”
(104 cm)
11”
(28 cm)
0”
60”
(152 cm)
840/960
41”
(104 cm)
11”
(28 cm)
0”
60”
(152 cm)
Table 7.1 Combustible Material & Service Clearances
Minimum
Combustible Material
Clearances
Recommended
Service
Clearances
NonNonAccess Access Access
Side
Side
Side
(C)
(A)
(C)
Model
Size
Access
Side
(A)
Front &
Rear
(B)
100/125
20”
(51 cm)
3”
(8 cm )
0”
36”
(91 cm)
150/175
25”
(64 cm)
3”
(8 cm )
0”
42”
(107 cm)
200/225
27”
(69 cm)
4”
(10 cm)
0”
42”
(107 cm)
250/300
30”
(76 cm)
5”
(13 cm)
0”
48”
(123 cm)
350/400
41”
(104 cm)
11”
(28 cm)
0”
6”
(15 cm)
60”
(152 cm)
500/600
30”
(76 cm)
5”
(13 cm)
0”
48”
(123 cm)
700/800
41”
(104 cm)
11”
(28 cm)
0”
60”
(152 cm)
840/960
41”
(104 cm)
11”
(28 cm)
0”
60”
(152 cm)
5-572.11
7
SOUND ATTENUATION / ROOF CURB INSTALLATION
SOUND AND VIBRATION LEVELS
4.
All mechanical equipment generates some sound and vibration
that may require attenuation. For critical areas, an acoustical
consultant should be retained to assist in the application.
Locating the equipment away from the critical area is desirable
within ducting limitations. Frequently, units can be located above
utility areas, corridors, restrooms, and other non-critical areas.
Generally, a unit should be located within 15 feet (457 cm)
of a primary support beam to minimize structure deflections.
Smaller defections usually results in reduced vibration and noise
transmission.
Install the unit over roof decking with 2" (5 cm) acoustic
fiberglass lining within curb area for sound attenuation. The
return air duct should be acoustically lined and should be
installed with a flexible connection. If the ceiling space is used
as a plenum, the acoustically lined return intake duct should
form an inverted tee with five foot minimum legs in each
direction.
The discharge duct should be acoustically insulated and should
have a flexible connection as illustrated.
5.
6.
7.
Outside dimensions must be held when installing curb.
Top surface must be level and straight to insure weathertightness. All corners must be square.
Final electric and gas connections must be made after unit
is installed to allow for tolerance in setting of unit on curb.
For electrical power supply allow approximately eight feet
of wire, plus provisions for weathertight flexible conduit for
connection to unit, as required by local codes.
Maintain a 12" (30 cm) minimum height from top of roof
deck to top of curb.
Caulk butt joints after curb is assembled and installed on
roof structural members and roof flashing is added.
Figure 8.2 - Typical Curb Details
Curb Gasketing*
or Caulk by Others
2"x4" (5x10 cm)
Counterflashing
Wooden
(By Others)
Nailing Strip*
Roofing
Curb*
Material
(By Others)
Figure 8.1 - Suggested Sound Attenuation
Insulation
(By Others)
Cant Strip
(By Others)
2" (5 cm) Acoustic
Fiberglass
(By Others)
Roof Insulation
(By Others)
Roof
Truss
6" (15 cm)
Inverted
Channel
Both Sides
(By Others)
Roof Deck
*Available as a factory supplied, field installed accessory.
CURB OR SUB-BASE MOUNTED SITES
An optional roof curb is available to simplify site preparation
and raise the unit above roof water and snow level for drainage.
It can be installed with the roof, and in advance of the unit. A
sub-base must be furnished by the installer if no curb is supplied
for the roof. The sub-base, either steel or concrete, must provide
required support with the unit bolted to sub-base. The following
are some general guidelines for roof curb installed units:
1. The roof structure must be adequately designed to
support the live weight load of the unit and any other
required support structure. For the bearing loads normally
encountered, the roof curb should be supported at points
no greater than 5 feet (152 cm) apart. Additional truss
reinforcement should be provided, if necessary.
2. Roof curb must be installed level. If roof is pitched it will be
necessary to construct a sub-base on which to install the
curb.
3. Roof curbs supplied by Modine are fabricated from 16
gauge galvanized steel and supplied knocked down for
assembly on the job site. The curb consists of two side
pieces, two end pieces, gasketing, four joiner angles,
four 2"x4" (5x10 cm) wood nailing strips, nuts, bolts, and
washers. Roof curbs over 120" (305 cm) long include two
additional side pieces and two splice plates. Refer to the
latest revision of Modine literature 5-590 for instructions.
8
5-572.11
ROOF CURB INSTALLATION
SITES D’INSTALLATION SUR REBORD OU
SOUS-FONDATION
Figure 9.1 - Détails d’un rebord typique
Un rebord de toit est proposé en option pour simplifier la
préparation du site et rehausser l'appareil au-dessus des
niveaux d'eau et de neige sur le toit pour l’évacuation. Il peut
être installé avec le toit et avant l'appareil. Une sous-fondation
doit être prévue par l’installateur si aucun rebord n’est fourni
pour le toit. La sous-fondation, en acier ou en béton, doit offrir le
soutien requis une fois l’appareil boulonné à celle-ci. Directives
générales pour les appareils installés sur un rebord de toit :
1. La structure du toit doit être correctement conçue
pour soutenir la charge utile de l'appareil et de toute
autre structure de soutien requise. Pour les charges
normalement rencontrées, le rebord de toit doit être
soutenu à des endroits se trouvant à une distance
maximale de 152 cm (5 ft). Au besoin, une poutre de
renforcement supplémentaire devra être fournie.
2. Le rebord de toit doit être installée de niveau. Si le toit
est incliné, il faudra prévoir la construction d’une sousfondation sur laquelle le rebord sera installé.
3. Les rebords de toit offerts par Modine sont fabriqués avec
de l’acier galvanisé de calibre 16 et fournis démontés
pour l’assemblage sur le chantier. Le rebord comprend
deux pièces latérales, deux pièces d’extrémité, des joints,
quatre angles de menuisier, quatre bandes de clouage
en bois de 5 x 10 cm (2" x 4"), des écrous, des boulons
et des rondelles. Les rebords de toit mesurant plus de
305 cm (120") de longueur incluent deux pièces latérales
supplémentaires et deux plaques d’épissure. Pour les
instructions, reportez-vous à la dernière version de la
documentation 5-590 de Modine.
4. Les dimensions extérieures doivent être respectées lors de
l’installation du rebord. La surface supérieure doit être de
niveau et droite pour assurer l’étanchéité météorologique.
Tous les angles doivent être carrés.
5. Les branchements électriques et raccordements au gaz
définitifs doivent être établis après l’installation de l'appareil
sur le rebord. Pour l'alimentation électrique, comptez
approximativement 2,4 m (8 ft) de câble et prévoyez un
conduit flexible étanche pour le raccordement à l'appareil,
selon les exigences des codes locaux.
6. Maintenez une hauteur minimale de 30 cm (12") du haut du
platelage de toit jusqu’à la partie supérieure du rebord.
7. Calfeutrez les aboutages une fois le rebord assemblé et
installé sur les membres structuraux du toit et après avoir
ajouté le solin de toit.
5-572.11
Joint de rebord ou calfeutrage
effectué par des tiers
5 x 10 cm (2” x 4”)
Contre-solin
Bande de
(par des tiers)
clouage en bois*
Matériau de toiture
Rebord*
(par des tiers)
Isolant
(par des tiers)
Tasseau biseauté
(par des tiers)
5 cm (2”)
Fibre de verre
acoustique
(par des tiers)
Isolant de toit
(par des tiers)
Ferme
de toit
15 cm (6”)
Profilé des deux côtés
Platelage de toit
(par des tiers)
*Disponible en accessoire installé sur le terrain.
9
SLAB MOUNT INSTALLATION / RIGGING INSTRUCTIONS
Slab Mounted Units
Table 10.1 - Slab Anchor Bolt Dimensions
For Horizontal Discharge (Model Digit 2=B or C)
For ground level installation of a horizontal-discharge unit,
prepare a level concrete slab at least 4" (10 cm) thick on
adequate footings and a generous bed of gravel for drainage
(See Figure 10.1). The slab should include threaded 5/8-inch
anchor bolts spaced as shown in Figure 10.1 and Table 10.1.
Anchor bolts should extend at least 1.5" (4 cm) above the
surface of the pad to allow clearance for mounting washers,
nuts and bolts (mounting washers, nuts and bolts by others).
The slab should extend out at least 6" (15 cm) around the
perimeter of the unit.
Digit 2 Model Size
B
All
150/175
All
82.91”
40.61”
(2105.9 cm) (1031.5 cm)
200/225
All
82.91”
42.71”
(2105.9 cm) (1084.8 cm)
E, F, G, or H
82.91”
45.75”
(2105.9 cm) (1162.1 cm)
I, J, or K
118.5”
45.75”
(3009.9 cm ) (1162.1 cm)
E, F, G, or H
82.91”
57.27”
(2105.9 cm) (1454.7 cm)
I, J, or K
118.5”
57.27”
(3009.9 cm ) (1454.7 cm)
G or H
116.03”
45.75”
(2947.2 cm) (1162.1 cm)
I, J, K, or L
151.62”
45.75”
(3851.2 cm) (1162.1 cm)
G or H
116.03”
57.27”
(2947.2 cm) (1454.7 cm)
I, J, K, or L
151.62”
57.27”
(3851.2 cm) (1454.7 cm)
840/960
All
185.02”
57.27”
(4699.5 cm) (1454.7 cm)
100/125
All
106.89”
36.36”
(2715.0 cm) (923.5 cm )
150/175
All
106.89”
40.61”
(2715.0 cm) (1031.5 cm)
200/225
All
106.89”
42.71”
(2715.0 cm) (1084.8 cm)
E, F, G, or H
106.89”
45.75”
(2715.0 cm) (1162.1 cm)
I, J, or K
142.48”
45.75”
(3619.0 cm) (1162.1 cm)
E, F, G, or H
106.89”
57.27”
(2715.0 cm) (1454.7 cm)
I, J, or K
142.48”
57.27”
(3619.0 cm) (1454.7 cm)
350/400
700/800
Figure 10.1 - Slab-Mounted Make-Up Air Unit
B
C
A
250/300
A & B ARE BETWEEN
ANCHOR POINTS
Figure 10.2 - Modèle d’air d’appoint installé sur dalle
DALLE EN BÉTON
SUR UN LIT DE GRAVIER
(10 cm (4”) MINIMAL)
B
10
350/400
A
A ET B SE TROUVENT
ENTRE LES POINTS D’ANCRAGE
5-572.11
B
100/125
500/600
CONCRETE SLAB
ON GRAVEL BED
(4” (10 cm) MIN)
A
82.91”
36.36”
(2105.9 cm) (923.5 cm )
250/300
Modèles montés sur dalle
Pour l’évacuation horizontale (dont le deuxième caractère
du numéro de modèle = B ou C)
Pour l’installation au niveau du sol d’un appareil à évacuation
horizontale, préparez une dalle de béton de niveau d’une
épaisseur d’au moins 10 cm (4") sur des semelles adéquates
et un lit généreux de gravier pour l’évacuation (reportez-vous
à la Figure 10.2). La dalle doit comprendre des boulons
d’ancrage filetés de 5/8" espacés comme dans la Figure 10.2
et le Tableau 11.1. Les boulons d'ancrage doivent se prolonger
au-delà de la surface de la dalle d’au moins 4 cm (1,5") pour
permettre un dégagement suffisant pour la mise en place des
rondelles, des boulons et des écrous (par des tiers). La dalle
doit se prolonger d’au moins 15 cm (6") autour de l’appareil.
Blower Type
(Digit 16)
SLAB MOUNT INSTALLATION / RIGGING INSTRUCTIONS
Tableau 11.1 Dimensions des boulons d’ancrage à la dalle
2e
chiffre
Taille de
modèle
Type de
ventilateur
(16e chiffre)
B
100/125
Tout
82.91”
36.36”
(2105.9 cm) (923.5 cm )
150/175
Tout
82.91”
40.61”
(2105.9 cm) (1031.5 cm)
200/225
Tout
82.91”
42.71”
(2105.9 cm) (1084.8 cm)
E, F, G, or H
82.91”
45.75”
(2105.9 cm) (1162.1 cm)
I, J, or K
118.5”
45.75”
(3009.9 cm ) (1162.1 cm)
E, F, G, or H
82.91”
57.27”
(2105.9 cm) (1454.7 cm)
I, J, or K
118.5”
57.27”
(3009.9 cm ) (1454.7 cm)
G or H
116.03”
45.75”
(2947.2 cm) (1162.1 cm)
I, J, K, or L
151.62”
45.75”
(3851.2 cm) (1162.1 cm)
G or H
116.03”
57.27”
(2947.2 cm) (1454.7 cm)
I, J, K, or L
151.62”
57.27”
(3851.2 cm) (1454.7 cm)
840/960
Tout
185.02”
57.27”
(4699.5 cm) (1454.7 cm)
100/125
Tout
106.89”
36.36”
(2715.0 cm) (923.5 cm )
150/175
Tout
106.89”
40.61”
(2715.0 cm) (1031.5 cm)
200/225
Tout
106.89”
42.71”
(2715.0 cm) (1084.8 cm)
E, F, G, or H
106.89”
45.75”
(2715.0 cm) (1162.1 cm)
I, J, or K
142.48”
45.75”
(3619.0 cm) (1162.1 cm)
E, F, G, or H
106.89”
57.27”
(2715.0 cm) (1454.7 cm)
I, J, or K
142.48”
57.27”
(3619.0 cm) (1454.7 cm)
250/300
B
A
AVERTISSEMENT
350/400
500/600
700/800
C
250/300
350/400
Le non-respect d’une bonne procédure de levage et des
procédures de sécurité qui s’appliquent pourrait mener à
des dommages matériels ou à des blessures graves, voire
mortelles. Le levage doit être effectué uniquement par une
entreprise spécialisée dans le gréage. Utilisez TOUS les
points de levage. Testez le levage pour assurer un bon
équilibre et un bon gréage. Ne procédez jamais au levage de
l’appareil par vents forts.
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.
Four 3/4-inch holes at the extended ends of the mounting
channels are supplied to facilitate lifting the unit with eyebolts
furnished by the installer. With the lifting points identified, the
units can be lifted by crane or helicopter.
1. Follow site preparation instructions for the roof curb, slab,
or 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 curb
or stand on which the unit will be installed.
4. If the unit will be installed on a roof curb:
a. Thoroughly clean and dry the top of the curb surface.
b. Lay a bead of weather resistant caulking on top
perimeter of roof curb as illustrated in Figure 8.2. Note:
If roof curb is supplied by Modine, full perimeter gasket
material is supplied and caulking is not necessary.
5. When lifting the equipment, connect sturdy steel
cables, chains, or straps with eye loops as illustrated in
Figure 11.1. For stability in lifting and lowering and to
prevent damage to the unit, include a spreader bar as
shown in Figure 11.1. Avoid twisting or uneven lifting of the
unit. The cable length from the lifting point on the unit to
the spreader bar should always be longer than the distance
between the outer lifting points.
6. Test lift the unit to check for proper rigging balance before
hoisting to the desired installation location.
7. Once lifted to the installation location, orient the hoisted
unit to match the ductwork locations and set evenly on the
curb or stand.
8. Following the instructions in this manual, make final unit
connections for ductwork, utilities, and controls.
Figure 11.1 - Typical Rigging
General Rigging Instructions
INSTALLER’S
CABLES AND
SPREADERS
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. Never lift in high winds.
INSTALLER’S
EYE BOLTS
ROOF CURB
5-572.11
11
DUCT INSTALLATION / UTILITY CONNECTIONS
Duct Installation
1.
5.
The blower section inlet and/or return air connections,
as well as the furnace furnace discharge are designed to
accept 90° flanged ductwork as shown in Figure 12.1. To
determine locations and dimensions of connections, refer
to the dimensional drawings later in this manual.
Figure 12.1 - Duct Connections
UNIT INLET OR
DISCHARGE
OPENING
1/2"
6.
On horizontal discharge units with Model Digit 2=B, provide
removable access panels on the downstream side of the
unit as shown in Figure 12.1. These openings 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 the heat exchanger due to a lack of
sufficient airflow (CFM). This is not required on horizontal
discharge units with Model Digit 2=C because the cooling
coil cabinet access door can be removed for this purpose.
When a roof curb is used in conjunction with a factory
supplied return air connector, the ductwork can be
fastened to the connectors prior to the unit installation.
The connectors will accept 90° flanged ductwork. See
Figure 12.3.
Figure 12.3 - Discharge and/or Return Air Connectors
UNIT BASE
90° FLANGED
DUCTWORK
2.
3.
4.
90° FLANGED
DUCTWORK
(BY INSTALLER)
ACCESS PANEL FOR
HORIZONTAL DISCHARGE UNITS
(MODEL DIGIT 2=B)
Provide an airtight seal between the ductwork and the unit.
Seams with cracks in the ductwork should be permanently
caulked and/or taped. All duct connections outside the
building MUST be weathertight to prevent rain and snow
from entering the ductwork.
Acoustic duct liners are recommended on all internal supply
and return air ducts.
Provide uniform air distribution over the heat exchanger.
Use turning vanes in the supply ductwork where required to
obtain uniform air distribution. See Figure 12.2.
Figure 12.2 - Recommended Discharge Duct Configs
DIMENSION “B” SHOULD NEVER
BE LESS THAN 1/2 OF DIMENSION “A”
TURNING
VANES
(3” MAX)
PROVIDE LEAK TIGHT ACCESS
PANELS IN DISCHARGE DUCT
FOR HEAT EXCHANGER INSPECTION.
ROOF CURB
RETURN AIR
CONNECTOR
DISCHARGE AIR
CONNECTOR
CAULK ALL MATING SURFACES BEFORE
INSTALLING DUCTWORK TO CONNECTORS
OR SETTING THE UNIT (CAULK BY INSTALLER)
Utility Connections
Utility and control connections can be made to the unit from
the bottom for roof curb-mounted units or through the fixed
side panels for horizontal supply and return units. Holes can be
made in fixed side panels to accommodate utility connections
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 and water leaks.
Venting
1.
TURNING
VANES
(3” MAX)
PROVIDE LEAK TIGHT ACCESS
PANELS IN DISCHARGE DUCT
FOR HEAT EXCHANGER INSPECTION.
2.
3.
4.
TURNING
VANES
(3” MAX)
12
5-572.11
Installation of venting must conform with local building
codes, or in the absence of local codes, with the National
Fuel Gas Code, ANSI Z223.1 (NFPA 54) - Latest Edition.
In Canada, installation must be in accordance with CAN/
CGA-B149.1 for natural gas units and CAN/CGA-B149.2
for propane units.
Units are shipped with the power exhauster discharge
cover factory installed.
Do not modify or obstruct the combustion air inlet louvers
or the power exhauster discharge cover.
Do not add any vents other than those supplied by the
manufacturer.
THIS PAGE INTENTIONALLY LEFT BLANK
5-572.11
13
UNIT INSTALLATION
Gas Connections
1.
WARNING
1. All field gas piping must be pressure/leak tested prior to
operation. Never use an open flame. Use a soap solution
or equivalent for testing.
2. Gas pressure to appliance controls must never exceed
3.4 kPa (14" W.C. or 1/2 psi).
3. To reduce the opportunity for condensation, the minimum sea level input to the appliance, as indicated on the serial
plate, must not be less than 5% below the rated input, or
5% below the minimum rated input of dual rated units.
AVERTISSEMENT
2.
3.
4.
1. Toutes les canalisations de gaz sur site doivent être
testées (pression/fuites) avant usage. Ne recherchez
jamais les fuites avec une flamme nue. Utilisez plutôt de
l’eau savonneuse ou un produit équivalent.
2. La pression de gaz aux commandes de l’appareil ne doit
jamais dépasser 3.4 kPa (35,5 cm C.E. ou 1/2 psi).
3. Pour réduire le risque de condensation, l’entrée minimum
dans l’appareil au niveau de la mer, telle qu’indiquée sur la
plaque de série, ne doit pas être moins de 5 % inférieure à
la valeur d’entrée nominale des appareils à double valeur
nominale.
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.
5.
ATTENTION
La purge de l’air des tuyauteries de gaz doit se faire selon la
procédure ANSI Z223.1 de la dernière édition du « National
Fuel Gas Code » ou des codes CAN/CGA-B149 du Canada.
IMPORTANT
6.
1. Unit can be operated up to a maximum of 10,000 feet
(3048 m).
2. To prevent premature heat exchanger failure, the input to
the appliance, as indicated on the serial plate, must not
exceed the rated input by more than 5%.
IMPORTANT
1. L’unité peut être utilisée jusqu’à un maximum de 3048 m
(10,000 ft).
2. Pour éviter une défaillance prématurée de l’échangeur de
chaleur, le pouvoir calorifique du gaz utilisé ne doit pas
excéder de plus de 5 % la valeur nominale inscrite sur la
plaque signalétique de l’appareil.
14
5-572.11
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 62 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 61.3 for an example Model
ID plate.
For the length of pipe necessary, determine the pipe
diameter from Table 16.1 or Table 16.2 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 100-225 are 1/2" connections, 250-960 are 3/4"
connections). Avoid pipe sizes smaller than 1/2". The inlet
pressure to the unit must be 6-7" W.C. for natural gas and
11-14" W.C. for propane gas. When sizing the inlet gas
pipe diameter, 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.
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 shutoff and easy servicing of controls, including a 1/8" NPT
plugged tapping accessible for test gauge connection (See
Figure 15.1). 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 15.1).
UNIT INSTALLATION
Figure 15.1 - Recommended Sediment Trap/Manual
Shut-off Valve Installation - Side or Bottom Gas
Connection
GAS
SUPPLY LINE
GAS
SUPPLY LINE
MANUAL GAS
SHUT-OFF VALVE
GROUND
JOINT
UNION
W/ BRASS
SEAT
TO
CONTROLS
PLUGGED
1/8" NPT TEST
GAGE CONNECTION
3"
MIN.
SEDIMENT
TRAP
7.
When Pressure/Leak testing, pressures above 14" W.C.
(1/2 psi), close the field installed shut-off valve, disconnect
the appliance and its combination gas control from the gas
supply line, and plug the supply line before testing. When
testing pressures 14" W.C. (1/2 psi) or below, close the
manual shut-off valve on the appliance before testing.
5-572.11
15
UNIT INSTALLATION
Table 16.3 - Burner Orifice Sizing and Gas
Consumption
Table 16.1 - Gas Pipe Capacities - Natural Gas j
Pipe
Length (ft)
10
20
30
40
50
60
70
80
90
100
125
150
175
200
250
Capacity in MBH by Nominal Pipe Diameter
3”
9,009
6,195
4,977
4,253
3,770
3,423
3,150
2,930
2,741
2,594
2,300
2,079
1,911
1,785
1,575
Model
Size
j G
as 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" w.c. and gas specific gravity of 0.60.
300
1∕2”
138
95
76
65
58
53
48
44
42
40
35
32
29
27
24
3∕4”
287
197
159
135
120
109
100
93
87
83
74
66
61
57
50
1”
540
371
298
255
226
205
188
175
165
155
138
125
114
107
95
1 1∕4” 1 1∕2”
1,113 1,659
762 1,145
612
917
524
784
464
695
420
630
386
580
360
540
338
506
319
478
282
423
256
384
235
353
219
329
194
291
2”
3,203
2,195
1,764
1,512
1,344
1,218
1,113
1,038
974
921
816
739
680
632
561
2 1∕2”
5,103
3,507
2,814
2,405
2,132
1,932
1,775
1,659
1,554
1,470
1,302
1,176
1,082
1,008
894
Table 16.2 - 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
k Gas pipe capacities based on Table 6.3.1(d) of NFPA 54 for schedule 40
metallic pipe with inlet pressure of 11.0" w.c., with a pressure drop of 0.5"
w.c. and gas specific gravity of 1.50.
16
100
125
150
175
200
225
250
350
400
500
l
600
l
700
l
800
l
840
m
960
m
Gas Type
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
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
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
2
2
3
3
3
3
4
4
6
6
4
4
6
6
6
6
j B
ased on natural gas properties of 1050 Btu/ft³ and specific gravity of
0.60.
k B
ased on propane gas properties of 2500 Btu/ft³ 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.
5-572.11
UNIT INSTALLATION
CONSIDERATIONS FOR ELEVATION
The standard ratings for the duct furnace(s) used in these
units 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 18. Unit
can be operated up to a maximum of 10,000 feet (3048 m).
needed later for Start-Up. Proceed to the section on this page
titled “Selection of the Proper High Altitude Kit”.
Equation 17.1 - Manifold Pressure for Gas Heating
Values Different Than Shown in Table 17.1
Where:
Manifold Pressure Adjustment
The unit manifold pressure is factory set for operation at
elevations up to 2000 feet as follows:
• For Natural Gas units, 3.5" W.C. based on a gas heating value
of 1,050 BTU/ft³.
• For Propane Gas units, 10.0" W.C. based on a gas heating
value of 2,500 BTU/ft³.
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 17.1 shows the standard
derated heating values of natural and propane gases at various
elevations.
Table 17.1 - Gas Heating Values at Altitude (Btu/ft³)
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
Propane
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
MPELEV
= Manifold Pressure (" W.C.) at installed
elevation
BTUTBL
= BTU/ft³ content of gas from Table 17.1
BTUACT
= BTU/ft³ content of gas obtained from the
utility company
MPSL
= Manifold Pressure (" W.C.), at Sea Level
(use 3.5" W.C. for natural gas and
10.0" 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 17.2
Table 17.3 shows the contents of the kit. For more information,
refer to the latest revision of Modine Bulletin 75-530.
Table 17.2 - High Altitude Kit Selection Table jkl
Model
Model
Size
All
All
Elevation Above Sea Level (ft)
2,001-5,500 5,501-6,500 6,501-7,500
Item Code
67248
67248
67248
j Applies to both installations in the U.S. and Canada.
k Applies to both natural and propane gas.
l S
izes 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.
j Values shown are for 3.5" W.C. manifold pressure for Natural Gas and
10.0" W.C. for Propane Gas. If the local utility supplies gas with a different
Btu/ft³ value, use Equation 17.1 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/ft³ for Canada
m 2,250 Btu/ft³ for Canada
n When installed at altitudes above 2,000', a pressure switch may need to
be changed. Refer to Table 17.2 and Table 17.3 to determine if a switch
change is required.
If the utility is supplying gas with heating values SAME as
shown in Table 17.1, the manifold pressure should remain set
to 3.5" W.C. for natural gas and 10.0" 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 17.1, use Equation 17.1 to determine the
appropriate manifold pressure for the elevation and gas heating
value being supplied. Note what that value is, as it will be
Table 17.3 - High Altitude Kit Contents
Item
Code
67248
Kit Contents
High Altitude
Conversion Label
Pressure
Switch
Installation
Instructions
Yes
No
Yes
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.
5-572.11
17
UNIT INSTALLATION
Electrical Connections
2.
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°C.
4. Ensure that the supply voltage to the appliance, as
indicated on the serial plate, is not 5% greater than rated
voltage.
AVERTISSEMENT
1. Débranchez l’alimentation électrique avant d’effectuer
des connexions ou de travailler sur l’appareil. Respectez
toutes les procédures de sécurité qui s’appliquent pour
éviter toute mise en marche accidentelle. Le non-respect
de cette directive peut entraîner des blessures ou la mort
causées par un choc électrique ou des pièces mobiles, en
plus d’endommager l’appareil.
2. Tous les appareils doivent être branchés de manière
strictement conforme au diagramme fourni. Tout câblage
différent de celui du schéma peut créer des risques de
dommages matériels ou de blessures.
3. Tout câblage usine d’origine exigeant un remplacement
doit être remplacé par un câble d’indice thermique nominal
de 105 °C.
4. Assurez-vous que la tension d’alimentation de l’appareil,
comme indiqué sur la plaque de série, n’est pas de 5 %
supérieure à la tension nominale.
3.
4.
5.
6.
7.
Table 18.1 - 24V and Digital Control Wire Lengths
CAUTION
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 attempt to reuse any mechanical or electrical
component which has been wet. Such component must be
replaced.
8.
ATTENTION
1. Vérifiez que la tension d’alimentation de l’appareil n’est pas
inférieure de plus de 5 % à la tension nominale inscrite sur
la plaque de série.
2. Ne tentez pas de réutiliser un composant mécanique ou
électrique qui a été mouillé. Ces composants doivent être
remplacés.
1.
18
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
located in the blower compartment. 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) may 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 hole 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.
The wire gauge must be sized according to the National
Electric Code or CSA code based on amp draw and length
of run. Refer to Table 18.1 for maximum wire lengths that
can be wired between components and the terminal block
on the unit based on the wire gauge being used.
Installation of wiring must conform with local building
codes, or in the absence of local codes, with the National
Electric Code ANSI/NFPA 70 - Latest Edition. Unit must
be electrically grounded in conformance to this code.
In Canada, wiring must comply with CSA C22.1, Part 1,
Electrical Code.
5-572.11
Maximum Distance (feet) from
Control Device to Unit
Minimum
Recommended
Wire Gauge
24V Control Wiring
Digital Control Wiring
22
20
18
16
14
n/a
n/a
75
125
175
120
200
300
500
n/a
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:
• 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 19.1).
• Remove approximately 3/8” of insulation from the end of
the wire and push the stripped wire into the oval hole in
the terminal.
• 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).
UNIT INSTALLATION
Figure 19.1 - 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
9.
Factory Mounted Option Locations (Figure 29.1) 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 29.1. 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.
Figure 19.2 - Recommended Accessory Field
Installed Disconnect Switch Mounting Locations
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. Depending on the unit configuration, the
sensor may be duct mounted or remote mounted.
• 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.
• 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.
Evaporative Cooler Installation
For units equipped with an evaporative cooler (Model Digit
22=D), refer to Installation and Service Manual - Evaporative
Coolers (Literature 5-588).
Evaporative Cooler operating conditions.
• Min. Water Pressure: 35 psig (241 kPa)
• Max. Water Pressure: 100 psig (689 kPa)
• Min. Water Temperature: 40 F (4 C)
• Max. Water Temperature: 130 F (54 C)
Conditions d’utilisation du refroidisseur par évaporation.
• Pression d’eau : 241 kPa (35 psig)
• Pression d’eau : 689 kPa (100 psig)
• Température de l’eau : 4 °C (40 °F)
• Température de l’eau : 54 °C (130 °F)
Figure 19.3 - Evaporative Cooler (Model Digit 22=D)
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
5-572.11
19
UNIT INSTALLATION
Cooling Coil Units
Direct Expansion (DX) Piping
Units with a cooling section (Model Digit 2=C or P) can be
provided with a factory installed direct expansion (DX) coil, or
the coil can be field supplied and installed by others. For units
equipped with a factory installed cooling coil (Model Digit 23=1),
refer to the packing slip to determine the coil type provided.
The section includes a full coverage, 3-way sloping stainless
steel drain pan to remove condensate from coil headers and
piping components. 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 1" 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 1.5" (3.8 cm) 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. 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"(10.2 cm), 5"(12.7 cm), 6"(15.2 cm),
7.5" (19.1 cm), and 10" (25.4 cm) deep coils.
Figure 20.1 - Cooling Section (DX Coil Shown)
Optional double
wall construction
The refrigerant lines should be insulated to prevent warming
or cooling of the refrigerant. If the suction line is allowed to be
cooled, liquid will condense in the line and can severely damage
the compressor. If the liquid line is warmed, the refrigerant
can "flash" into a gas. This will cause erratic operation of
the expansion device and impair the heat transfer ability of
the cooling coil. Long runs of piping need to be periodically
supported to prevent excess vibration that can damage the
piping and joints. It is recommended to provide dampening
supports at intervals of length equivalent to 15 tube diameters.
Figure 20.2 - General DX Piping
SUCTION HEADER
DISTRIBUTOR
EQUALIZER LINE
LIQUID LINE
SUCTION LINE
REMOTE
SENSING BULB
2.
3.
Optional Factory
Installed
DX coil.
Fin spacings
of 10,12 or 14 fins
per inch
Adjustable
mounting bracket
for 4 and 6 row
coils
4.
5.
6.
7.
Full coverage
3-way sloping
409 stainless
steel drain pan
Right or left hand coil
header access to match
gas controls
1” stubbed drain
connection
8.
Condensate Drain Pan Trap
The condensate drain line needs to include a P-trap immediately
downstream of the connection to the unit. This trap should
extend at least 2" (5 cm) below the connection to prevent air
pressure from forcing air into the unit. The trap should be primed
with a water/glycol solution to prevent freezing.
20
NOZZLE
EXPANSION
VALVE
(BY OTHERS)
1.
DX single circuit (shown) and
dual circuit coils available
COIL
5-572.11
STRAPS
SUCTION CONNECTION
Inspect the refrigerant distributor and verify that the nozzle
is in place.
All field brazing 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.
The use of filter-dryers in the system piping is
recommended along with a sight glass that has a moisture
indicator.
Connect the suction line and suction connection.
Install the expansion valve (by others). Follow the
expansion valve manufacturer's recommendations for
installation to avoid damaging the valve.
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.
If the coil holds pressure, the installation can be
considered leak free. If the pressure drops by 5 psi or
less, repressurize the coil and wait another 10 minutes. If
the pressure drops again, there are more than likely one or
more small leaks, which should be located and repaired.
Pressure losses greater than 5 psi would indicate a larger
leak, which should be isolated and repaired. Be sure to
check valves and fittings as potential sites for leakage or
bleed.
Use a vacuum pump to evacuate the coil and any
interconnecting piping that has been open to atmosphere.
Measure the vacuum in the piping using a micron gauge
located as far from the pump as possible (the vacuum
at the pump will be greater than the rest of the system).
Evacuate the coil to 500 microns or less then close the
valve between the pump and the system. If the vacuum
holds to 500 microns or less for one minute, the system is
ready to be charged or refrigerant pumped down in another
portion of the system can be opened to the coil.
UNIT INSTALLATION
A steady rise in microns would indicate that moisture is still
present and that the coil should be further vacuumed until
the moisture has been removed.
9. Failure to obtain a high vacuum is indicative of a great
deal of moisture or a small leak. Break the vacuum with a
charge of dry nitrogen or other suitable gas and recheck
for leaks (soapy water works well). If no leaks are found,
continue vacuuming the coil until the desired vacuum is
reached.
10 All field piping must be self-supporting.
Table 21.1 - Cooling Coil Performance Limits
Cooling Model
Type
Size
Min
CFM
100
802 l
125
926
150
1,111
175
1,296
200
1,481
225
1,667
250
1,852
300
2,222
350
2,593
400
2,963
DX
Single Circuit
Dual Circuit
Max
CFM j
Area
(ft²)
Max
CFM j
Area
(ft²)
Max
Cooling
(Tons) k
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
j Based on 550 feet per minute (FPM) coil face velocity.
k Based on 95°F/75°F Entering Dry Bulb/Wet Bulb.
l Model Size 100 minimum CFM for DX Dual Circuit is 745.
5-572.11
21
START-UP PROCEDURE
Start-Up Procedure
IMPORTANT
1. T
o prevent premature heat exchanger failure, observe
heat exchanger tubes by looking at the heat exchanger
through the field installed access openings in connecting
ductwork or the unit access doors where viewing the heat
exchanger is possible. 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 26 for Blower
Adjustments.
2. Start up and adjustment procedures, installation, and
service of these appliances must be performed by a
qualified installation and service agency.
IMPORTANT
1. P
our éviter la défaillance prématurée de l’échangeur de
chaleur, examinez les tubes de l’échangeur de chaleur en
le regardant à travers les ouvertures d’accès installées
sur les lieux lors de la connexion des tuyaux ou les portes
d’accès à l’unité où il est possible de voir l’échangeur
de chaleur. Si le bas des tubes devient rouge lorsque
la soufflante et la chaudière canalisée sont en marche,
vérifiez que le régime de la soufflante est approprié pour
l’application. Pour le réglage de la soufflante, reportezvous à la page 26.
2. Les procédures de démarrage et de réglage, l’installation
et le service de ces appareils doivent être confiés à un
centre d’installation et de service qualifié.
Refer to page 60 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 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 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.
22
12. For units with a return air damper, the return air damper
linkage needs to be adjusted. Refer to Damper Linkage
Adjustment.
13. Check to make sure that the damper opens properly
without binding.
14. Check the blower wheel for proper direction of rotation
when compared to the air flow direction arrow on the
blower housing. Blower wheel rotation, not air movement,
must be checked as some air will be delivered through the
duct furnace with the blower wheel running backwards.
15. Check the blower speed (rpm). Refer to Blower
Adjustments for modification.
16. Check the motor speed (rpm).
17. Check the motor voltage. On three phase systems, check
to make sure all legs are in balance.
18. Check the motor amp draw to make sure it does not
exceed the motor nameplate rating. On three phase
systems, check all legs to insure system is balanced.
19. Recheck the gas supply pressure at the field installed
manual shut-off valve. The minimum inlet pressure should
be 6" W.C. on natural gas and 11" W.C. on propane gas.
The maximum inlet pressure for either gas is 14" W.C. If inlet pressure exceeds 14" W.C., a gas pressure regulator
must be added upstream of the combination gas valve.
20. Open the field installed manual gas shut-off valve.
21. Open the manual main gas valve on the combination
gas valve. Call for heat with the thermostat and allow the
pilot to light for intermittent pilot ignition. If the pilot does
not light, purge the pilot line. If air purging is required,
disconnect the pilot line at outlet of pilot valve. In no case
should the 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.
5-572.11
START-UP PROCEDURE
Pilot Burner Adjustment
The pilot burner is orificed to burn properly with an inlet pressure
of 6-7" W.C. on natural gas and 11-14" W.C. on propane gas.
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" to 1" long and
encompassing 3/8"-1/2" of the tip of the flame sensing rod
(See Figure 23.1).
4. Replace the cap from the pilot adjustment screw.
Figure 23.1 - Correct Pilot Flame
Flame Sensing Rod
3/4" to 1"
5-572.11
23
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 “OFF”.
2. Remove the 1/8" pipe plug in the pipe tee or gas valve and
attach a U-tube type water manometer which is at least 12"
high and capable of reading to 0.1" W.C. See Figure 24.1.
3. Turn the field installed manual gas shut-off valve to “ON”.
Figure 24.1 - Checking Gas Pressure with 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 24.1. 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, or 9). Refer to the
appropriate instructions for the valve type on the unit.
For Units with Model Digit 12=4 or 7:
The low fire gas pressure needs to be adjusted. This needs to
be repeated on each furnace in multiple furnace units. Using
Figure 24.2 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 cover plate (2), 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" W.C. for natural gas and 1.6" 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" W.C. for natural gas and 10" 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, remove the manometer, and
replace the 1/8" pipe plug.
N
(Natural)
P
(Propane)
Furnace
Model Digit 12
1, 2, 4, 7
9
1, 2, 4, 7
9
24
1
10
2
3
4
5
9
Manifold Pressure
3.5”
4.0”
10.0”
10.5”
8
7
j F
or 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.
(continued next page)
Figure 24.2 - Maxitrol Modulating Valve Adjustments
Table 24.1 - Manifold Gas Pressure - Main Valve
Furnace
Model Digit 11
After adjustment, move the field installed manual shut-off
valve to the “OFF” position, remove the manometer, and
replace the 1/8" 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 "Air Shutter Adjustment".
If the unit has Electronic Modulation gas controls (Model
Identification Digit 12=4, 7, or 9), skip steps 7 through 9 in
this section and proceed to the next section "Check/Adjust
Pressure for the Modulating Valve", otherwise continue to
the next step.
5-572.11
6
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
START-UP PROCEDURE
Check/Adjust Pressure for the Modulating Valve (continued)
1. 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.
2. Proceed to the section "Air Shutter Adjustment".
6.
7.
8.
9.
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" 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 "Air Shutter Adjustment".
Figure 25.1 - Maxitrol EXA Modulating Valve
BUTTON #2
SUPPLY POWER TERMINALS
CONTROL SIGNAL TERMINALS
BUTTON #1
1
2
3
4
POSITION FEEDBACK
WIRING TERMINALS
ON
DIP SWITCHES
(1=“OFF”, 2=“ON”, 3=“OFF”)
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" W.C. for propane gas per instructions and Table 24.1
on the previous page. For multiple furnace units, the
furnaces without the modulating valves are to remain
at 3.5" W.C. for natural gas or 10.0" 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 25.1.
3. Verify that the DIP switches are properly set to the "OFF"
position for switches 1 and 3 and "ON" 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" 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" W.C. cannot be attained, recheck the inlet gas
pressure as described previously. After addressing
any issues, if 3.5" 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" 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.
5. 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.
d.
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 24.1. 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 56.1). 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. To 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. To decrease primary air, move the air shutters away from
the manifolds until flames no longer lift from burner ports,
but being careful not to cause yellow tipping.
3. Re-tighten set screws after adjustment.
5-572.11
25
START-UP PROCEDURE
Blower Adjustments
All belt drive supply fan speed adjustments can be made with
the adjustable sheave on the blower motor as follows:
1. Refer to page 43 to determine correct blower speed
according to job requirements, then proceed to the next
step.
2. Turn off power to the unit at the disconnect switch. If
equipped with gas heat option, turn all hand gas valves to
the “OFF” position.
3. Loosen the belt tension and remove the belt.
4. On the motor sheave, loosen the set screw on the side
away from the motor (see Figure 26.1).
Figure 26.1 - Motor Sheave Adjustment
SET SCREW
MOTOR
SHAFT
6.
7.
8.
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
ADJUSTABLE HALF
OF SHEAVE
5.
11. Check the motor amps to ensure the maximum motor amp
rating is not exceeded. Verify airflow volume and repeat
steps above for further adjustment.
12. If equipped with gas heat, turn on the gas and initiate
burner operation.
13. Verify the temperature rise and supply air temperature of
the heating section do not fall outside the range or exceed
the maximums shown in Table 37.1.
14. After 24 hours of operation, retighten the setscrews to the
torque listed in the owners manual on the bearing, sheave,
and blower wheel to avoid damage to the unit.
Turn outer side of motor sheave clockwise until motor
sheave is fully closed.
From fully closed position, turn outer side of motor sheave
counterclockwise until the proper number of turns open
are achieved. Turns should be done in half-turns (180°
rotations). Each half turn results in a change of blower
speed and air volume of approximately 2.5-5%. Adjusting
the half of the sheave inward increases blower speed,
adusting outward decreases blower speed.
Tighten the set screw on the flat portion of the motor shaft.
Replace the belt and verify that the belts are aligned in the
sheave grooves properly and are not angled from sheave
to sheave.
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 26.3.
4. Tighten the 5/16" hex head screw on the ball joint.
Figure 26.3 - Damper Linkage Adjustment
BALL JOINT
CONNECTING ROD
BLADE ARM
DAMPER
BLADE
Figure 26.2 - Belt Tension Adjustment
Furnace Control Operating Sequence
IMPORTANT
To prevent premature heat exchanger failure, with all control
systems, a blower starting mechanism must be provided so
that the blower is running or energized within 45 seconds of
the gas control operation.
3/4" DEFLECTION
WITH 5 LBS. OF FORCE
Retighten motor base. Motor base should be shifted for
proper belt tension which is 3/4" deflection with about 5 lbs.
of force. Refer to Figure 26.2.
10. Turn on power to the unit and initiate blower motor
operation. Do not fire gas controls until blower adjustment
has been made or unit may cycle on high limit control.
IMPORTANT
9.
26
Pour éviter la panne prématurée de l'échangeur thermique,
avec tous les systèmes de commande, un mécanisme
de démarrage de la soufflerie doit être fourni pour que
la soufflerie démarre dans les 45 secondes qui suivent
l'activation de la commande de gaz.
5-572.11
START-UP PROCEDURE
c.
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.
Control Options (see page 30) could change the listed
sequence of operation for the unit based on their function. The
descriptions given below are for the basic duct furnace.
Single Furnace Controls
Single furnace units (Model Digits 4-6=100 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 or 7):
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:
• Modulating room thermostat
• Modulating duct thermostat with remote temperature set
point adjuster
• Building Management System (BMS) signal by others
(an inverted signal where 0VDC is high fire and 10VDC
is low fire).
• Electronic Modulating Control with Modine Control
System (Model Digit 12=9): These furnaces utilize a singlestage 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:
• A duct temperature sensor
• A space temperature sensor
• There is also BMS integration capability for BACnet or
LonWorks protocol systems.
The control operating sequence for all furnaces is as follows:
1. The thermostat calls for heat or is enabled by the BMS.
2. The power exhauster relay is energized starting the
power exhauster motor. Once the motor has reached full
speed, the differential pressure switch closes. The power
exhauster pre-purge time delay relay then closes after 20
to 40 seconds and energizes the gas control circuit.
3. The pilot valve opens and the spark igniter sparks in an
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.
4. Once the pilot is lit, the flame sensor proves the pilot and
stops the spark igniter from sparking.
5. The main gas valve is opened and the main burner is
controlled as follows:
a. Single-Stage Furnaces (Model Digit 12=1): The main
burner is lit to 100% full fire.
b. Two-Stage Furnaces (Model Digit 12=2): The main
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.
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.
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. BMS Signal (Model Digit 12=7): The main gas valve
is opened 100% and the burner firing rate is modulated
between 40% and 100% full fire. A BMS 0-10VDC
signal (inverted, such that 0 VDC is high fire and 10
VDC 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.
Note:
For further information regarding the operation of any of
the electronic modulating system options above, consult
the literature provided with the unit.
e. Modulating with Modine Control System (Model
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
6.
7.
5-572.11
with the space sensor used to reset the supply air
temperature setpoint. For additional information, refer to
the Modine Control System Manual, literature #74-510
that shipped with the unit.
If the unit was provided with a time delay relay, the blower
starts after 30 to 45 seconds.
Once the temperature is satisfied, both the main and pilot
valves close 100%. Blower operation may or may not
continue, depending on application.
27
START-UP PROCEDURE
Multiple Furnace Controls
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).
• Two furnace units would be controlled as 2-stage
(50%/50%).
• 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): For
control of multiple electronic modulation furnaces for BMS
control (0-10VDC control signal), each furnace would be
individually controlled. Refer to the section for Single Furnace
Controls, Electronic Modulation Control (Model Digit 12=7).
• 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.
the reduced airflows, the unit must be applied as follows:
The unit has 2-stage or modulating gas controls.
The unit is provided with a discharge air thermostat.
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°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 28.1 - Extended Range VAV Minimum Airflow
Minimum Airflow (CFM)
Input Rating
(Digit 4-6)
100
125
150
175
200
225
250
300
350
400
500
600
700
800
840
960
Variable Air Volume Applications
Units may be supplied with field installed 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 28.1 and Table 37.1, unless certain conditions are
followed. Refer to the following section titled "Extended VAV
Airflow Limits" for additional information.
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:
• Two speed which may be controlled by a manual high/low
switch which may be factory mounted on the control panel or
shipped loose for field installation or by exhaust fan interlocks.
• Building management control which allows for an external
signal of 0-10VDC to adjust the unit airflow.
Additional options are available when the unit is configured with
the Modine Control System option (Model Digit 12=9).
Low ATR
(Digit 10=H)
Extended
Standard
Range 
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
2,888
5,000
3,300
3,125
2,063
3,750
2,475
4,375
2,888
5,000
3,300
6,562
4,331
7,500
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.
2.
Extended VAV Airflow Limits
If certain conditions are followed, the allowable minimum CFM
of the system can be extended to:
75% of the minimum listed CFM in Table 37.1 for high air
temperature rise units (Model Digit 10=H)
66% of the minimum listed CFM in Table 37.1 for low air
temperature rise units (Model Digit 10=L).
Refer to Table 28.1 for a summary of the reduced minimum
airflows, indicated in the column "Extended Range". To allow
28
High ATR
(Digit 10=H)
Extended
Standard
Range 
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
1,969
3,000
2,250
-
5-572.11
Airflow must be properly distributed across the coil face and
should not vary by more than 20%.
Air velocities should be maintained between 200 and 550
feet per minute. Refer to Table 21.1.
COMPONENT/OPTION LOCATIONS
For location of standard and optional factory installed components, refer to Figure 29.1 and the descriptions on the following pages.
Figure 29.1 - Factory Mounted Option Locations
1. Discharge Thermostat (not shown)
2. Low Gas Pressure Switch
3. High Gas Pressure Switch
4. Power Exhauster
5. Timed Freeze Protection
6. Ignition Controller
8. Control Relay
9. Time Delay Relay
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
16. Dead Front Disconnect Switch
17. Step Down Transformer Fuses
18. Step Down Transformer
19. Factory Installed Minimum Positioner
22. Return Air Fire Stat
23. Blower Housing
24. Pillow Block Bearings
25. Blower Motor
26. Filters
27. Fresh Air Damper
29. Rainhood and Birdscreen
30. Direct Drive Damper Actuator
32. Damper to Damper Linkage
33. Return Air Damper
35. Motor and Blower Vibration Isolation
36. Blower Support
37. Convenience Outlet
38. Blower Door Switch
39. Dirty Filter Switch
40. Motor Starter
41. Mild Temperature Thermostat
43. Warm-Up Stat
44. Blower Supply Power Terminal Strip
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
53. Direct Drive Damper Actuator
54. Discharge Damper
For Modine Control System Units Only
(Model Digit 12=9):
Furnace Control Panel(s) for
Modine Control System Equipped Units (Model Digit 12=9)
57
56
13
58
12
11
12
11
59
6
6
49
50
50
49
48
10
10
60
Single Furnace Units or
Primary Furnace on Multiple Furnace Units
Secondary Furnace(s) on Multiple Furnace Units
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)
64 Carel pGD1 Digital Display/Interface Module
(not shown)
5-572.11
29
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. Refer to
Figure 29.1 for the descriptions on the following pages.
(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
R
B
W
R
B
W
(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"
W.C. for natural gas, 11" W.C. for propane gas).
(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" W.C. for
natural gas, 10" W.C. for propane gas).
Low and High Gas Pressure Switches
THERMOSTAT BODY
(COVER REMOVED)
b. 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.
(4) Duct Furnace Power Exhauster – (STD)
The power exhauster, on a call for heat, creates a combustion
draft through the duct furnace prior to the pilot being energized.
The draft is proven through the power exhauster motor
centrifugal switch that closes when the motor reaches full
speed. The unit door includes a power exhauster discharge
cover and inlet combustion louvers. For information about
venting, refer to the Installation – Venting section.
Note: Second stage S350
module not shown.
c.
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
(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°-75°F adjustable) and will shut down the unit.
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.
Timed Freeze Protection Module
d. Supply Air Sensor (Model Digit 12=9) (not shown)
Used on units with Modine Control System option,
the sensor includes either a fixed or adjustable length
sensor field installed in duct work. Refer to Literature
74-541 latest revision for instructions.
30
5-572.11
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 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.
(8) Control Relay – (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 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 is not cold. The time delay relay
also keeps the motor running for approximately 30 seconds after
the call for heat has been satis­fied to remove the residual heat
from the heat exchanger. For single phase units below 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 terminal strip is labeled to match the electrical wiring
diagram provided with the unit. 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.
(15) Blower Low Voltage 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 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
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.
AVERTISSEMENT
Débranchez l’alimentation électrique avant d’effectuer des
connexions ou de travailler sur l’appareil. Respectez toutes
les procédures de sécurité qui s’appliquent pour éviter
toute mise en marche accidentelle. Le non-respect de cette
directive peut entraîner des blessures ou la mort causées
par un choc électrique ou des pièces mobiles, en plus
d’endommager l’appareil.
The dead front disconnect switch is factory installed in the
blower 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 31.1). When in the “OFF”
position, power is disconnected to all unit wiring electrically
following the switch (See Warning). For servicing the unit,
the disconnect switch can be manually overridden by using a
wrench and turning the disconnect switch shaft 90° clockwise.
Figure 31.1 Dead Front Disconnect Switch Assembly
BLOWER SECTION
ELECTRICAL
COMPARTMENT
ACCESS DOOR
DISCONNECT
SWITCH HANDLE
OPERATION
INSTRUCTION
LABEL
(11) Power Exhaust 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.
(12) Furnace 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.
DISCONNECT
SWITCH HANDLE
SHOWN IN THE
"ON" POSITION
(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 for the gas
controls, damper actuator, relays, etc. Refer to Model Digit 15
of the unit model nomenclature to determine the volt-amp (VA)
capacity of the transformer.
(14) Control Relay – (OPT)
The control relay is factory installed in the blower electrical
section. See description of Option 8 for additional details.
SUPPLY POWER
WIRING TERMINALS
(SEE WARNING)
DISCONNECT
SWITCH HANDLE
SHOWN IN THE
"OFF" POSITION
(17) Step Down Transformer Fuses – (OPT)
The transformer fuses are factory installed in the blower
electrical section. The fuses are included to protect the
transformer.
5-572.11
31
COMPONENT DESCRIPTIONS
(18) Step Down Transformer – (OPT)
The step down transformer is factory installed in the blower
electrical section. The transformer is required as follows:
Without Evap Cooler (Model Digit 22=0)
• Supply voltage of 460V/3Ph or 575V/3Ph (Model Digit 14=F or
G). The transformer reduces the voltage to 115V for the power
exhauster(s).
With Evap Cooler (Model Digit 22=D)
• Supply voltage of 208V/1Ph or 208V/3Ph (Model Digit 14=B
or D). The transformer reduces the voltage to 115V for the
evaporative cooler. The power exhauster(s) will be 208V.
• Supply voltage of 460V/3Ph or 575V/3Ph (Model Digit 14=F or
G). The transformer reduces the voltage to 115V for the power
exhauster(s) and evaporative cooler.
For all other configurations, the transformer is not required.
(19) Minimum Positioner – (OPT) (All Except Model Digit
12=9)
The factory installed minimum positioner is installed in the
blower 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.
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.
Figure 32.1 - Minimum Positioner
(22) Return Air Fire Stat – (OPT)
The return air fire stat is factory installed in the blower electrical
section with the sensor in the return air stream. In case of
elevated temperatures at the sensor, 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
temperature, take corrective action, and then reset the switch.
(23) Blower Housing – (STD)
The blower section contains a double width, double inlet (DWDI)
blower wheel. Both sides of the blower must be free from
obstructions for proper operation. For Right Hand units (Model
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 (Model Digit 9 = L), 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.
bearings. Spider bearings are permanently lubricated and
do not require lubrication. Pillow block bearings are shipped
non-greased from the factory and require lubrication before
start-up. For lubrication recommendations, see Lubrication
Recommendations.
(25) Blower Motor – (STD)
The blower motor 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" permanent filters, 2" pleated throwaway filters in MERV 8
or 13 ratings. For filter replacement, refer to Maintenance.
(27) Fresh Air Damper – (OPT)
When a fresh air damper is supplied with the unit, the damper
is used as an outside air shut-off damper. The damper is ultra
low leak, Class II leakage resistance (less than 10 CFM/ft² at 1"
W.C.) dampers with self-compensating stainless steel side seals
and santoprene and galvanized steel blade seals.
(29) Rainhood and Birdscreen – (OPT)
The rainhood and birdscreen is shipped loose for field
installation at the back of the blower section. For installation
instructions, refer to Literature 5-589, latest revision.
(30) Direct Drive Damper Actuator – (OPT)
The direct drive damper actuator is factory installed on the side
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
(Model 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 (Model Digit 9 = L), the
actuator should rotate in the clockwise direction when viewed
from the service side of the unit. Two different types of dampers
actuators can be provided: Two Position and Modulating.
• 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, "Setting the Damper Limiter"). 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° 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 accom­plished by the following:
(continued next page)
(24) Pillow Block Bearings – (OPT)
The blower can be provided with either spider or pillow block
32
5-572.11
COMPONENT DESCRIPTIONS
1.
2.
3.
4.
5.
6.
etermine the maximum outside air % required.
D
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
below which is shown at 50% rotation limit.)
Position the limiter to the desired position, making sure the
locating “teeth” on the limiter are engaged into the locating
holes on the actuator.
Fasten the limiter to the actuator using the screw provided.
Test the damper rotation either manually with the manual
crank or apply power. Re-adjust if necessary.
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, "Adjusting the Damper End Switch".
Figure 33.1 - Two-Position Damper Actuator Limiter
• Modulating Damper Actuator: A modulating actuator is
provided with Air Control options (Model Digits 20-21=GA,
GC, or GE). The actuator provides incremental operation of
the fresh air damper (the return air damper is controlled by
the fresh air damper position). Full 90° rotation of the actuator
requires 150 seconds. Actuators operate using a 0-10 Vdc
input signal 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 74510 for additional information.
(32) Damper to Damper Linkage – (OPT)
Units with fresh and return air dampers include a damper
actuator that controls the fresh air damper. The return air
damper position is controlled by the fresh air damper through
the connecting rod. For adjustment, refer to Damper Linkage
Adjustment.
(33) Return Air Damper – (OPT)
When a return air damper is supplied with the unit, the damper
is factory installed in the blower section. The return air damper is
used as an air balancing damper so low leak, Class III leakage
resistance (less than 40 CFM/ft² at 1" W.C.) dampers with selfcompensating stainless steel side seals and santoprene blade
seals are used.
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 in the
center of the adjustable switch pointer as shown below.
3. Gently rotate the crank until the switch pointer is at the
desired switch point in degrees as shown.
(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
grommets provide 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.
Figure 33.3 - Blower/Motor Vibration Isolation
Figure 33.2 - Adjusting the Damper End Switch
BLOWER
SUPPORT
BLOWER
SUPPORT
RAIL
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.
5-572.11
33
COMPONENT DESCRIPTIONS
(37) Convenience Outlet – (OPT)
Setting the Dirty Filter Switch
The range of the switch is adjustable between 0.17" to 5.0" W.C.
1. Ensure that the unit filters are clean or replace if necessary.
2. Connect leads of a continuity tester to the NO and C
terminals of the pressure switch. See the figure below.
3. Turn the set screw of the pressure switch clockwise until
it stops. This will set the pressure at 5.0" W.C. and the
continuity tester should be sensing an open circuit.
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
approx­imately 0.25" W.C.) This will allow for the increase in
static pressure due to dirty filters.
WARNING
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.
AVERTISSEMENT
Débranchez l’alimentation électrique avant d’effectuer des
connexions ou de travailler sur l’appareil. Respectez toutes
les procédures de sécurité qui s’appliquent pour éviter
toute mise en marche accidentelle. Le non-respect de cette
directive peut entraîner des blessures ou la mort causées
par un choc électrique ou des pièces mobiles, en plus
d’endommager l’appareil.
Figure 34.2 Dirty Filter Pressure and/or Air Flow Proving Switch
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 installed inside the blower section
door on the access side of the unit. If the door is removed, the
switch interrupts power to the low voltage circuit. For single
phase units 1-1/2 Hp and less, the 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 switch deenergizes the motor starter that controls blower motor operation.
For servicing, the switch has an override position that can be
manually pulled out to override the switch as shown below. For
units with Modine Control System option (Model Digit 12=9), the
switch is wired to a digital input on the unit controller.
Figure 34.1 Blower Door Switch with Manual Override
OPEN
DOOR CLOSED DOOR
POSITION
POSITION
OVERRIDE
POSITION
COM
NC NO
(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.
34
POSITIVE
PRESSURE
CONNECTION
NEGATIVE
PRESSURE
CONNECTION
C
NO
PRESSURE
ADJUSTMENT
SET SCREW
(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.
(continued next page)
5-572.11
COMPONENT DESCRIPTIONS
Figure 35.1 - Motor Starter
A1
1
(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, 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 Modine Control System controller (Model Digit
12=9). For additional information, refer to the Furnace Control
Operating Sequence section in this manual.
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 "Variable Air Volume
Applications" on page page 28 for additional information).
The control changeover options include two speeds, 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.
(41) Mild Temperature Stat – (OPT) (All Except Digit 12=9)
The mild temperature thermostat is factory installed in the
blower electrical section. 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 Literature 75-540).
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.
(43) Warm-Up Stat – (OPT) (All Except Model Digit 12=9)
A warm-up stat can be provided with Air Control options (Model
Digits 20-21=EA, GC, or GE) and factory installed in the blower
electrical section with the sensor in the return air stream. The
warm-up thermostat monitors the return air temperature upon
changing to the occupied mode and prevents the fresh air
dampers from opening until the temperature of the return air has
reached the desired set point (typically 65°F or 5°F below the
room temperature).
(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.
(48) Air Flow Proving Switch – (OPT)
The air flow proving switch is factory installed in the duct furnace
electrical junction box. The air flow proving switch monitors
the pressure differential between the duct furnace and the
atmosphere. The purpose of the air flow proving switch is to cut
power to the gas controls if a positive pressure is not measured
by the switch. This could be caused by a lack of air movement
through the heat exchanger.
Note:
The air flow proving switch will prevent any heat
exchanger warm-up because the gas controls can not
be energized until air flow is proven.
Setting the Air Flow Proving Switch
The range of the switch is adjustable between 0.17" to 5.0" 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" W.C.
3. Turn the screw counter-clockwise until the gas controls
light and then one additional full turn. This will allow for dirty
filters or other slight system static pressure increases.
(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.
• Automatic – (STD): The automatic reset high limit will reset
when the switch is cooled.
(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.
(46) Electronic Modulation Amplifier – (OPT)
An electronic modulation amplifier is provided factory installed
in the duct furnace electrical junction box when the unit is
equip­ped with Electronic Modulating Gas Controls (Model 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.
5-572.11
35
COMPONENT DESCRIPTIONS
(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.
(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).
(53) Direct Drive Discharge Damper Actuator – (OPT)
The direct drive damper actuator is factory installed on the side
of the discharge damper (available as an option on units with
Model Digit 2=D or P). All discharge damper actuators are low
voltage (24V), two-position, spring return type. For Right Hand
units (Model 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 (Model Digit 9 =
L), the actuator should rotate in the clockwise direction when
viewed from the service side of the unit.
The actuator provides open/closed operation of the discharge
air damper. When the actuator is energized, the damper is
opened to 100% outside air in 75 seconds. Actuators are spring
return, so when the damper is de-energized, the 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° rotation (adjustable). When the damper is
closed, the unit is not operating.
(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).
(54) Discharge Damper – (OPT)
When a discharge air damper is supplied with the unit, the
damper is factory installed in the downturn plenum section. The
discharge air damper is used an outside air shut-off damper so
ultra low leak, Class II leakage (less than 10 CFM/ft² at 1" W.C.)
dampers with self-compensating stainless steel side seals and
santoprene and galvanized steel blade seals are used.
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:
(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.
(64) Carel pGD1 Digital Display/Interface Module (not
shown) - (OPT)
The interface allows a user to access the Carel controller
remotely 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. Also included is a
buzzer to indicate alarm conditions. The interface can be used
as a handheld device or can be wall mounted. Maintenance
personnel may wish to have the pGD1 mounted in an equipment
control room.
Refer to the latest revision of the Modine Control System
Manual, literature 74-510 for additional information
(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.
(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 - (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.
(60) Wiring Channels with Cover - (STD)
The wiring channels organize and separate high voltage and
low voltage wiring.
36
5-572.11
GENERAL PERFORMANCE DATA
Table 37.1 - General Performance Data
Model Size
(Digits 4-6)
Btu/Hr
Input j
Btu/Hr
Output j
100
100,000
81,000
125
125,000
101,250
150
150,000
121,500
175
175,000
141,750
200
200,000
162,000
225
250
300
350
400
500
600
700
800
840
960
225,000
250,000
300,000
350,000
400,000
500,000
600,000
700,000
800,000
1,050,000
1,200,000
182,250
202,500
243,000
283,500
324,000
405,000
486,000
567,000
648,000
850,500
972,000
Blower Style/Size
(Digit 16)
Size
Temperature Rise (°F)
Minimum
CFM k
Maximum
CFM
Maximum
Minimum
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 R
atings are shown for elevations up to 2,000 feet. For higher elevations, refer to section "Considerations for Elevation" on page 17.
k For Variable Air Movement Applications, see page page 28.
5-572.11
37
GENERAL PERFORMANCE DATA
Table 38.1 - Air Temperature Rise jkl
Air Temperature Rise Through Unit (°F)
Model Size
Btu/Hr
Input j
Btu/Hr
Output j
20
40
50
60
70
80
90
100
110
120
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 "Considerations for Elevation" on page 17.
k Minimum Air Temperature Rise, Maximum Air Temperature Rise, and Maximum Discharge Air Temperature are as follows:
-For Model Sizes 100-400, Min Air Temp Rise is 20°F, Max Air Temp Rise is 100°F, and Max Discharge Air Temp is 150°F.
-For Model Sizes 500-800, Min Air Temp Rise is 40°F, Max Air Temp Rise is 120°F, and Max Discharge Air Temp is 150°F.
-For Model Sizes 840-960, Min Air Temp Rise is 60°F, Max Air Temp Rise is 120°F, and Max Discharge Air Temp is 150°F.
-Note that these are typical limits but may vary by Model Size. Refer to Table 37.1 for actual limits.
l For Variable Air Movement Applications, see page 28.
Air Temperature Limits
The maximum allowable discharge air temperature is 150°F. The maximum allowable air temperature rise per furnace for Low Air
Temperature Rise Units is 60°F. All system units are designed for a maximum allowable total static pressure of 3.0" W.C.
38
5-572.11
OPTION & ACCESSORY PRESSURE DROP DATA
Table 39.1 - Option & Accessory Pressure Drop Tables (in ''W.C.) j
Filters
Unit Size
100/125
Digit 16
C, D, E, F
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
E, F, G, H
350/400
700/800
840/960
I, J, K
Evap Cooler, 12” Media
CFM
2”
Permanent
2” Farr
Aeropleat
2”
Farr 30/30
Without
Pre-Filters
With
Pre-Filters
Downturn
Plenum
741
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
4,630
1,111
1,500
2,000
2,500
3,000
3,500
4,000
4,500
5,000
5,200
5,556
1,481
2,000
2,500
3,000
3,500
4,000
4,500
5,000
5,500
6,000
6,500
1,852
2,000
2,500
3,000
3,500
4,000
4,500
5,500
6,500
7,250
1,925
3,000
4,000
5,000
6,000
7,000
8,000
9,000
10,400
11,111
2,593
3,000
3,500
4,000
4,500
5,000
5,500
6,000
6,500
7,000
2,593
3,000
4,000
5,000
6,000
7,000
8,000
9,000
10,000
11,050
12,000
12,500
13,000
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
0.22
0.24
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
0.28
0.30
0.02
0.04
0.07
0.10
0.14
0.19
0.24
0.30
0.37
0.39
0.04
0.05
0.08
0.11
0.15
0.18
0.23
0.27
0.32
0.34
0.38
0.03
0.04
0.06
0.08
0.10
0.12
0.15
0.18
0.21
0.25
0.28
0.05
0.06
0.09
0.11
0.15
0.18
0.22
0.31
0.42
0.51
0.03
0.05
0.09
0.12
0.16
0.21
0.27
0.33
0.42
0.47
0.04
0.05
0.06
0.08
0.10
0.12
0.14
0.17
0.19
0.22
0.02
0.03
0.04
0.06
0.08
0.11
0.13
0.16
0.19
0.23
0.27
0.29
0.31
0.02
0.04
0.08
0.15
0.23
0.34
0.46
0.60
0.08
0.12
0.23
0.36
0.53
0.73
0.97
1.23
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
0.47
0.51
4000 Max CFM for Evap
0.03
0.09
0.05
0.15
0.09
0.24
0.14
0.34
0.20
0.46
0.27
0.61
0.35
0.77
0.45
0.95
0.55
1.15
0.60
1.23
5200 Max CFM
0.04
0.12
0.07
0.19
0.10
0.27
0.15
0.36
0.20
0.47
0.27
0.60
0.34
0.73
0.42
0.89
0.50
1.05
0.60
1.23
6000 Max CFM
0.05
0.15
0.06
0.17
0.09
0.24
0.13
0.32
0.17
0.41
0.23
0.52
0.29
0.64
0.43
0.91
0.60
1.23
6500 Max CFM
0.02
0.08
0.05
0.15
0.09
0.23
0.14
0.34
0.20
0.46
0.27
0.61
0.35
0.77
0.45
0.95
0.60
1.23
10400 Max CFM
0.05
0.16
0.07
0.20
0.10
0.25
0.13
0.32
0.16
0.39
0.20
0.47
0.24
0.55
0.29
0.64
0.34
0.74
0.39
0.85
0.03
0.11
0.04
0.14
0.08
0.22
0.12
0.31
0.18
0.42
0.24
0.55
0.32
0.70
0.40
0.86
0.50
1.04
0.61
1.24
11050 Max CFM
Other
Rainhood
Discharge
and
Damper
Birdscreen
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
0.75
0.81
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
0.23
0.26
j A
ccessory / Option static pressure losses are approximate. Please consult the Accuspec selection software for static pressure losses at other than listed
CFM.
5-572.11
39
BLOWER PERFORMANCE DATA
Table 40.1 - Unit Performance Tables jk
Digit
Unit Size 16
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
Air
Temp.
Rise
0.25
CFM BHP RPM
100°F / - 741
670
80°F/100°F 926 0.13
758
62°F/77°F 1200 0.22
828
53°F/66°F 1400 0.30
982
41°F/51°F 1800 0.55
1145
34°F/42°F 2200 0.93
28°F/36°F 2600 1.45 1315
25°F/31°F 3000 2.16 1489
497
41°F/51°F 1800 0.28
553
34°F/42°F 2200 0.43
614
28°F/36°F 2600 0.63
680
25°F/31°F 3000 0.91
748
22°F/27°F 3400 1.26
802
20°F/25°F 3704 1.58
873
- / 23°F 4100 2.09
969
- / 20°F 4630 2.93
727
100°F/117°F 1111 0.19
793
86°F/100°F 1296 0.27
832
79°F/93°F 1400 0.32
994
62°F/72°F 1800 0.59
1166
51°F/59°F 2200 1.00
43°F/50°F 2600 1.58 1344
37°F/43°F 3000 2.35 1526
86°F/100°F 1296
474
79°F/93°F 1400 0.17
526
62°F/72°F 1800 0.28
588
51°F/59°F 2200 0.44
657
43°F/50°F 2600 0.67
729
37°F/43°F 3000 0.96
804
33°F/38°F 3400 1.35
880
29°F/34°F 3800 1.82
959
26°F/31°F 4200 2.40
24°F/28°F 4700 3.30 1058
1158
21°F/25°F 5200 4.40
871
100°F/113°F 1481 0.36
943
89°F/100°F 1667 0.48
975
85°F/95°F 1750 0.54
74°F/83°F 2000 0.76 1077
1181
66°F/74°F 2250 1.04
59°F/67°F 2500 1.38 1288
54°F/61°F 2750 1.79 1396
49°F/56°F 3000 2.28 1506
594
85°F/95°F 1750 0.29
642
74°F/83°F 2000 0.40
746
59°F/67°F 2500 0.68
857
49°F/56°F 3000 1.09
972
42°F/48°F 3500 1.66
37°F/42°F 4000 2.40 1091
1211
33°F/37°F 4500 3.34
30°F/33°F 5000 4.52 1332
425
85°F/95°F 1750 0.20
449
74°F/83°F 2000 0.26
507
59°F/67°F 2500 0.42
571
49°F/56°F 3000 0.65
639
42°F/48°F 3500 0.97
710
37°F/42°F 4000 1.38
783
33°F/37°F 4500 1.90
858
30°F/33°F 5000 2.54
933
27°F/30°F 5500 3.32
25°F/28°F 6000 4.25 1009
0.50
BHP
RPM
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
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
BHP
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
0.75
RPM
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
BHP
RPM
BHP
RPM
BHP
RPM
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
-
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
-
0.38
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
-
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
-
0.47
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
-
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
-
2.00
BHP
RPM
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
-
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
BHP
RPM
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
-
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
-
BHP
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
-
3.00
RPM
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 39.1. 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
5-572.11
BLOWER PERFORMANCE DATA
Table 41.1 - Unit Performance Tables jk
Digit
Unit Size 16
Air
Temp.
Rise
CFM
0.25
BHP RPM
250/300 E,F 100°F / 120°F 1852 M 0.26
0.39
83°F / 100°F 2222
Start 300
0.51
74°F / 89°F 2500
0.80
62°F / 74°F 3000
1.19
53°F / 63°F 3500
1.69
46°F / 56°F 4000
2.34
41°F / 49°F 4500
37°F / 44°F 5000
3.14
34°F / 40°F 5500
4.11
250/300
G,H 100°F / 120°F 1852
Start 300
83°F / 100°F 2222
0.28
74°F / 89°F 2500
0.35
62°F / 74°F 3000
0.53
53°F / 63°F 3500
0.76
46°F / 56°F 4000
1.07
41°F / 49°F 4500
1.45
37°F / 44°F 5000
1.92
34°F / 40°F 5500
2.50
31°F / 37°F 6000
3.16
28°F / 34°F 6500
3.96
250/300 I, J, K 46°F / 56°F 4000
37°F / 44°F 5000
31°F / 37°F 6000
1.94
2.93
26°F / 32°F 7000
4.24
23°F / 28°F 8000
6.40
20°F / 24°F 9259
End 250
- / 22°F 10000 7.97
- / 20°F 11111 10.79
100°F / - 2593
0.61
350/400 E,F
96°F / - 2700
0.67
Start 400
87°F / 100°F 2963
0.85
74°F / 85°F 3500
1.30
65°F / 74°F 4000
1.86
58°F / 66°F 4500
2.57
52°F / 59°F 5000
3.44
47°F / 54°F 5500
4.50
100°F / - 2593
0.43
350/400 G,H
87°F / 100°F 2963
0.57
Start 400
74°F / 85°F 3500
0.85
65°F / 74°F 4000
1.19
58°F / 66°F 4500
1.61
52°F / 59°F 5000
2.22
47°F / 54°F 5500
2.77
43°F / 49°F 6000
3.53
40°F / 46°F 6500
4.42
100°F / - 2593
350/400 I,J,K
87°F
/
100°F
Start 400
2963
65°F / 74°F 4000
52°F / 59°F 5000
1.37
43°F / 49°F 6000
2.20
37°F / 42°F 7000
3.34
4.84
32°F / 37°F 8000
6.75
29°F / 33°F 9000
26°F / 30°F 10000 9.13
24°F / 27°F 11000 12.01
23°F / 26°F 11500 13.66
532
582
625
706
793
882
974
1067
1161
424
447
492
542
594
649
706
767
822
881
559
632
707
804
862
949
668
686
730
826
918
1012
1109
1206
479
516
574
631
690
767
813
876
939
515
588
665
744
824
906
988
12.09
0.50
BHP RPM
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
-
BHP
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
-
2.00
RPM
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
-
BHP
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
-
3.00
RPM
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 39.1. 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.
5-572.11
41
GENERAL PERFORMANCE DATA
Table 42.1 - 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
I, J, K
Start 800
700/800
L
End 700
840/960
I, J, K
End 840
840/960
End 840
L
Air
Temp
Rise
120°F / 106°F / 100°F / 120°F
93°F / 111°F
82°F / 99°F
74°F / 89°F
67°F / 81°F
62°F / 74°F
57°F / 68°F
120°F / 100°F / 120°F
93°F / 111°F
74°F / 89°F
62°F / 74°F
53°F / 63°F
46°F / 56°F
41°F / 49°F
- / 44°F
- / 43°F
- / 40°F
- / 40°F
62°F / 74°F
53°F / 63°F
46°F / 56°F
41°F / 49°F
- / 44°F
- / 43°F
- / 40°F
- / 40°F
120°F / 115°F / 105°F / 120°F
104°F / 119°F
94°F / 108°F
86°F / 99°F
80°F / 91°F
120°F / 104°F / 119°F
86°F / 99°F
65°F / 74°F
58°F / 66°F
52°F / 59°F
47°F / 54°F
43°F / 49°F
40°F / 46°F
65°F / 74°F
58°F / 66°F
52°F / 59°F
47°F / 54°F
47°F / 54°F
43°F / 49°F
40°F / 46°F
- / 42°F
- / 41°F
120°F / 111°F / 105°F / 120°F
97°F / 111°F
86°F / 99°F
78°F / 89°F
70°F / 80°F
65°F / 74°F
62°F / 71°F
60°F / 68°F
86°F / 99°F
78°F / 89°F
70°F / 80°F
65°F / 74°F
60°F / 68°F
- / 63°F
Total Static Pressure Inches "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 0.82
0.84 575 1.06
0.97 598 1.20
1.18 633 1.43
1.61 693 1.88
2.13 755 2.43
2.77 818 3.10
3.53 882 3.89
4.41 946 4.80
0.46 401 0.69
0.69 443 0.95
0.82 464 1.09
1.43 542 1.75
2.31 624 2.68
3.51 709 3.94
5.09 797 5.57
7.11 885 7.65
9.62 975 10.21
10.77 1011 11.38
12.66 1065 13.31
13.04 1075 13.69
1.69 512 1.97
2.57 580 2.89
3.73 650 4.09
5.21 721 5.60
7.04 793 7.48
7.88 823 8.34
9.27 866 9.75
9.54 874 10.03
1.51 685 1.80
1.68 708 1.98
2.15 763 2.48
2.23 770 2.55
2.89 834 3.25
3.68 900 4.06
4.61 965
0.87 443 1.14
1.26 488 1.55
2.02 558 2.36
4.44 707 4.89
6.19 784 6.69
8.36 861 8.91
11.00 940 11.60
14.16 1019 14.81
17.88 1098 18.59
3.26 566 3.60
4.54 626 4.92
6.13 687 6.54
8.06 749 8.52
8.17 752 8.62
10.37 811 10.86
13.09 873 13.63
16.26 936 16.83
18.02 968 18.61
2.72 630 3.09
3.36 672 3.76
3.93 705 4.35
4.87 754 5.33
6.80 837 7.31
9.20 921 9.76
12.28 1010 12.89
15.60 1091 16.27
17.58 1134 18.27
19.71 1177
5.01 675 5.40
6.78 742 7.21
9.04 812 9.51
11.48 876 12.00
14.50 945 15.05
18.02 1013 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 1.26 779 1.50
736 1.54 807 1.80
753 1.70 822 1.97
779 1.96 846 2.24
827 2.46 889 2.77
878 3.07 936 3.40
932 3.79 986 4.15
988 4.63 1038
580 1.23 657
604 1.54 675
618 1.71 686 2.05
673 2.46 733 2.84
738 3.48 791 3.91
809 4.84 857 5.31
886 6.58 928 7.10
965 8.76 1001 9.33
1048 11.43 1083 12.05
1081 12.64 1115 13.29
1132 14.64 1164 15.32
1141 15.03 1174 15.72
615 2.57 664 2.89
671 3.56 714 3.92
731 4.84 770 5.23
795 6.43 830 6.86
860 8.39 892 8.85
887 9.28 918 9.76
927 10.74 957 11.24
935 11.02 964 11.53
830 2.43 896 2.77
847 2.63 912 2.98
893 3.17 953 3.54
899 3.26 959 3.63
953 4.00 1009 4.40
1010 4.87 1062
591 1.72 657 2.04
623 2.20 683 2.54
677 3.10 731 3.49
801 5.82 845 6.30
869 7.72 909 8.25
939 10.04 976 10.62
1011 12.84 1045 13.47
1085 16.15 1117 16.83
1159
654 4.31 696 4.67
706 5.70 744 6.10
760 7.40 794 7.85
815 9.45 847 9.93
818 9.56 850 10.04
872 11.88 902 12.40
930 14.72 958 15.27
989 18.00 1015 18.59
1019 19.82 1045
736 3.88 785 4.30
772 4.60 818 5.04
800 5.23 845 5.69
843 6.27 885 6.76
918 8.36 956 8.90
995 10.91 1030 11.50
1078 14.16 1110 14.80
1154 17.63 1184 18.32
1194 19.69 1224
753 6.21 789 6.62
812 8.09 846 8.54
877 10.48 908 10.97
937 13.04 966 13.57
1000 16.18 1028 16.75
1065 19.82 1091
-
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 2.84 1149
1054 3.23 1162
1064 3.44 1170
1080 3.78 1183
1110 4.43 1208
1145
946 5.01 1041
984 6.28 1072
1032 7.90 1113
1089 9.92 1163
1151 12.38 1220
1218 15.35 1283
1247
1290
1298
874
916 7.35 984
964 9.16 1027
1016 11.33 1074
1038 12.31 1095
1071 13.90 1126
1078 14.21 1132
1131 4.69 1236
1142 4.94 1245
1172
1176
879 3.84 974
894 4.47 985
924 5.62 1010
1009 8.87 1085
1061 11.04 1131
1117 13.66 1183
1176 16.74 1238
1239
848 6.66 918
885 8.25 950
925 10.17 987
969 12.43 1027
972 12.56 1029
1016 15.08 1070
1065 18.14 1116
960 6.52 1038
986 7.38 1061
1007 8.13 1081
1040 9.33 1111
1100 11.71 1166
1164 14.56 1226
1234
925 8.81 988
973 10.91 1032
1026 13.54 1081
1076 16.32 1129
1132 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 39.1. 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.
42
5-572.11
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. 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
2. Use Table 39.1 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.
3. Use Table 40.1 through Table 42.1 to determine the
blower speed (RPM) required to meet the job requirements.
4. Use Table 44.1 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 "Blower
Adjustments" on page page 26
Example:
Determine motor sheave turns open for a unit operating at 4000
CFM with a design external static pressure (ESP) of 0.60"W.C.
as follows:
1. 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
2. From Table 39.1, the unit includes 2" Farr 30/30 Filters
(0.08"W.C. static) and Rainhood & Birdscreen (0.07"W.C.
static). Total static pressure is 0.08+0.07+0.60=0.75"W.C.
3. From Table 41.1, the blower speed is 1078 RPM.
4. From Table 44.1, 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"W.C.,
the process above would be repeated with the new TSP of
0.90"W.C.
Figure 43.1 - Blower Section
ADJUSTABLE
MOTOR SHEAVE
ON MOTOR
1/4" PERIMETER
GASKETED BLOWER
CONNECTION
FILTER RACK
BOTTOM SUPPORTED
BLOWER AND MOTOR
DIRECT DRIVE
DAMPER ACTUATOR
CONVENIENCE
OUTLET (OPTION)
BLOWER DOOR
SAFETY SWITCH
(OPTION)
5-572.11
43
BLOWER SHEAVE ASSEMBLY DATA
Table 44.1 - Sheave Assembly Data
Blower Type
Digit 16
A or B
(9-7 Blower)
C or D
(9-9 Blower)
E or F
(12-12 Blower)
G or H
(15-15 Blower)
I or J
(18-18 Blower with
Under 15 HP Motor)
K
(18-18 Blower with
15 HP Motor & Up)
L
(20-18 Blower)
44
Sheave
Digit 19
Blower RPM by Sheave Turns Open Setting (Approx.)
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
656-1001
1001
967
932
898
863
829
794
760
725
691
656
C, D, E
978-1265
1265
1236
1208
1179
1150
1122
1093
1064
1035
1007
978
F, G
1150-1561
1561
1520
1479
1438
1397
1356
1314
1273
1232
1191
1150
H, I
1526-1858
1858
1825
1792
1758
1725
1692
1659
1626
1592
1559
1526
J, K
1763-2147
2147
2109
2070
2032
1993
1955
1917
1878
1840
1801
1763
656
A, B
RPM Range
A, B
656-1001
1001
967
932
898
863
829
794
760
725
691
C, D, E
978-1265
1265
1236
1208
1179
1150
1122
1093
1064
1035
1007
978
F, G, H
1150-1561
1561
1520
1479
1438
1397
1356
1314
1273
1232
1191
1150
I, J, K
1526-1858
1858
1825
1792
1758
1725
1692
1659
1626
1592
1559
1526
L,M,N
1763-2147
2147
2109
2070
2032
1993
1955
1917
1878
1840
1801
1763
A, B
468-715
715
690
666
641
616
592
567
542
517
493
468
C, D, E
644-874
874
851
828
805
782
759
736
713
690
667
644
F, G, H
863-1078
1078
1057
1035
1014
992
971
949
928
906
885
863
I, J, K, Q
1029-1332
1332
1302
1271
1241
1211
1181
1150
1120
1090
1059
1029
L,M,N
1150-1438
1438
1409
1380
1352
1323
1294
1265
1236
1208
1179
1150
O, P
1327-1659
1659
1626
1593
1559
1526
1493
1460
1427
1393
1360
1327
A, B, C
410-625
625
604
582
561
539
518
496
475
453
432
410
D, E, F
568-771
771
751
730
710
690
670
649
629
609
588
568
G, H, I
767-958
958
939
920
901
882
863
843
824
805
786
767
J, K, L, O
934-1136
1136
1116
1096
1075
1055
1035
1015
995
974
954
934
M, N
1136-1380
1380
1356
1331
1307
1282
1258
1234
1209
1185
1160
1136
A, B, C
491-649
649
633
617
602
586
570
554
538
523
507
491
D, E, F, G
586-744
744
728
712
697
681
665
649
633
618
602
586
H, I, J
682-821
821
807
793
779
765
752
738
724
710
696
682
K, L, M, N
821-1009
1009
990
971
953
934
915
896
877
859
840
821
O, P, Q, R
995-1161
1161
1144
1128
1111
1095
1078
1061
1045
1028
1012
995
S, T, U
1101-1285
1285
1267
1248
1230
1211
1193
1175
1156
1138
1119
1101
A, B, G, H
826-1009
1009
991
972
954
936
918
899
881
863
844
826
C, D, I, J
995-1161
1161
1144
1128
1111
1095
1078
1061
1045
1028
1012
995
E, F, K, L
1101-1285
1285
1267
1248
1230
1211
1193
1175
1156
1138
1119
1101
M, N
1232-1438
1438
1417
1397
1376
1356
1335
1314
1294
1273
1253
1232
A, B
491-649
649
633
617
602
586
570
554
538
523
507
491
C, D, E
626-765
765
751
737
723
709
696
682
668
654
640
626
F, G, H, I, J, K
765-901
901
887
874
860
847
833
819
806
792
779
765
L, M, N, O, P, Q
901-1059
1059
1043
1027
1012
996
980
964
948
933
917
901
R, S, T, U, V
995-1161
1161
1144
1128
1111
1095
1078
1061
1045
1028
1012
995
W, X, Y, Z
1101-1285
1285
1267
1248
1230
1211
1193
1175
1156
1138
1119
1101
5-572.11
DIMENSIONS - UNIT
Figure 45.1 - Outdoor STANDARD Blower Package Unit (Model Digit 2=B, Digit 16=A through H) n
500 - 800 Model Shown
Y
33.50
33.50
48.00
Qty (4) Drill Locator
Dimples for Field
Drilled Electrical
Conduit Entry Holes
(spaced 2.0" apart)
2.32
Optional Rainhood
& Birdscreen
P (OVER ROOF)
3.97
E (Height)
X
F (Width)
(Inside)
24.00
(Inside)
24.00
(Inside)
K (INSIDE)
N
A
9.00
9.21
1
2
1
4.5
14.55
3
24.00
4.35
(Inside)
Optional Return Air
Duct Connection
2
24.94
Fresh Air
Duct Connection
4
1
2
1.50
5.29
9.21
6.28
6.28
1.50
3.00
5.29
S
Figure 45.2 - Outdoor STANDARD Blower Downturn Package Unit (Model Digit 2=D, Digit 16=A through H) n
500 - 800 Model Shown
Z
29.32
33.50
33.50
48.00
Qty (4) Drill Locator
Dimples for Field
Drilled Electrical
Conduit Entry Holes
(spaced 2.0" apart)
2.32
Optional Rainhood
& Birdscreen
P Over Roof
3.97
A
24.00
(Inside)
9.21
4.27
24.00
(Inside)
Downturn
1
Duct Connection
2
24.94
1
24.00
(Inside)
Optional Return Air
Duct Connection
2
T
24.00
(Inside) N
K Inside
4.5
Fresh Air
Duct Connection 14.55
3
4.35
4
1
9.21
2
1.50
1.50
5.29
5.29
6.28
3.00
6.28
Table 45.1 - Outdoor STANDARD Blower Unit (Model Digit 2=B or D, Digit 16=A through H) n
Model Blower Type Furnace
Size
(Digit 16)
Qty
All
100/125
All
150/175
All
200/225
250/300 E, F, G, or H
350/400 E, F, G, or H
G or H
500/600
G or H
700/800
1
1
1
1
1
2
2
Dimensions (Inches)
A
E
F
K
N
P
S
T
Y
Z
33.75 18.98 17.69 20.02 39.23 34.56 84.41 108.39 81.49 110.82
33.75 18.98 21.94 23.99 39.23 38.82 84.41 108.39 81.49 110.82
37.75 22.98 24.06 23.99 43.23 40.94 84.41 108.39 81.49 110.82
37.75 22.98 27.09 29.96 43.23 44.05 84.41 108.39 81.49 110.82
37.75 22.98 38.60 41.90 43.23 55.57 84.41 108.39 81.49 110.82
37.75 22.98 27.09 29.96 43.23 44.05 117.53 146.77 114.94 144.12
37.75 22.98 38.60 41.90 43.23 55.57 117.53 146.77 114.94 144.12
Gas
Conn.
1/2
1/2
1/2
3/4
3/4
3/4
3/4
j For Right Hand Access Units - Location of drill locator dimples/knockouts 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/knockouts 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 as side electrical connections.
m For Left Hand Access Units - Location of drill locator dimples for field drilled electrical connection, entry holes identical as side electrical connections.
n All dimensions shown are in inches.
5-572.11
45
DIMENSIONS - UNIT
Figure 46.1 - Outdoor EXTENDED Blower Package Unit (Model Digit 2=B, Digit 16=I, J, K, or L) n
500 - 800 Model Shown
Y
47.27
E
36.58
BLOWER CABINET
ROOF EXTENSION
(”L” BLOWERS ONLY)
6.56
P (OVER ROOF)
OPTIONAL RAINHOOD
& BIRDSCREEN
2.32
3.97
22.98 (HEIGHT)
X
F (WIDTH)
(INSIDE)
24.00
(INSIDE)
9.00
4.5
FRESH AIR
14.55
DUCT CONNECTION
9.21
4.29
2
24.94
1
1
QTY (4) DRILL LOCATOR DIMPLES
FOR FIELD DRILLED ELECTRICAL
CONDUIT ENTRY HOLES
(SPACED 2.0" APART)
2
S
24.00
(INSIDE)
43.23
K (INSIDE)
4
1
9.21
3
24.00
(INSIDE)
3.00
2
4.35
1.50
5.29
6.28
1.50
5.29
6.28
OPTIONAL RETURN AIR
DUCT CONNECTION
Figure 46.2 - Outdoor EXTENDED Blower Downturn Package Unit (Model Digit 2=D, Digit 16=I, J, K, or L) n
500 - 800 Model Shown
Z
29.32
47.27
E
36.58
BLOWER CABINET
ROOF EXTENSION
(”L” BLOWERS ONLY)
6.56
P (OVER ROOF)
2.32
OPTIONAL RAINHOOD
& BIRDSCREEN
3.97
24.00
(INSIDE)
24.00
(INSIDE)
K (INSIDE)
43.23
4.5
9.21
24.00
(INSIDE)
4.27
DOWNTURN
DUCT
CONNECTION
QTY (4) DRILL LOCATOR DIMPLES
24.00
FOR FIELD DRILLED ELECTRICAL
(INSIDE)
CONDUIT ENTRY HOLES
OPTIONAL RETURN AIR
(SPACED 2.0" APART)
DUCT CONNECTION
2
24.94
1
1
2
14.55
FRESH AIR
DUCT CONNECTION
3
4.35
4
1
1.50
5.29
6.28
2
9.21
3.00
1.50
5.29
6.28
T
Table 46.1 - Outdoor EXTENDED Blower Unit (Model Digit 2=B or D, Digit 16=I, J, K, or L) n
Model
Size
250/300
Dimensions (Inches)
Blower Type Furnace
(Digit 16)
Qty
E
F
K
P
S
T
Y
Z
I, J, or K
1
33.50
27.09
29.96
44.05
120.00 141.34 117.34 141.34
Gas
Conn.
3/4
350/400
I, J, or K
1
33.50
38.60
41.90
55.57
120.00 141.34 117.34 141.34
3/4
500/600
I, J, K, or L
2
67.00
27.09
29.96
44.05
153.12 182.36 150.74 180.00
3/4
700/800
I, J, K, or L
2
67.00
38.60
41.90
55.57
153.12 182.36 150.74 180.00
3/4
840/960
I, J, K, or L
3
100.50
38.60
41.90
55.57
186.52 215.77 184.14 213.40
3/4
j For Right Hand Access Units - Location of drill locator dimples/knockouts 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/knockouts 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 as side electrical connections.
m For Left Hand Access Units - Location of drill locator dimples for field drilled electrical connection, entry holes identical as side electrical connections.
n All dimensions shown are in inches.
46
5-572.11
DIMENSIONS - UNIT
Figure 47.1 - Outdoor STANDARD Blower Cooling Package Unit (Model Digit 2=C, Digit 16=A through H) n
105.49
48.00
33.50
24.00
QTY (4) DRILL LOCATOR DIMPLES
FOR FIELD DRILLED ELECTRICAL
CONDUIT ENTRY HOLES
(SPACED 2.0" APART)
OPTIONAL RAINHOOD
& BIRDSCREEN
P (OVER ROOF)
2.20
3.97
J (HEIGHT)
X
H (WIDTH)
(INSIDE)
G
A
1
7.65
24.00
(INSIDE)
4.5
FRESH AIR
DUCT CONNECTION 14.55
9.21
2
24.00
4.35
(INSIDE)
OPTIONAL RETURN AIR
DUCT CONNECTION
24.94
108.39
24.00
(INSIDE) N
K (INSIDE)
3
9.21
4
1
2
1.50
1.50
3.00
5.29
5.29
6.28
6.28
Figure 47.2 - Outdoor STANDARD Blower Cooling & Downturn Packaged Unit (Model Digit 2=P, Digit 16=A-H) n
134.82
48.00
33.50
24.00
29.32
QTY (4) DRILL LOCATOR DIMPLES
FOR FIELD DRILLED ELECTRICAL
CONDUIT ENTRY HOLES
(SPACED 2.0" APART)
OPTIONAL RAINHOOD
& BIRDSCREEN
P (OVER ROOF)
2.20
3.97
G
A
1
2
9.21
24.00
(INSIDE)
4.27
24.00
(INSIDE)
DOWNTURN
DUCT CONNECTION
137.63
4.5
9.21
4
1
2
1.50
1.50
5.29
OPTIONAL RETURN AIR
DUCT CONNECTION
24.94
4.29
FRESH AIR
DUCT CONNECTION 14.55
3
4.35
24.00
(INSIDE) N
K (INSIDE)
24.00
(INSIDE)
3.00
5.29
6.28
6.28
Table 47.1 - Outdoor STANDARD Blower Unit (Model Digit 2=C or P, Digit 16=A through H) n
j
k
l
m
n
Dimensions (Inches)
Model
Size
Blower Type
(Digit 16)
100/125
All
33.75 28.75 21.00 25.00 20.02 39.23 34.56
1/2
150/175
All
33.75 28.75 24.00 25.00 23.99 39.23 38.82
1/2
200/225
All
37.75 32.75 27.00 28.00 23.99 43.23 40.94
1/2
250/300
E, F, G, or H 37.75 32.75 30.00 28.00 29.96 43.23 44.05
3/4
350/400
E, F, G, or H 37.75 32.75 42.00 28.00 41.90 43.23 55.57
3/4
A
G
H
J
K
N
P
Gas
Conn.
For Right Hand Access Units - Location of drill locator dimples/knockouts for field drilled gas connection entry holes - one side of unit and one on bottom.
For Left Hand Access Units - Location of drill locator dimples/knockouts for field drilled gas connection entry holes - one side of unit and one on bottom.
For Right Hand Access Units - Location of drill locator dimples for field drilled electrical connection, entry holes identical as side electrical connections.
For Left Hand Access Units - Location of drill locator dimples for field drilled electrical connection, entry holes identical as side electrical connections.
All dimensions shown are in inches.
5-572.11
47
DIMENSIONS - UNIT
Figure 48.1 - Outdoor EXTENDED Blower Cooling Package Unit (Model Digit 2=C, Digit 16=I, J, K, or L) n
141.34
24.00
33.50
36.58
47.27
QTY (4) DRILL LOCATOR DIMPLES
FOR FIELD DRILLED ELECTRICAL
CONDUIT ENTRY HOLES
(SPACED 2.0" APART)
OPTIONAL RAINHOOD
& BIRDSCREEN
2.32
P (OVER ROOF)
3.97
28.00 (HEIGHT)
X
H (WIDTH)
(INSIDE)
24.00
(INSIDE)
1
7.65
4.5
14.55
FRESH AIR
DUCT CONNECTION
9.21
2
24.94
OPTIONAL RETURN AIR
DUCT CONNECTION
24.00
(Inside)
K (INSIDE)
3
24.00
(INSIDE)
9.21
4
1
2
1.50
3.00
1.50
5.29
5.29
143.98
N
6.28
6.28
Figure 48.2 - Outdoor EXTENDED Blower Cooling & Downturn Unit (Model Digit 2=P, Digit 16=I, J, K, or L) n
170.66
29.32
33.50
24.00
36.58
47.27
QTY (4) DRILL LOCATOR DIMPLES
FOR FIELD DRILLED ELECTRICAL
CONDUIT ENTRY HOLES
(SPACED 2.0" APART)
2.32
OPTIONAL RAINHOOD
& BIRDSCREEN
P (OVER ROOF)
3.97
24.00
(INSIDE)
1
24.00
(INSIDE)
4.27
2
9.21
24.94
DOWNTURN
DUCT CONNECTION
OPTIONAL RETURN AIR
DUCT CONNECTION
24.00
(INSIDE)
4.35
K (INSIDE)
4.5
FRESH AIR
14.55
DUCT
CONNECTION
24.00
(INSIDE)
9.21
4
1
2
3
1.50
1.50
5.29
6.28
N
3.00
5.29
6.28
173.22
Table 48.1 - Outdoor EXTENDED Blower Unit (Model Digit 2=C or P, Digit 16=I, J, K, or L) n
Model
Size
Dimensions (Inches)
Blower Type
(Digit 16)
F
H
K
N
P
Gas
Conn.
250/300
I, J, or K
27.09
30.00
29.96
43.23
44.05
3/4
350/400
I, J, or K
38.60
42.00
41.90
43.23
55.57
3/4
j
k
l
m
n
For Right Hand Access Units - Location of drill locator dimples/knockouts for field drilled gas connection entry holes - one side of unit and one on bottom.
For Left Hand Access Units - Location of drill locator dimples/knockouts for field drilled gas connection entry holes - one side of unit and one on bottom.
For Right Hand Access Units - Location of drill locator dimples for field drilled electrical connection, entry holes identical as side electrical connections.
For Left Hand Access Units - Location of drill locator dimples for field drilled electrical connection, entry holes identical as side electrical connections.
All dimensions shown are in inches.
48
5-572.11
DIMENSIONS - UNIT BASE
Figure 49.1 - Unit Base Dimensions k
A
C To end of Unit
F
G
M
M
6.28
B
J
Drill Locator Dimple
for Field Drilled Gas
Connection Entry Hole
Left Hand Access Units
Inside
E
Drill Locator Dimple
for Field Drilled Gas
Connection Entry
Hole Right Hand
Access Units
6.28
M
M
Return Air Opening
Supply Air Opening
24.00 Inside
4.29
Inside
E
24.00
H
4.35
Inside
Table 49.1 - Outdoor Unit Base Rail Dimensions for Model Digit 2=B or D k
Dimensions (Inches)
Model
Blower Type
Digit 2=B
Digit 2=D
Size
(Digit 16)
A
C
A
C
B
E
F
Digit 2=B or D
G
H
J
M
100/125
150/175
200/225
250/300
250/300
All
All
All
E,F,G, or H
I, J, or K
84.41
84.41
84.41
84.41
120.00
81.49
81.49
81.49
81.49
117.34
113.63
113.63
113.63
113.63
149.22
110.82
110.82
110.82
110.82
146.66
37.36
41.61
43.71
46.75
46.75
19.52
23.49
23.49
29.46
29.46
78.66
78.66
78.66
78.66
114.23
53.72
53.72
53.72
53.72
84.29
1.53
1.53
1.53
1.53
1.28
34.50
38.75
40.85
43.89
43.89
7.49
7.63
8.69
7.21
7.21
350/400
350/400
E,F,G, or H
I, J, or K
84.41
120.00
81.49
117.34
113.63
149.22
110.82
146.66
58.27
58.27
41.40
41.40
78.66
114.23
53.72
82.29
1.53
1.28
55.41
55.41
7.00
7.00
500/600
500/600
G or H
I, J, K, or L
117.53
153.12
114.94
150.74
146.77
182.36
144.12
180.00
46.75
46.75
29.46
29.46
78.66
114.23
53.72
82.29
1.53
1.28
43.89
43.89
7.21
7.21
700/800
700/800
G or H
I, J, K, or L
117.53
153.12
114.94
150.74
146.77
182.36
144.12
180.00
58.27
58.27
41.40
41.40
78.66
114.23
53.72
82.29
1.53
1.28
55.41
55.41
7.00
7.00
840/960
I, J, K, or L
186.52
184.14
215.77
213.40
58.27
41.40
114.23
82.29
1.28
55.41
7.00
Table 49.2 - Outdoor Unit Base Rail Dimensions Model Digit 2=C or P k
Dimensions (Inches)
Model
Blower Type
Digit 2=C
Digit 2=P
Size
100/125
150/175
200/225
250/300
250/300
350/400
350/400
(Digit 16)
A
C
A
C
B
E
F
Digit 2=C or P
G
H
J
M
All
All
All
E,F,G, or H
I, J, or K
E,F,G, or H
I, J, or K
108.39
108.39
108.39
108.39
143.98
108.39
143.98
105.49
105.49
105.49
105.49
141.34
105.49
141.34
137.63
137.63
137.63
137.63
173.22
137.63
173.22
134.82
134.82
134.82
134.82
170.66
134.82
170.66
37.36
41.61
43.71
46.75
46.75
58.27
58.27
19.52
23.49
23.49
29.46
29.46
41.40
41.40
78.66
78.66
78.66
78.66
114.23
78.66
114.23
53.72
53.72
53.72
53.72
82.29
53.72
82.29
1.53
1.53
1.53
1.53
1.28
1.53
1.28
34.50
38.75
40.85
43.89
43.89
55.41
55.41
7.49
7.63
8.69
7.21
7.21
7.00
7.00
j Gas connection for 1st furnace. For Model sizes 500-800 add 33.5” for second furnace gas connection.
For Model sizes 840-960 add 33.50” and 67.00” for second and third furnace gas connections.
k All dimensions shown are in inches.
5-572.11
49
DIMENSIONS - ROOF CURBS
Figure 50.1 - Roof Curb Dimensions k
DISCHARGE AIR OPENING
FOR UNITS WITH MODEL
DIGIT 2= D OR P ONLY
Table 50.1 - Roof Curb Dimensions Model Digit 2=B or D k
Model
Blower Type
Size
100/125
150/175
200/225
250/300
250/300
350/400
350/400
500/600
500/600
700/800
700/800
840/960
(Digit 16)
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
Digit 2=B
A
88.77
88.77
88.77
88.77
124.61
88.77
124.61
121.89
157.74
121.89
157.74
191.14
B
C
76.77
76.77
76.77
76.77
112.61
76.77
112.61
109.89
145.74 105.98
109.89
145.74 105.98
179.14 105.98
D
39.76
39.76
73.16
Dimensions (Inches)
Digit 2=D
A
B
C
D
117.98 105.98
117.98 105.98
117.98 105.98
117.98 105.98
153.83 141.63 105.98 35.85
117.98 105.98
153.83 141.63 105.98 35.85
151.10 139.10 105.98 33.12
186.98 174.98 105.98 69.00
151.10 139.10 105.98 33.12
186.98 174.98 105.98 69.00
220.39 208.39 105.98 102.41
Digit 2=B or D
E
41.84
46.18
48.22
51.25
51.25
62.76
62.76
51.25
51.25
62.76
62.76
62.76
F
29.84
34.18
36.22
39.25
39.25
50.76
50.76
39.25
39.25
50.76
50.76
50.76
G
5.22
5.41
6.43
4.96
4.96
4.74
4.74
4.96
4.96
4.74
4.74
4.74
H
19.52
23.49
23.49
29.46
29.46
41.40
41.40
29.46
29.46
41.40
41.40
41.40
J
74.84
74.84
74.84
74.84
110.41
74.84
110.41
74.84
110.41
74.84
110.41
110.41
Table 50.2 - Roof Curb Dimensions Model Digit 2=C or P k
Model
Blower Type
Size
100/125
150/175
200/225
250/300
250/300
350/400
350/400
(Digit 16)
All
All
All
E,F,G, or H
I, J, or K
E,F,G, or H
I, J, or K
Dimensions (Inches)
Digit 2=P
Digit 2=C
A
112.74
112.74
112.74
112.74
148.59
112.74
148.59
B
C
100.74
100.74
100.74
100.74
136.59 105.98
100.74
136.59 105.98
D
30.61
30.61
A
141.98
141.98
141.98
141.98
177.83
141.98
177.83
B
129.98
129.98
129.98
129.98
165.83
129.98
165.83
C
100.74
100.74
100.74
100.74
105.98
100.74
105.98
j Gas connection for 1st furnace. For Model sizes 500-800 add 33.5” for second furnace gas connection.
For Model sizes 840-960 add 33.50” and 67.00” for second and third furnace gas connections.
k All dimensions shown are in inches.
50
5-572.11
Digit 2=C or P
D
29.24
29.24
29.24
29.24
59.85
29.24
59.85
E
41.84
46.18
48.22
51.25
51.25
62.76
62.76
F
29.84
34.18
36.22
39.25
39.25
50.76
50.76
G
5.22
5.41
6.43
4.96
4.96
4.74
4.74
H
J
19.52 74.84
23.49 74.84
23.49 74.84
29.46 74.84
29.46 110.41
41.40 74.84
41.40 110.41
DIMENSIONS - COOLING COILS
Figure 51.1 - DX Coil Drawing l
Airflow Direction
Rows 2
W
7.5
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 51.1 - DX Coil Dimensions l
DX - Single Circuit 
DX - Dual Circuit 
Model Size
Cooling MBH
FH
H
S
FL
I
L
FL
I
L
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 & 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 & 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 & 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.
l All dimensions shown are in inches.
5-572.11
51
DIMENSIONS - RAINHOOD, REMOTE PANEL & EVAPORATIVE COOLER
Figure 52.1 - Rainhood and Birdscreen Dimensions (inches)
1.09
A
1.14
42.66 Approx.
31.19
Table 52.1 - Rainhood and
Birdscreen Dimensions (inches)
1.14
Rainhood & Birdscreen
Model Size
A
100/125
31.94”
150/175
38.24”
200/225
38.24”
250/300
41.34”
350/400
52.85”
500/600
41.34”
700/800
52.85”
840/960
52.85”
32.71
44.56
.75
Figure 52.2 - Evaporative Cooler (Model Digit 22=D)
J-BOX
Top View
1.25”
PUMP
C
W/2 -1.50”
Drain
1/2" 1/2"
NPTNPT
DRAIN
NPT
Overflow
1/2"1/2"
NPT
OVERFLOW
1.50
W
3.00”
1.50”
4.50”
Side View
Figure 52.3 - Remote Panel Dimensions (inches)
OPTIONAL
1” PRE-FILTER
RACK
NOTES:
1. Holes visable on right
side are also on the left
side in the same location.
2. Holes on top are also on
the back in the same
location horizontally.
5.57
1.25”
3.53
BLOWER
SECTION
36.00”
A
3.38
2.13
3.53
B
12"
MEDIA
Table 52.3 - Remote Panel Dimensions (inches)
H
Remote Panel Type
A
B
C
Light and Switch Panels Only
7.06”
-
2.81”
Light and Switch Panels with Single Stage
Thermostat or Electronic Set Point Adjustor
10.60”
3.53”
4.58”
Light and Switch Panels with
Two Stage Thermostat
13.09”
6.03”
5.82”
1/2" NPT
WATER INLET
4.50”
3.00”
2.56
.25”
LEVELING LEGS
25.50”
Table 52.2 - Evap Cooler Dimension, Performance, and Weight Data
Blower Type
Model Size (Digit 16)
H (in.)
100/125
52
All
34
12” GlasDek Media (Digit 23 = D)
W (in.)
Maximum
Cooling CFM
Media
Face Area (ft²)
Maximum Face
Velocity (ft/min)
Dry Weight (lbs)
Op. Weight (lbs)
30
4000
5.0
800
159
295
150/175
All
34
36
5200
6.5
800
169
336
200/225
All
38
36
6000
7.5
800
174
341
250/300
E,F,G, or H
38
39
6500
8.1
800
182
363
250/300
I, J, or K
56
39
10400
13.0
800
214
404
350/400
E,F,G, or H
38
51
8500
10.6
800
228
473
350/400
I, J, or K
47
51
11050
13.8
800
244
496
500/600
G or H
38
39
6500
8.1
800
182
363
500/600
I, J, K or L
56
39
10400
13.0
800
214
404
700/800
G or H
38
51
8500
10.6
800
228
473
700/800
I, J, K or L
47
51
11050
13.8
800
244
496
840/960
I, J, K or L
47
51
11050
13.8
800
244
496
5-572.11
WEIGHTS
Table 53.1 - Unit Operating Weights j
Dampers
Digit 2
Model Blower Type
Size
(Digit 16)
B
D
C
P
100/125
All
474
578
584
688
6
26
46
150/175
All
511
621
626
736
6
29
52
200/225
All
588
707
714
833
6
29
250/300
E,F,G, or H
626
747
756
877
8
33
250/300
I, J, or k
875
996
1005
1126
15
350/400
E,F,G, or H
738
876
887
1025
12
350/400
I, J, or k
1019
1057
1168
1306
500/600
G or H
959
1080
n/a
n/a
500/600
I, J, k, or L
1208
1329
n/a
700/800
G or H
1153
1291
n/a
700/800
I, J, k, or L
1352
1490
840/960
I, J, k, or L
1767
1905
Double Wall (all sections)
Fresh Air Fresh & RainMotor Filters
Only Return Air hood
Digit 2
D
C
P
67
38
73
72
107
70
43
78
77
112
52
72
46
86
85
125
60
83
46
88
87
129
33
60
83
93
135
134
176
38
70
90
53
102
101
150
17
38
70
90
96
145
144
193
8
33
60
83
46
88
n/a
n/a
n/a
15
33
60
83
93
135
n/a
n/a
n/a
12
38
70
90
53
102
n/a
n/a
n/a
n/a
17
38
70
90
96
145
n/a
n/a
n/a
n/a
17
38
70
90
96
145
n/a
n/a
See Motor Data
B
Evap
Cooler
See Evaporative Cooler Data
Base Unit
j All weights in pounds and are approximate.
Table 53.2 - Motor Operating Weights j
Digit 17 - Motor Size
Digit 14 Supply Voltage
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
Digit 18
- Motor
Type
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 - TE
15
23
30
-
-
-
-
-
-
-
-
-
6 - TE 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.
5-572.11
53
MAINTENANCE
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
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.
AVERTISSEMENT
tension should be rechecked shortly after the unit has been
installed to check for belt stretching. After the initial start-up,
monthly checks are recommended.
Filters
If the unit is supplied with a dirty filter switch and light, clean or
replace the filters any time the dirty filter light comes on.
Units which do not have a dirty filter warning light should have
the filters checked monthly. Clean or replace if necessary. In
dirty atmospheres, filter maintenance may be required more
often.
Figure 54.1 - Filter Replacement Arrangement for
STANDARD Blower Size (Model Digit 16=A through H)
Pour l’entretien et les réparations de cet appareil, utilisez
uniquement des pièces d’origine certifiées. Pour la liste
complete des pièces de rechange, consultez Modine
Manufacturing Company. Le numéro de modèle complet,
le numéro de série et l’adresse du fabricant figurent sur la
plaque signalétique fixée à l’appareil. Toute substitution de
pièce ou decommande non approuvée par le fabricant sera
aux risques du propriétaire.
FILTER
SPACER
B
B
CAUTION
B
C
B
C
B
B
B
B
A
A
150/175
100/125
75
FILTER
SPACER
Do not attempt to reuse any mechanical or electrical
component which has been wet. Such component must be
replaced.
A
A
A
A
A
ATTENTION
A
C
A
A
A
A
A
C
A
A = 20'' x 25''
B = 16” x 25”
C = 15” x 25”
IMPORTANT
350/400
700/800
250/300
500/600
200/225
Ne tentez pas de réutiliser un composant mécanique ou
électrique qui a été mouillé. Ces composants doivent être
remplacés.
FILTER SPACER TO BE INSERTED
ON NON-ACCESS SIDE OF UNIT
Figure 54.2 - Filter Replacement Arrangement for
EXTENDED Blower Size (Model Digit 16 = I, J, K, or L)
To check most of the Possible Remedies in the
troubleshooting guide listed in Table 58.1, refer to the
applicable sections of the manual.
A
A
A
D
NON-ACCESS
SIDE
NON-ACCESS
SIDE
FILTER
SPACER
IMPORTANT
A
FILTER
SPACER
A
Pour essayer la plupart des solutions possibles suggérées
dans le guide de dépannage du Tableau 58.1 reportez-vous
aux sections correspondantes du manuel.
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.
Electrical Wiring
The electrical wiring should be checked annually for loose
connections or deteriorated insulation.
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
54
FILTER
SPACER
5-572.11
C
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
MAINTENANCE
Cooling Coil Maintenance
1.
2.
3.
eriodically, inspect the coil for signs of corrosion
P
and leaks. Repair and replacement of the coil and the
connecting piping, valves, etc., must be performed as
needed by a qualified technician.
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 airside 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.
For DX coils, replace the filter dryer(s) as needed.
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.
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 & 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)
5-572.11
55
MAINTENANCE
Manifold Assembly Removal
To remove the manifold (Refer to Figure 56.1):
1. Shut off gas and electric supply.
2. Remove the side access panel.
3. Disconnect gas manifold at ground union joint.
4. Remove the two screws holding the manifold to the heat
exchanger support.
5. Slide the manifold through the manifold bracket.
6. Clean the orifices and adjust the air shutters as necessary.
7. Follow steps 3-6 in reverse to install the manifold assembly.
8. Turn on the electric and gas supply.
9. Check the ground union joint for leaks with a soap solution.
Tighten if necessary.
10. Install the side access panel.
Figure 56.1 - Manifold Assembly Removal
SERIAL
PLATE
ELECTRICAL
JUNCTION BOX
Burner and Pilot Assembly Removal
To remove the burner (Refer to Figure 56.2):
1. Shut off gas and electric supply.
2. Disconnect the pilot supply line from the gas valve.
3. Disconnect the ignition cable from the ignition controller
(located in the electrical junction box). Feed the cable
through the bushing in the bottom of the junction box.
4. Remove the screws holding the burner side access panel.
Attached to the panel are the burner retaining pins that
align the burner.
5. Slide the burner assembly out. The pilot is attached to the
burner assembly.
6. Examine the burner and pilot assembly for cleanliness
and/or obstructions as necessary (see Duct Furnace for
cleaning instructions).
7. Replace the burner assembly in reverse order. In replacing
the burner, be certain that the rear burner slots are located
properly on the burner retaining pins. Do not force the
burner side access panel, it will not fit if the burner is not
properly aligned.
8. Reconnect the ignition cable and pilot gas supply line.
9. Turn on the electric and gas supply.
Figure 56.2 - Burner and Pilot Assembly Removal
GROUND
UNION
JOINT
MANIFOLD
BURNER SIDE
ACCESS PANEL
PILOT
ASSEMBLY
IGNITION
CABLE
PILOT
SUPPLY
LINE
HEAT
EXCHANGER
SUPPORT
56
5-572.11
AIR SHUTTERS
(NOT SHOWN)
ARE LOCATED
ON THE
MANIFOLD
THIS PAGE INTENTIONALLY LEFT BLANK
5-572.11
57
SERVICE & 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
ATTENTION
Ne tentez pas de réutiliser un composant mécanique ou
électrique qui a été mouillé. Ces composants doivent être
remplacés.
IMPORTANT
To check most of the Possible Remedies in the
troubleshooting guide listed in Table 58.1, refer to the
applicable sections of the manual.
AVERTISSEMENT
Pour l’entretien et les réparations de cet appareil, utilisez
uniquement des pièces d’origine certifiées. Pour la liste
complete des pièces de rechange, consultez Modine
Manufacturing Company. Le numéro de modèle complet,
le numéro de série et l’adresse du fabricant figurent sur la
plaque signalétique fixée à l’appareil. Toute substitution de
pièce ou decommande non approuvée par le fabricant sera
aux risques du propriétaire.
IMPORTANT
Pour essayer la plupart des solutions possibles suggérées
dans le guide de dépannage du Tableau 58.1 reportez-vous
aux sections correspondantes du manuel.
CAUTION
Do not attempt to reuse any mechanical or electrical
component which has been wet. Such component must be
replaced.
Table 58.1 - Troubleshooting
Trouble
Pilot does not light
Main burners do not light (Pilot is lit)
Lifting Flames (See Figure 59.1)
Yellow Tipping
(With propane gas, some yellow tipping is
always present.)
Flashback
Possible Cause
1.
2.
3.
Main gas is off.
Power supply is off.
Air in gas line.
4.
Dirt in pilot orifice.
5.
Gas pressure out of proper range.
6.
7.
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.
8.
Safety device has cut power.
1.
2.
3.
4.
5.
1.
2.
Defective valve.
Loose wiring.
Defective pilot sensor
Defective ignition controller.
Improper thermostat wiring.
Too much primary air.
Main pressure set too high.
3.
Orifice too large.
1.
Insufficient primary air.
2.
Dirty orifice.
5.
6.
7
8.
1.
2.
3.
4.
5.
1.
2.
3.
Open manual gas valve.
Turn on main power.
Purge gas line.
C
heck for plugged pilot orifice and clean with
compressed air if necessary.
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.
a. Check all ignition controller wiring.
b. Replace sensor if cracked or worn
c. Replace ignition controller.
C
heck 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.
C
heck orifice size with those listed on the serial
plate.
1.
Increase primary air.
2.
C
heck orifices and clean with compressed air if
necessary.
Check manifold, replace if necessary.
3.
Misaligned orifice.
3.
1.
Too much primary air.
1.
Reduce primary air.
2.
Main pressure set too high.
3.
Orifice too large.
2.
3.
Adjust to a maximum of 14” W.C.
C
heck orifice size with those listed on the serial
plate.
(Continued next page)
58
Possible Remedy
1.
2.
3.
4.
5-572.11
SERVICE & TROUBLESHOOTING (CONTINUED)
Troubleshooting (Continued)
Trouble
Possible Cause
Possible Remedy
Floating Flames (See Figure 59.2)
1.
2.
3.
Insufficient primary air.
Main pressure set too high.
Orifice too large.
4.
1.
2.
Blocked vent cap.
Main pressure set too high.
Orifice too large.
3.
1.
Blocked vent cap.
Unit cycling on high limit. j
a. Obstructions/leaks in duct system.
b. Main pressure set too high.
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).
4. Check/replace thermostat.
Flame Rollout (See Figure 59.3)
Not Enough Heat
c. Blower motor not energized.
d. Loose belt
e. Blower speed too low.
f. Blocked/damaged venting system.
g. Defective high limit switch.
Too Much Heat
Power Exhauster Motor Will Not Start
2.
Main pressure set too low.
3.
Too much outside air.
4.
Thermostat malfunction.
5.
6.
Gas controls wired incorrectly.
Unit undersized.
1.
2.
Thermostat malfunction.
Gas controls do not shut-off.
a. Gas controls wired incorrectly.
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.
5. Check unit wiring against the wiring diagram.
6. Check design conditions. If unit is undersized, an
additional unit(s) or other heat source must be added.
1. Check/replace thermostat.
2.
a. Check unit wiring against the wiring diagram.
b. Check for loose or worn wires.
3. Adjust to a maximum of 14” W.C.
4. Replace gas valve.
1. Turn on main power.
2. Check control transformer.
3. Check/replace thermostat.
4. Replace power exhauster relay.
5. Replace power exhauster motor.
j T
he 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 29.1, indicator (49) for the location of the 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 58.1.
Figure 59.1 - Lifting Flame Condition
Figure 59.2 Floating Flame Condition
Figure 59.3 Flame Rollout Appearance
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START-UP CHECKLIST
Start-Up Checklist
Indirect Gas-Fired Heating Equipment
Job Name:
Date:
Address:
Model No.:
City & State:
Order No.:
Start-Up Check List “ALL ITEMS MUST BE CHECKED”
Serial No.:
1. All shipping straps, braces, tie downs removed?
2. Unit installed level and secure?
3. Gas burner properly located and aligned?
4. Blower and motor alignment okay?
5. Bearings aligned and tight on shaft/bearing supports?
6. Electrical connections checked and secure?
7. Gas piping checked and tightened if necessary?
8. Any visible damage to unit?
Describe: ______________________________________________
If damaged, was the damage repaired?
9. Air inlet and discharge checked for obstructions?
10. Bearings checked for proper lubrication?
11. Filters in place and correct to direction of air flow?
12. Belt tension checked?
13. Electric supply to unit: ______ Volts, ______ Hz, ______ Phase
14. Gas supply to unit: ______ Natural, ______ Propane
15. Gas supply pressure to unit: ______ " W.C., ______ PSIG
16. Inlet and/or discharge dampers operating correctly?
17. Blower rotation correct?
18. Blower speed: Hi Speed ______ RPM, Lo Speed ______ RPM
19. Motor speed: Hi Speed ______ RPM, Lo Speed ______ RPM
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? ______ " 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: __________ (°F/psi/Inches W.C./etc.)
Device: _______________ Setting: __________ (°F/psi/Inches W.C./etc.)
Device: _______________ Setting: __________ (°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: _________________
60
5-572.11
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 61.1 - Furnace Serial Plate Location
SERIAL
PLATE
Replacement Parts Ordering
When servicing, repairing or replacing parts on these units,
locate the model identification plate of the unit and always give
the complete Model Number and Serial Number from the model
identification plate. The model identification plate is located on
the blower section electrical compartment door. For a complete
description of the model number, see Weatherproof Model
Nomenclature on page 62.
Figure 61.2 - Furnace Serial Plate (sample shown, actual data may vary)
Figure 61.3 - Model Identification Plate (sample shown, actual data may vary)
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MODEL NOMENCLATURE FOR SYSTEM UNITS
Weatherproof 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)
H or O - Outdoor HVAC Unit
15 - Transformer (TR)
1 - 40 VA
2 - 75 VA
3 - 150 VA
2 - Unit Configuration (UC)
B - Blower Package - Furnace & Blower
C - Cooling Package - Furnace, Blower, & Cooling Cabinet
D - Downturn Package - Furnace, Blower, & Downturn
P - Packaged Unit - Furnace, Blower, Cooling Cabinet, & Downturn
16 - Blower Size & Bearing Type (BB)
C - 9-9 Spider Bearings
H - 15-15 Pillow Block Bearings
D - 9-9 Pillow Block Bearings I - 18-18 Spider Bearings under 15 Hp
E - 12-12 Spider Bearings
J - 18-18 Pillow Block Brngs under 15 Hp
F - 12-12 Pillow Block Brngs K - 18-18 Pillow Block Brngs, 15 Hp & Up
G - 15-15 Spider Bearings
L - 20-18 Pillow Block Bearings
3 - Venting (V)
P - Power
4,5,6 - Furnace Input Rating (MBH) (Except for 840 & 960)
100 - 100,000 Btu/Hr Input
350 - 350,000 Btu/hr Input
125 - 125,000 Btu/Hr Input
400 - 400,000 Btu/Hr Input
150 - 150,000 Btu/Hr Input
500 - 500,000 Btu/Hr Input
175 - 175,000 Btu/Hr Input
600 - 600,000 Btu/Hr Input
200 - 200,000 Btu/Hr Input
700 - 700,000 Btu/Hr Input
225 - 225,000 Btu/Hr Input
800 - 800,000 Btu/Hr Input
250 - 250,000 Btu/Hr Input
840 - 1,050,000 Btu/Hr Input
300 - 300,000 Btu/hr Input
960 - 1,200,000 Btu/Hr Input
7 - Heat Exchanger/Burner/Drip Pan Material (HE)
T - 409 Stainless Steel Heat Exchanger/Burner/Drip Pan
8 - Development Sequence Designation (DS)
F - Single Stage
M - 2-stage or Modulating
9 - Access Side (AS)
R - Right Hand
L - Left hand
10 - Air Temperature Rise (ATR)
H - High 60°-100°F
L - Low 20°-60°F
11 - Gas Type (GT)
N - Natural with ignition controller
P - Propane with ignition controller
12 - Gas Valve (GV)
1 - Single Stage
2 - Two Stage
4 - Electronic Modulation
7 - Electronic Modulation 0-10 Vdc External Input
9 - Electronic Modulation with Modine Control System
13 - Additional Safety Switches (SS)
0 - No Switches (Standard)
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
62
E - 230/60/3
F - 460/60/3
G - 575/60/3
4 - 250 VA
0 - None
17 - Motor Horsepower (HP)
A - 1/3 Hp
L - 1/3 Hp with Motor Starter
B - 1/2 Hp
M - 1/2 Hp with Motor Starter
C - 3/4 Hp
N - 3/4 Hp with Motor Starter
D - 1 Hp
P - 1 Hp with Motor Starter
E - 1-1/2 Hp
Q - 1-1/2 Hp with Motor Starter
F - 2 Hp
R - 2 Hp Hp with Motor Starter
G - 3 Hp
S - 3 Hp with Motor Starter
H - 5 Hp
T - 5 Hp with Motor Starter
I - 7-1/2 Hp
W - 7-1/2 Hp with Motor Starter
J - 10 Hp
X - 10 Hp with Motor Starter
K - 15 Hp
Y - 15 Hp with Motor Starter
V - 20 Hp
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-Z - (See Sheave Tables)
20,21 - Air Control (AC)
AA - RA Opening
BA - FA Opening
CA - FA & RA Openings
DA - FA Dampers w/ 2 pos motor (No RA)
EA - FA & RA Dampers w/ 2 pos motor
GA - FA & RA Mod motor w/ 0-10 Vdc External Input
GC - FA & RA Mod motor w/ Minimum Position (Factory Mounted)
GE - FA & RA Mod motor w/ 3 pos. damper (100% RA, Variable, 100% OA)
22 - Evaporative Cooling (EC)
0 - None
D - 12" GLASdek Media, Stainless Steel Casing
23 - Cooling Coil (CC)
0 - None
1 - Factory Installed Coil
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5-572.11
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Modine Manufacturing Company
1500 DeKoven Avenue
Racine, WI 53403
Phone: 1.800.828.4328
www.modinehvac.com
© MODINE MANUFACTURING COMPANY 2023
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