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Model DBG, DCG

1. sae mene J Over Roof 3 86 L N Vent Dia zz 2 20 fe I 34 25 PN M PM 2 al L 7 24 00 H k B Height Outside lI inside G INSIDE 24 00 p A Inside C Width Outside f An PA e lt _ Y Jal 1026 gt Lm 9 21 dy 555 oat s s2 SZK F td 2 03 LL 5 65 Min approx Qty 4 Drill Locator Dimples for alda 4 35 3 00 Field Drilled Electrical Conduit Entry Holes spaced 2 0 apart Return Air Duct Connection 1 50 s 500 800 Model Shown Figure 43 2 DCG Indoor Gravity Vented Cooling Package Unit Dimensions 36 67 29 36 48 08 J Over Roof r 12 674 L N Vent Dia 2 00 2 00 i Outlet Air Duct Connection F Height H Inside G INSIDE 24 00 X l Inside i K E Width Inside E a COH 6 165 10 26 F 529 boss Sa b 7 HICKS e e 24 00 34 27 Min approx ay A Dai Locator Dimples for inside 4 35 L 3 00 lel rile lectrical Conduil y Entry Holes spaced 2 0 apart Return Air Duct Connection 1 50 116 98 Table 43 1 DBG DCG Indoor Gravity Vented Unit Dimensions All dimensions in inches Qty Furnace
2. Motor Sheave Blower Sheave Sheave Browning Assembly Eon PIE Belt No Diameter Bore Diameter Bore 3H35129B1 41 0 625 10 9 1 B71 3H35129B2 41 0 875 10 9 1 B71 3H35129B3 4 1 1 125 10 9 1 B70 3H35129B4 4 7 0 625 10 9 q BX71 3H35129B5 4 7 0 875 10 9 1 BX71 3H35129B6 4 7 1 125 10 9 1 BX71 3H35129B7 5 5 1 375 12 4 1 BX71 3H35129B8 59 0 875 12 4 1 BX77 3H35129B9 5 9 1 125 12 4 1 BX75 3H35129B10 5 9 1 375 12 4 1 BX75 3H35129B11 5 3 1 125 8 9 1 BX68 3H35129B12 55 1 375 9 4 1 BX68 3H35129B13 5 5 1 625 9 4 1 BX75 3H35129B14 55 1 625 9 4 1 BX75 3H35129B15 7 1 125 10 4 1 B73 3H35129B16 7 1 375 10 4 1 B72 3H35129B17 7 1 625 10 4 1 B78 3H35129B18 7 1 625 10 4 1 B78 3H35129B19 7 1 375 9 4 1 B70 3H35129B20 7 1 625 9 4 1 B77 3H35129B21 7 1 625 9 4 1 B77 3H35130B1 5 5 1 625 9 4 1 44 ty 2 B74 3H35130B2 55 1 625 9 4 1 44 ay 2 B74 3H35130B3 7 1 625 10 4 1 44 ty 2 B78 3H35130B4 7 1 625 10 4 1 44 ty 2 B78 3H35130B5 7 1 625 9 4 1 44 ay 2 B77 3H35130B6 7 1 625 9 4 1 44 ty 2 B77 3H35130B13 7 1 875 12 4 1 44 ty 2 B82 3H35130B14 7 1 875 12 4 1 44 ay 2 B82 3H35130B15 7 1 875 10 4 1 44 ty 2 B79 3H35130B16 7 1 875 10 4 1 44 ty 2 B79 3H35130B17 7 1 875 9 4 1 44 ay 2 B77 3H35130B18 7 1 875 9 4 1 44 ty 2 B77 3H35130B19 7 1 875 8
3. 5 562 8 OPTIONS b Two stage Electronic Type Thermostat Includes a factory installed discharge air sensor The thermostat body is field installed remotely and includes the discharge air set point adjuster that must be field set Refer to Literature 5 577 latest revision Figure 19 1 Two stage Electronic Type Thermostat Sensor Duct Furnace Electrical Control Box CR J Sensor c Electronic Modulating Discharge Air Thermostat Includes a factory installed mixing tube and discharge air sensor for cooling package units For blower package units the air sensor is factory wired but field installed in duct work The set point adjuster is field installed remotely and must be field set Refer to Literature 5 578 latest revision Figure 19 3 Electronic Modulating Discharge Air Thermostat Electrical Control Box Mixing Tube gt Discharge air Sensor Terminals Air flow 2 Low Gas Pressure Switch OPT The low gas pressure switch is factory installed in the duct furnace above the gas train The switch monitors the gas pressure upstream of all the gas controls and shuts off the electric supply to the ignition controller and combination gas valve if low gas pressure is experienced This will shut off all gas flow to the burner The switch has an automatic reset so that if the gas pressure is interrupted
4. Figure 22 2 Enthalpy Changeover Set Point Control Points 5 90 35 100 105 110 29 a 35 38 41 143 SONTAGL CONTROL POINT GURYE APPAGE F rE AT SDE RM APPROXIMATE DRY BULE TEMPERATURE F C HIGH LIMIT URYE FOR W6210D W73100 BATT 22 5 562 8 OPTIONS Outdoor Enthalpy Changeover Set Point The outdoor enthalpy changeover set point returns the outdoor air damper to the minimum position when the enthalpy rises above its set point Enthalpy set point scale markings located on the enthalpy controller are A B C and D See Figure 24 2 for the corresponding control point The factory installed 620 ohm jumper placed across terminals Sp and is required for proper operation and should not be removed Refer to suppliers literature supplied with the unit for additional information 32 Damper to Damper Linkage OPT Units with fresh and return air dampers include a damper actuator that controls the fresh air damper The return air damper position is controlled by the fresh air damper through the connecting rod For adjustment refer to Damper Linkage Adjustment 33 Return Air Damper OPT When a return air damper is supplied with the unit the damper is factory installed in the blower section The return air damper is used as an air balancing damper so low leak Class III leakage resistance less than 40 CFM ft2 at 1 W C dampers with self
5. MODINE mame ae e April 2010 INSTALLATION AND SERVICE MANUAL gas fired indoor gravity vented duct furnaces make up air units models DBG DCG 200 LISTED 9900100 FOR YOUR SAFETY IF YOU SMELL GAS 1 Open windows 2 Don t touch electrical switches 3 Extinguish any open flame 4 Immediately call your gas supplier FOR YOUR SAFETY The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous IMPORTANT The use of this manual is specifically intended WARNING for a qualified installation and service agency A qualified installation and service agency must perform all installation and service of these appliances Improper installation adjustment alteration service or maintenance can cause property damage injury or death and could cause exposure to substances which have been RSA OSA ke AAA cause Inspection on Arrival cancer AN E r SO K Er Fepros UCING 1 Inspect unit upon arrival In case of damage report it harm Read the installation operating and immediately to transportation company and your local factory maintenance instructions thoroughly before sales representative installing or servicing this equipment 2 Check rating plate on unit to verify that power supply meets available electric power at the point of installation 3 Inspect unit upon arrival for conformance with descript
6. 1296 0 25 609 0 37 734 1400 0 17 474 0 28 615 0 40 737 1800 0 28 526 0 41 650 0 55 760 0 70 859 0 85 952 2200 0 44 588 0 59 697 0 75 796 0 91 887 1 09 972 1 27 1052 1 67 1201 2600 0 67 657 0 83 753 1 01 842 1 19 925 1 39 1004 1 59 1078 2 02 1218 2 47 1348 2 96 1469 3000 0 96 729 1 15 815 1 35 895 1 55 972 1 76 1044 1 98 1114 2 45 1245 2 94 1368 3 45 1483 3400 1 35 804 1 55 881 1 77 955 2 00 1025 2 23 1092 2 47 1157 2 96 1280 3 49 1396 4 03 1505 3800 1 82 880 2 05 951 2 29 1018 2 53 1083 2 79 1146 3 04 1206 3 58 1322 4 14 1431 4 72 1535 4200 2 40 959 2 66 1023 2 92 1085 3 18 1145 3 45 1204 3 73 1260 4 30 1369 4 90 1472 4700 3 30 1058 3 58 1116 3 87 1172 4 16 1227 4 46 1281 4 76 1333 5200 4 40 1158 4 71 1212 1481 0 36 871 0 48 1016 0 60 1144 0 73 1259 0 85 1366 0 99 1465 1 26 1646 1 54 1808 1 84 1958 1667 0 48 943 0 61 1078 0 75 1198 0 88 1309 1 03 1411 1 17 1507 1 47 1682 1 77 1842 2 09 1988 1750 0 54 975 0 68 1106 0 82 1224 0 96 1332 1 11 1433 1 26 1527 1 57 1700 1 88 1857 2 21
7. position power is disconnected to all unit wiring electrically following the switch See Warning To open see Figure 20 1 For servicing the unit the disconnect switch can be manually overridden by using a wrench and turning the disconnect switch shaft 90 clockwise See Figure 20 1 Fusible and circuit breaker switches available For fusible switches Class J time delay fuses must be field provided matching the fuse size listed on the Model Identification plate 17 Step Down Transformer Fuses OPT The transformer fuses are factory installed in the electrical section The fuses are included to protect the transformer Fuses included 18 Step Down Transformer OPT The step down transformer is factory installed in the eletrical section The transformer is required for power exhausted units with a supply voltage of 460V 3Ph and 575V 3Ph 19 Factory Installed Minimum Positioner OPT The factory installed minimum positioner is installed in the electrical section and is used with a modulating damper actuator to set the minimum percentage of outside air The minimum positioner dial is manually set between 0 to 100 resulting in a 2 to 10 VDC signal being sent to the damper actuator When used in conjunction with the Proportional Temp Controller the positioner sets the minimum outside air percentage and the Proportional Temp Controller then modulates between the minimum position and 100 outside air Figure 20 2
8. Minimum Positioner Belimo 20 5 562 8 OPTIONS 20 Extended Grease Line Zerk Fittings OPT The extended grease line zerk fittings are factory installed on the exterior corner post between the electrical and blower sections The zerk fittings allow pillow block bearings to be lubricated with a grease gun Refer to Lubrication Recommendations for lubricant recommendations 21 Extended Grease Lines OPT The extended grease lines are factory installed in the blower section from the Extended Grease Line Zerk Fittings to the Pillow Block Bearings The grease lines allow the pillow block bearings to be lubricated without requiring the service personnel to remove both blower doors to access the bearings 22 Return Air Fire Stat OPT The return air fire stat is factory installed in the electrical section with the sensor in the return air stream In case of elevated temperatures in the return air stream the manual reset switch shuts down the entire unit If the limit temperature is exceeded a service person must inspect the unit for the cause of the high discharge temperature take corrective action and then reset the switch For single phase units 1 1 2 HP and less the fire stat de energizes a relay that controls blower motor operation For three phase units and single phase units 2 HP and greater the fire stat de energizes the motor starter that controls blower motor operation 23 Blow
9. compensating stainless steel side seals and santoprene blade seals are used 34 Proportional Temperature Controller Sensor OPT A proportional temperature controller sensor is provided with Air Control options GF GG GH GK GM or GN Digits 20 8 21 and factory installed in the blower section The sensor provides the mixed air temperature signal to the A350P Proportional Temperature Controller which is mounted in the electrical section 35 Motor and Blower Vibration Isolation OPT The motor vibration isolation is factory installed in the blower section below the blower support bracket The four 4 13 32 neoprene vibration mount grommet provides isolation of the blower housing and motor from the blower support channels The blower vibration isolation is factory installed in the blower section between blower discharge and the blower duct connection The blower duct connection is not rigidly mechanically fastened and the 1 4 thick gasketing around the duct transition provides vibration isolation 36 Blower Support STD The blower supports are factory installed in the blower section The blower supports are used to rigidly support the weight of the blower and motor during operation and shipping 37 Convenience Outlet OPT A WARNING Do not perform service on the convenience outlet without disconnecting its power supply The convenience outlet power supply is separate from main power supply to the
10. 0 63 t o o Zo o EJ u M 236 0 75 Suspension i Hanging Locations ry Typical 4 Corners B J E Inside Suspension oint lt 24 00 Inside gt eee ini oint Lifting Liftin i Pon Point F p Y q 5 D Return Air gt 14 35 e a Opening 145 N Dimensions Blower Type Digit 16 E N 75 All 100 125 All 150 175 All 200 225 All 250 300 E F G or H 250 300 I J or K 350 400 E F G or H 350 400 I J or K 500 600 G or H 500 600 I J K or L 700 800 G or H 700 800 I J K or L 840 960 I J K or L Table 45 2 Indoor Gravity Vented Cooling Package Units All dimensions in inches Blower Type Digit 16 75 All 100 125 All 150 175 All 200 225 All 250 300 E F G orH 250 300 I J or K 350 400 E F G orH 350 400 l J or K 5 562 8 45 DIMENSIONS COOLING COILS Figure 46 1 DX Coil Drawing All dimensions in inches J Airflow Direction TOP VIEW eis Coil for Right Hand Units 1 5 gt Rows 2 3 4 6 W 7 5 6 7 5 10 4 RE Digit 9 R Headers on opposite side for Left Hand Units FRONT VIEW Distributor Inlet Liquid Line Connection s Second Inlet on Dual Circuit Coils SIDE VIEW Airflow Direction Suction Line
11. 1 The thermostat calls for heat 2 The pilot valve opens and the spark ignitor sparks in an attempt to light the pilot If the unit was not provided with a time delay relay the blower starts at this time 3 Once the pilot is lit the flame sensor proves the pilot and stops the spark ignitor from sparking 4 The main gas valve is opened and the main burner is lit to 100 full fire 5 If the unit was provided with a time delay relay the blower starts after 30 to 45 seconds 6 The modulating gas valve can be controlled by either an electronic modulating room or duct thermostat The thermostat can modulate the firing rate between 40 through 100 full fire The call for heat is created by a resistance signal 8000 to 12000 ohms in the thermostat The amplifier converts this resistance into a DC voltage 0 to 12 volts DC with 0 volts high fire and 12 volts low fire The output voltage is applied to the modulating gas valve to control the gas flow to the main burner As the temperature drops the voltage drops causing the modulating valve to open further If the discharge air temperature increases the voltage increases causing the modulating valve to close allowing less gas flow to the main burner For further information regarding the operation of the electronic modulating system consult the literature provided with the unit 7 The unit continues to operate in this manner until the thermostat is satisfied at which time both t
12. 2 Remove the cap from the pilot adjustment screw For location see the combination gas control literature supplied with unit 3 Adjust the pilot length by turning the screw in or out to achieve a soft steady flame 3 4 to 1 long and encompassing 3 8 1 2 of the tip of the thermocouple or flame sensing rod See Figure 13 1 4 Replace the cap from the pilot adjustment screw Figure 13 1 Correct Pilot Flame f 3 4 to 1 die JU dl Main Burner Adjustment The gas pressure regulator integral to the combination gas control is adjusted at the factory for average gas conditions It is important that gas be supplied to the duct furnace in accordance with the input rating on the serial plate Actual input should be checked and necessary adjustments made after the duct furnace is installed Over firing a result of too high an input reduces the life of the appliance and increases maintenance Under no circumstances should the input exceed that shown on the serial plate Measuring the manifold pressure is done at the tee in the manifold or at the pressure tap of the gas valve for standard gas string See Figure 14 1 To Adjust the Manifold Pressure 1 Move the field installed manual shut off valve to the OFF position 2 Remove the 1 8 pipe plug in the pipe tee or gas valve and attach a water manometer of U tube
13. 2003 2000 0 76 1077 0 92 1197 1 08 1306 1 24 1407 1 40 1502 1 57 1592 1 91 1758 2 26 1910 2 62 2051 2250 1 04 1181 1 21 1291 1 39 1393 1 57 1488 1 75 1577 1 94 1663 2 31 1822 2 69 1969 2500 1 38 1288 1 57 1389 1 77 1484 1 97 1573 2 17 1658 2 37 1739 2 78 1892 2750 1 79 1396 2 00 1490 2 22 1579 2 44 1663 2 66 1743 2 88 1820 3000 2 28 1506 2 51 1593 2 75 1677 2 98 1756 1750 0 29 594 0 43 723 0 58 838 0 75 944 0 94 1042 1 14 1134 1 58 1303 2 07 1458 2 60 1600 2000 0 40 642 0 54 759 0 71 866 0 88 966 1 08 1058 1 28 1146 1 74 1309 2 23 1458 2 78 1595 2500 0 68 746 0 85 845 1 04 938 1 23 1025 1 45 1108 1 67 1188 2 15 1337 2 67 1475 3 24 1604 3000 1 09 857 1 29 942 1 50 1024 1 72 1101 1 95 1176 2 19 1248 2 71 1384 3 27 1511 3 86 1632 3500 1 66 972 1 88 1047 2 12 1119 2 36 1188 2 61 1255 2 88 1320 3 43 1455 4 03 1563 4000 2 40 1091 2 65 1157 2 91 1221 3 18 1284 3 46 1345 3 75 1404 4 35 1518 4 98 1628 4500 3 34 1211 3 62 1270 3 91 1329 4 21 1385 4 51 1441 4 82 1495 5000 4 52 1332 4 82_ 1387 gt s 1750 0 20 425 0 33
14. 546 0 48 653 2000 0 26 449 0 40 562 0 56 662 0 74 754 2500 0 42 507 0 58 603 0 75 692 0 94 774 1 16 851 1 38 925 3000 0 65 571 0 83 654 1 02 732 1 23 807 1 45 877 1 69 944 2 21 1071 3500 0 97 639 1 17 713 1 38 782 1 60 850 1 84 914 2 10 975 2 64 1093 3 23 1202 3 86 1307 4000 1 38 710 1 60 776 1 83 839 2 08 899 2 34 958 2 60 1014 3 18 1123 3 80 1226 4 46 1324 4500 1 90 783 2 14 842 2 40 899 2 66 955 2 94 1008 3 23 1061 3 84 1161 4 48 1258 5000 2 54 858 2 81 911 3 08 963 3 37 1014 3 67 1064 3 98 1112 4 62 1206 5500 3 32 933 3 61 982 3 91 1030 4 22 1077 4 54 1123 4 87 1168 4 25 1009 4 57 1054 4 89 1099 25 F 28 F 6000 Total static pressure should include external static pressure and accessory option static pressure from Table 30 1 Unit internal resistance has been included in the unit performance tables Brake Horsepower and RPM values are approximate values only Please consult the AccuSpec selection software for values at other than listed CFM static pressures 5 562 8 31 BLOWER PERFORMANCE DATA Table 32 1 Unit Performance Tables 74 F
15. GT N Natural with ignition controller P Propane with ignition controller 12 Gas Valve GV 1 Single Stage 5 Electronic Modulation Master 2 Two Stage Electronic Modulation Slave 4 Electronic Modulation 7 Electronic Modulation 0 10 Vdc External Input 8 Electronic Modulation 4 20 mA External Input 13 Additional Safety Switches SS 4 No Switches Standard 1 Low Gas Pressure Switch Premium 0 No Switches Premium 2 High Gas Pressure Switch Premium 3 High and Low Gas Pressure Switch Premium 14 Supply Voltage SV A 115 60 1 E 230 60 3 B 208 60 1 F 460 60 3 C 230 60 1 G 575 60 3 D 208 60 3 15 Transformer TR 1 40VA 4 250 VA 2 75VA 0 None 3 150 VA GV SS SV TR BB HP MT SA AC EC CC 16 Blower Size amp Bearing Type BB A 9 7 Spider Bearings G 15 15 Spider Bearings B 9 7 Pillow Block Bearings H 15 15 Pillow Block Bearings C 9 9 Spider Bearings 18 18 Spider Bearings under 15 Hp D 9 9 Pillow Block Bearings J 18 18 Pillow Block Bearings under 15 Hp E 12 12 Spider Bearings K 18 18 Pillow Block Bearings for 15 Hp amp up F 12 12 Pillow Block Bearings L 20 18 Pillow Block Bearings 17 Motor Horsepower HP A 1 3 Hp 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 2H
16. OPTIONS 23 art sowa aed Po ay a EA BA 18 General Performance Data 0 0 0000 26 Unit Selection 0 2 0 aaa aaa aaa aaa cii 28 Blower Performance Data 0 0c eee eee 30 Blower Sheave Assembly Data 1 1 34 Electrical Data i uowas set w ee SW aw O P NA A PSE 38 MotorData 6a eaa a 484 beanie bien bea eee pode be 38 Dimensions Unit scce sete Sees ee ie arei ee vied a eee SE 43 WeighiS2 1400516407 A A add AE kad amen oe 47 Mater rr Ge a Ea AR ee 48 Service amp Troubleshooting 0 000 49 Model Designations 20000 0 52 Start Up Checklist 200 0 54 Model Nomenclature 0 2 00 0 55 Commercial Warranty a aeaaaee aaaeeeaa Back Page 5 562 8 SI METRIC CONVERSION FACTORS UNIT LOCATION SI METRIC CONVERSION FACTORS Table 3 1 To Convert Multiply By To Convert Multiply By 0 24 kPa CFH 1 699 m3 min 6 893 Btu ft3 0 0374 mJ m3 F 32 x 0 555 C pound 0 453 kg inches 25 4 mm Btu hr 0 000293 kW hr feet 0 305 meters gallons 3 785 liters CFM 0 028 m3 min psig 27 7 W C UNIT LOCATION A DANGER Appliances must not be installed where they may be exposed to a potentially explosive or flammable atmosphere IMPORTANT To prevent premature heat exchanger failure do not locate ANY gas fired appliances in areas where corrosive vapors i e chlorinated halogenated or acid are present
17. RPM 556 0 09 679 0 15 871 0 22 1031 0 29 1170 0 37 1296 0 45 1411 0 63 1617 0 81 1800 1 01 1968 700 0 14 747 0 21 924 0 29 1074 0 37 1206 0 46 1327 0 55 1438 0 75 1638 0 95 1818 1 17 1982 800 0 18 801 0 26 966 0 35 1109 0 44 1237 0 54 1354 0 64 1462 0 84 1658 1 06 1832 1 30 1996 1000 0 29 917 0 39 1062 0 50 1192 0 60 1310 0 72 1419 0 83 1522 1 07 1709 1 32 1879 1200 0 45 1042 0 57 1171 0 69 1289 0 82 1397 0 94 1499 1 08 1595 1 35 1773 1400 0 66 1173 0 80 1288 0 94 1395 1 08 1495 1 23 1589 1 38 1680 1600 0 93 1308 1 09 1412 1 25 1509 1 42 1601 1800 1 28 1445 1 46 1539 z z z 800 0 15 795 0 21 960 1000 0 20 822 0 28 975 0 36 1112 1200 0 19 705 0 27 862 0 35 1003 0 44 1131 0 54 1250 0 65 1361 1400 0 27 770 36 00 912 0 45 1041 0 55 1161 0 66 1273 0 77 1377 1 00 1572 1600 0 37 839 0 47 968 0 57 1087 0 68 1199 0 80 1304 0 92 1403 1 17 1589 1 44 1760 1 72 1920 1800 0 49 912 0 60 1030 0 72 1139 0 84 1244 0 96 1343 1 09 1437 1 36 1613 1 65 1777 1 94 1931 2000 0 65 987 0 77 1095 0 9
18. purged into heat exchanger Check the pilot flame length See Pilot Flame Adjustment 22 Once the pilot has been established check to make sure that the main gas valve opens Check the manifold gas pressure See Main Gas Adjustment and flame length See Air Shutter Adjustment while the supply fan blower is operating 23 Check to insure that gas controls sequence properly See Control Operating Sequence Verify if the unit has any additional control devices and set according to the instructions in the Control Options 24 Once proper operation of the unit has been verified remove any jumper wires that were required for testing 25 Close the electrical compartment door 26 Replace all exterior panels Refer to page 54 for the Start up Checklist Pilot Burner Adjustment The pilot burner is orificed to burn properly with an inlet pressure of 6 7 W C on natural gas and 11 14 W C on propane gas but final adjustment must be made after installation If the pilot flame is too long or large it is possible that it may cause soot and or impinge on the heat exchanger causing failure If the pilot flame is shorter than shown it may cause poor ignition and result in the controls not opening the combination gas control A short flame can be caused by a dirty pilot orifice Pilot flame condition should be observed periodically to assure trouble free operation To Adjust the Pilot Flame 1 Create a call for heat from the thermostat
19. unit When the main disconnect switch is de energized the convenience outlet power supply remains energized The convenience outlet is factory installed in the blower section for providing power for 115V service equipment trouble light power tools etc The 115V ground fault circuit interrupter GFCI is rated for 15 amps and includes test and reset switches A separate field supplied 115V 1Ph power supply must be routed through the electrical section wall into the back of the convenience outlet junction box 38 Blower Door Switch OPT The blower door switch is factory installed inside the blower section door on the access side of the unit When the blower section door is removed the momentary switch is released and interrupts power to the low voltage circuit For single phase units 1 1 2 Hp and less the door switch de energizes a relay that controls blower motor operation For three phase units and single phase units 2 Hp and greater the door switch de energizes the motor starter that controls blower motor operation For servicing the switch is equipped with an override position that can be manually pulled out to override the switch See Figure 23 1 Figure 23 1 Blower Door Switch with Manual Override Override Position blower may start Rest position Operating Point COM NC_NO 39 Dirty Filter Switch OPT The dirty filter pressure switch is factory installed in the elec
20. 0 10 Vdc or 4 20 mA The signal conditioner can accept a 0 10 Vdc signal when all the dip switches are in the OFF position and 4 20 mA signal when all the dip switches are in the ON position The signal conditioner converts the input signal into a DC voltage 0 to 12 volts DC with 0 volts high fire and 12 volts low fire The output voltage is applied to the modulating gas valve to control the gas flow to the main burner As the temperature drops the voltage drops causing the modulating valve to open further If the discharge air temperature increases the voltage increases causing the modulating valve to close allowing less gas flow to the main burner For further information regarding the operation of the electronic modulating system consult the literature provided with the unit 7 The unit continues to operate in this manner until the thermostat is satisfied at which time the BMS heat contact opens resulting in both the main and pilot valves closing 100 If the unit was not provided with a time delay relay the blower stops at this time 8 Ifthe unit was provided with a time delay relay the blower stops after 30 to 45 seconds Variable Air Movement Applications Units may be supplied with variable frequency drives for applications where variable air volume is required The minimum air flow may be varied between 30 and 100 of the full speed air flow depending on the controls selection of the unit Due to the extra rest
21. 18 9 23 0 9 3 85 0 72 0 N A 14 or W4 ODP 18 12 22 0 12 3 N A 15 or W5 24 0 N A 16 or W6 22 0 N A I7 or W7 21 0 8 8 82 5 18 or W8 TE 18 12 21 8 12 0 84 0 J1 or X1 ODP 32 6 76 0 59 0 J2 or X2 ODP HE 29 0 ODP 18 12 74 0 60 0 J3 or X3 ODP 18 9 27 7 11 2 TEFC N A J4 or X4 ODP 18 12 27 0 14 5 TE HE 84 5 J5 or X5 29 0 TEFC 18 9 76 0 58 0 J6 or X6 27 6 TEFC 18 12 J7 or X7 29 0 11 5 ODP J8 or X8 TE 18 12 30 0 17 0 ODP K1 or Y1 ODP 45 6 ODP 18 9 80 0 65 0 K2 or Y2 ODP HE 43 4 ODP 18 12 80 0 71 0 K3 or Y3 ODP 18 9 42 5 16 5 TEFC N A K5 or Y5 42 0 TE HE 84 0 K6 or Y6 40 3 TEFC 18 9 K7 or Y7 44 0 16 0 TEFC 18 12 K8 or Y8 TE 18 12 42 0 23 0 ODP V1 or Z1 ODP 61 6 ODP V2 or Z2 ODP HE 57 0 ODP 18 9 V3 or Z3 ODP 18 9 56 0 21 0 ODP 18 12 V4 or Z4 ODP 18 12 54 0 28 0 TE TE HE TEHE TEFC 18 9 TE 18 12 ODP ODP HE ODP 18 9 ODP 18 12 TE 18 12 ODP TE 18 9 Motors have no thermal overload Refer to page 42 for Motor Type abbreviations 5 562 8 39 MOTOR DATA Table 40 1 Mot
22. 3 Blower Section and Cooling Cabinet Discharge Duct Connections 5 562 8 INSTALLATION Venting 1 2 3 Gas fired heating equipment must be vented do not operate unvented Abuilt in draft diverter is provided additional external draft diverters are not required or permitted Gas fired heating equipment which has been improperly vented or which experiences a blocked vent condition may have flue gasses accidentally spilled into the heated space See page 25 for specific information about the blocked vent safety switch supplied on the unit Modine Manufacturing Company offers power exhausters as an accessory Power exhausters not supplied by Modine Manufacturing Company are not permitted General Venting Air Instructions LE 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 All units with single stage controls are Category I All units with two stage or modulating controls are Category II The installation of a Catagory ll unit must conform to the requirements from Table 6 1 in addition to those listed below From Table 43 1 or 44 1 select the size of vent pipe that fits the flue outlet for the unit Do not use a vent pipe smaller than the
23. 5 000 cfm 2 Outdoor design temp 10 F Indoor design temp 70 F 3 Heating output capacity 5000 cfm x 70 F 10 F x 1 08 324 000 Btu Hr 4 External Static Pressure 0 65 The unit with the controls on the Right Hand Side is to be provided with the following 2 Permanent Filters and Fresh Air Damper Heat exchanger and burner 409 Stainless Steel Gas Type Natural Gas Controls Electronic Modulating with Duct Sensing Supply Voltage 460V 60Hz 3Ph Altitude 1000 feet a oO ON 1 With the information listed above the basic model using the Model Nomenclature shown on page 55 can be selected as shown in the following example 1 Determine the Model Configuration and Venting The Model Configuration is determined by the required sections of the unit Blower only and the venting style gravity vented that are obtained from item 5 Using the Model Nomenclature on page 55 the Model Configuration and Venting DBG 2 Determine the Furnace Input Rating MBH Using the Heating output capacity the Furnace Input Rating is determined from Table 26 1 The closest model to 324 000 Btu Hr output has an Btu Hr Input rating of 400 000 Btu Hr so the Furnace Input Rating 400 3 Determine the Heat Exchanger Burner Drip Pan Material From item 2 in Selection Example Conditions the Heat Exchanger and Burner required are 409 Stainless Steel Because the Drip Pan material is not specified the standard Alumi
24. Disconnect power i Replace cover plate 2 and re install all wires from Maxitrol amplifier terminal 3 or duct furnace terminal 43 7 After adjustment move the field installed manual shut off valve to the OFF position and replace the 1 8 pipe plug 8 After the plug is in place move the field installed manual shut off valve to the ON position and recheck pipe plugs for gas leaks with soap solution 5 562 8 13 START UP PROCEDURE Figure 14 1 Checking Manifold Pressure with heat exchanger support locations To decrease primary air U Tube Manometer move the air shutters away from the manifolds until flames no longer lift from burner ports but being careful not to cause yellow tipping Retighten set screws after adjustment Propane Gas Flame Conirol An optimum flame will show a slight yellow tip Prior to flame adjustment operate furnace for at least fifteen minutes Loosen air shutter set screws and move the air shutters away from the manifold to reduce the primary air until the yellow flame tips appear Then increase the primary air until yellow tips diminish and a clean blue flame with a well defined inner cone appears Table 14 1 Manifold Pressure and Gas Consumption Model Size Type of Gas Natural Propane Btu Cu Ft 1040 2500 Specific Gravity High Fire Manifold Pressure Inches of Water Column Cfh Orifice Drill Size Cfh Orifice Drill Size Cfh Orifice Drill Size Cfh
25. J K or L 36 67 29 36 47 36 36 68 J Over Roof L 2 32 i Outlet Air E Duct 1 Se sara a Ilo d z Fresh Air Connection r wola Duct Connection 28 00 Height h 24 00 24 00 43 23 42 37 m Inside G ONSIDE Inside 44 80 E Width Inside 7 65 9 21 529 529 9 21 3 00 34 27 Min approx Return Air 4 35 F gt Qty 4 Drill Locator Dimples for Duct Connection 1 50 Field Drilled Electrical Conduit Entry Holes spaced 2 0 apart 152 84 Table 44 1 DBG DCG Indoor Gravity Vented Unit Dimensions with Blower Type I J K or L All dimensions in inches Qty of Dimensions Furnaces L N 250 300 I J or K 123 35 350 400 I J or K 123 35 500 600 J K or L 156 76 700 800 J K or L 156 76 840 960 I J K orL 185 99 For Right Hand Access Units Drill Locator Dimples for Field Drilled Electrical Conduit Entry Holes spaced 2 0 apart For Left Hand Access Units Drill Locator Dimples for Field Drilled Electrical Conduit Entry Holes spaced 2 0 apart Applies to units with Digit 16 L only 44 5 562 8 DIMENSIONS BASE Figure 45 1 Unit Base Dimensions C To end of unit gt
26. O71 Gt C1 CO C9 CO CO CO CO CO CO PO PO PO PO PO P PO Motors have no thermal overload Refer to page 42 for Motor Type abbreviations 5 562 8 41 MOTOR DATA Table 42 1 Motor Data for Digit 14 G 575V 60Hz 3Ph Digits Motor 17818 Size HP A5 or L5 Service Factor Efficiency B1 or M1 B5 or M5 C1 or N1 C5 or N5 D1 or P1 D5 or P5 D6 or P6 E1 or Q1 E5 or Q5 E6 or Q6 F1 or R1 F5 or R5 F6 or R6 G1 or S1 G5 or S5 G6 or S6 H1 or T1 H5 or T5 H6 or T6 11 or W1 I5 or W5 16 or W6 J1 or X1 J5 or X5 J6 or X6 K1 or Y1 K5 or Y5 K6 or Y6 V1 or Z1 V5 or Z5 V6 or Z6 Motors have no thermal overload Motor Type Abbreviations ODP Open Drip Proof ODP HE Open Drip Proof High Efficiency ODP 18 9 Open Drip Proof 2 speed 1800 900 RPM ODP 18 12 Open Drip Proof 2 speed 1800 1200 RPM TE Totally Enclosed TEFC Totally Enclosed Fan Cooled TE HE Totally Enclosed High Efficiency TE 18 9 Totally Enclosed 2 speed 1800 900 RPM TE 18 12 Totally Enclosed 2 speed 1800 1200 RPM TENV Totally Enclosed Non Ventilating 42 5 562 8 DIMENSIONS UNIT Figure 43 1 DBG Indoor Gravity Vented Blower Package Unit Dimensions
27. Orifice Drill Size Cfh Orifice Drill Size Cfh Orifice Drill Size TOP HOUSING 1 A Coven PLATE Cfh AL GA T 4 MAXIMUM ADJUSTMENT SCREW Orifice Drill Size 5 MAXIMUM ADJUSTMENT SPRING Cfh 6 SOLENOID 7 MINIMUM ADJUSTMENT SPRING Orifice Drill Size 8 PLUNGER 9 MINIMUM ADJUSTMENT SCREW Cfh 10 MINIMUM ADJUSTMENT SCREW STOP Orifice Drill Size Cfh Orifice Drill Size Cfh Orifice Drill Size Cfh Orifice Drill Size Air Shutter Adjustment Cfh i Orifice Drill Size Proper operation provides a soft blue flame with a well defined Cin inner core A lack of primary air will reveal soft yellow tipped Orifice Drill Size flames Excess primary air produces short well defined flames with a tendency to lift off the burner ports For both natural Cfh gt and propane gas the air shutters can be adjusted to control Orifice Drill Size the burner flame height The air shutters can be accessed by Cfh reaching behind the gas valve in Figure 14 1 The larger models Orifice Drill Size may require the removal of the manifold see Manifold Assembly Cfh Removal Orifice Drill Size Model contains 2 furnaces Values shown are per furnace Natural Gas Flame Control Model contains 3 furnaces Values shown are per furnace Control of burner flames on duct furnaces utilizing natural gas is achieved by resetting the primary air shutters See Figure 48 4 to either
28. Table 38 1 Control Step Down Transformer Amp Draws Digit 14 Supply Voltage Digit 15 A B c D E F G Transformer 115 60 1 208 60 1 230 60 1 208 60 3 230 60 3 460 60 3 575 60 3 0 1 2 3 4 Motor Service Thermal Weight Efficiency Size HP Factor Overload Ibs A5 B1 B5 C1 C5 D1 D5 E1 E5 Fi or R1 F5 or R5 G1 or S1 G5 or S5 Digits Motor Service Thermal Weight Efficiency 17 amp 18 Size HP Factor Overload Ibs Al N A B1 N A B5 N A c1 N A C5 D1 D5 E1 E5 F1 or R1 F5 or R5 H1 or T1 H5 or T5 38 5 562 8 MOTOR DATA Table 39 1 Motor Data for Digit 14 C 230V 60Hz 1Ph Digits Motor 17818 Size HP Al Service Factor Thermal Overload Weight Ibs Efficiency A5 B1 B5 C1 C5 D1 D5 E1 E5 F1 or R1 F5 or R5 G1 or S1 G5 or S5 H1 or T1 H5 or T5 Refer to page 42 for Motor Type abbreviations Motors manufacturers do not rate single phase motors for efficiency Frame Service Weight Table 39 2 Motor Data for Digit 14 D 208V 60Hz 3Ph Efficiency N A Digits 17 amp 18 12 or W2 Frame Size ODP HE 22 3 Service Factor Weight Ibs 91 7 N A 13 or W3 ODP
29. The furnace low voltage terminal strip is located in the duct furnace electrical junction box The terminal strip is labeled to match the electrical wiring diagram provided with the unit Low voltage labeling ranges from terminal numbers 1 to 79 All field wiring connections should be made to the top side of the terminals to prevent miswiring by modifying the factory wiring which is made to the bottom of the terminal strip 12 Furnace Supply Power Terminal Strip STD The furnace supply power terminal strip is located in the duct furnace electrical junction box The terminal strip is labeled to match the electrical wiring diagram provided with the unit Supply power labeling ranges from terminal numbers 80 to 99 All field wiring connections should be made to the bottom side of the terminals to prevent miswiring by modifying the factory wiring which is made to the top of the terminal strip 13 Control Step Down Transformer STD The control step down transformer is located in the duct furnace electrical junction box The transformer is used to step down the supply power 115V 208V 230V 460V 575V to 24V This transformer is used to control the gas controls damper actuator motor starter etc Refer to the unit model number to determine the volt amp VA capacity of the duct furnace The 15th digit indicates the VA See Model Nomenclature 14 Control Relay OPT The control relay is factory installed in the electrical
30. VENT CATEGORY III OR IV UNITS ONLY 1 Do not vent a Category or Il unit into a common vent with mechanical draft systems operating under positive pressure Category lll or IV units 2 When connecting vent to an existing chimney do not push vent pipe beyond internal surface of chimney 3 When venting into a common vent the area of the common vent should be equal to or greater than the area of the largest vent plus 50 percent of the area of all additional vents 4 When venting into a common vent the individual vents should enter at different levels 5 562 8 7 UNIT INSTALLATION Gas Connections 1 2 Table 8 1 allows for a 0 3 W C pressure drop in the supply pressure from the building main to the unit The inlet A WAR N N G pressure to the unit must be 6 7 W C for natural gas and 11 14 W C for propane gas When sizing the inlet gas pipe diameter make sure that the unit supply pressure can 1 All field gas piping must be pressure leak tested prior to be met after the 0 3 W C has been subtracted If the 0 3 operation Never use an open flame Use a soap solution or W C pressure drop is too high refer to the Gas Engineer s equivalent for testing Handbook for other gas pipe capacities 2 Gas pressure to appliance controls must never exceed 14 3 The gas piping to the unit can enter the unit from the side of W C 1 2 psi the unit or from below Install a ground joint union with brass seat and a manu
31. air flow proving switch is factory installed in the duct furnace electrical junction box The air flow proving switch monitors the pressure differential between the duct furnace and the atmosphere The purpose of the air flow proving switch is to cut power to the gas controls if a positive pressure is not measured by the switch This could be caused by a lack of air movement through the heat exchanger NOTE The air flow proving switch will prevent any heat exchanger warm up because the gas controls can not be energized until air flow is proven Setting the Air Flow Proving Switch The range of the air flow proving switch is adjustable between 0 17 to 5 0 W C 1 Set the thermostat so that there is a call for heat This should start the blower and burner ignition sequence 2 Turn the set screw of the pressure switch clockwise until it stops This will set the pressure at 5 0 W C 3 Turn the screw counter clockwise until the gas controls light and then one additional full turn This is approximately 0 25 W C This will allow for dirty filters or any other slight static pressure increases in the system 49 High Limit Switch Automatic STD The automatic reset high limit switch is factory installed in the duct furnace electrical junction box If the limit temperature is exceeded the gas controls are de energized until the switch is cooled Manual OPT The manual reset high limit switch is factory installed in plac
32. and then is returned the switch will automatically allow the unit to operate when gas conditions are returned to the allowable range of the pressure switch The pressure switch range is 2 to 14 W C and should be set to insure that the minimum inlet gas pressure is available 6 W C for natural gas 11 W C for propane gas Figure 19 4 Low or High Gas Pressure Switch o NC ho MJ Sf i Reset Switch o M High Pressure Switch only Pressure adjustment screw o D o Top cover removed 3 High Gas Pressure Switch OPT The high gas pressure switch is factory installed in the duct furnace above the gas train The switch monitors the gas pressure downstream of all the gas controls and shuts off the electric supply to the ignition controller and combination gas valve if high gas pressure is experienced right before the manifold This will shut off all gas flow to the burner The switch has a manual reset so that if the gas pressure is too high a service person must check the unit to make sure that none of the gas controls have been damaged by the high gas pressure and then reset the switch to allow the unit to operate when gas conditions are returned to the allowable range of the pressure switch The pressure switch range is 2 to 16 W C and should be set to insure that the maximum manifold gas pressure is not exceeded 3 5 W C for
33. as shown in Figure 7 1 and Table 7 1 if the following conditions are met Vent diameter is less than 12 inches vent is of double wall construction and is a listed product and the vent does not terminate within 10 feet of a vertical wall or similar obstruction For vents that have a diameter of 12 inches or larger constructed of single wall or terminate within 10 feet of a vertical wall or similar obstruction the vent pipe shall extend at least 2 feet higher than any portion of a building within a horizontal distance of 10 feet refer to Figure 7 2 Use a vent terminal to reduce downdrafts and moisture in vent A vent terminal that is very open will avoid spillage at unit s diverter relief opening and tripping of the blocked vent safety switch Check vent system to see that combustion products are being vented properly Operate unit for several minutes and then pass a lighted match around the edge of the diverter relief opening If the flame is drawn into the opening the vent system is drawing properly If not make adjustments to provide adequate draft see Figure 49 1 For instructions on common venting refer to the National Gas Code The vent must terminate no less than 5 feet above the vent connector Aunit located within an unoccupied attic or concealed space shall not be vented with single wall vent pipe Single wall vent pipe must not pass through any attic inside wall consealed space or floor INSTALLATION Table
34. cause the unit to over fire 5 562 8 17 OPTIONS Options Factory Installed Figure 18 1 Factory Mounted Option Locations 9 12 56 8 14 20 22 gt Po 0 OTOIO 3 2 JEJ F ool L ET A Jeres soos 5 BE 49 44 31 1 Discharge Thermostat 20 Extended Grease Line Zerk w 8 Blower Door Switch 2 Low Gas Pressure Switch 21 Extended Grease Lines 39 Dirty Filter Switch 3 High Gas Pressure Switch 22 Return Air Fire Stat 40 Motor Starter VFD Control 5 Timed Freeze Protection 23 Blower Housing 42 Proportional Temp Controller 6 Ignition Controller 24 Pillow Block Bearings 43 Warm Up Stat 8 Control Relay 25 Blower Motor 44 Blower Supply Power Terminal Strip 9 Time Delay Relay 26 Filters 45 Service Switches 10 Furnace Low Voltage Terminal Strip 27 Fresh Air Damper 46 Electronic Modulating Amplifier 12 Furnace Supply Power Terminal Strip 30 Direct Drive Damper Actuator 47 Electronic Modulating Gas Valve 13 Control Step Down Transformer 31 Enthalpy Controller 48 Air Flow Proving Switch 14 Control Relay 32 Damper to Damper Linkage 49 High Limit Switch 15 Blower Low Voltage Terminal Strip 33 Return Air Damper 50 Supply Air Fire Stat 16 Dead Front Disconnect Switch 34 Proportional Temp Controller Sensor 51 Main Gas Valve 17 Step Down Transformer Fuses 35 Motor
35. enthalpy controller is provided with Air Control option GJ Digits 20 amp 21 and factory installed in the blower section The purpose of the enthalpy controller is to use outside air for cooling whenever possible to reduce compressor operation of the mechanical cooling system The economizer functions as a true first stage of cooling and provides maximum fuel economy during the cooling cycle An enthalpy sensor is provided with Air Control option GJ and field installed in the inlet air stream The enthalpy sensor senses and combines the temperature and humidity of the outdoor air to provide the 4 20 mA input signal to the Enthalpy Controller HEATING and VENTILATING MODE When the space thermostat calls for heat or it is in the fan ON position without a call for cooling ventilation mode the economizer is automatically locked out It holds the outdoor air damper at the minimum position setting COOLING MODE When the space thermostat calls for cooling the system operates as follows Outdoor Air Enthalpy is Below Changeover Set Point 1 The outdoor air damper is proportioned open and the return air damper is proportioned closed to maintain between 50 F and 56 F at the mixed temperature air sensor 2 During economizer operation mechanical cooling is operated by the second stage of the cooling on the space thermostat Outdoor Air Enthalpy is Above Changeover Set Point 1 The outdoor air damper is closed to its minimum positio
36. having a temperature rating of at least 105 C 11 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 A CAUTION 1 Purging of air from gas supply line should be performed as described in ANSI Z223 1 latest edition National Fuel Gas Code or in Canada in CAN CGA B149 codes 2 Do not attempt to reuse any mechanical or electronic ignition controllers which has been wet Replace defective controller 3 Ensure that the supply voltage to the appliance as indicated on the serial plate is not 5 less than the rated voltage IMPORTANT 1 To prevent premature heat exchanger failure do not locate ANY gas fired appliances in areas where corrosive vapors i e chlorinated halogenated or acid are present in the atmosphere 2 To prevent premature heat exchanger failure the input to the appliance as indicated on the serial plate must not exceed the rated input by more than 5 3 To prevent premature heat exchanger failure observe heat exchanger tubes by looking at the heat exchanger through the field installed access openings in connecting ductwork in cooling package units
37. listed are for the maximum coil dimensions If the coil supplied is smaller than the listed dimensions field supplied blank off plates are required to prevent air bypass around the coil The coil is supported by two 14 gauge support rails which contain mounting provisions for fastening 4 5 6 7 5 8 5 and 10 deep coils When obtaining the specifications from a coil manufacturer it is important to obtain the pressure drop through the coil so that the proper motor horsepower can be selected Figure 10 1 Cooling Section Optional double wall construction DX single circuit shown and dual circuit coils available Optional Factory Installed DX or Chilled Water coil Fin spacings of 6 8 10 12 or 14 fins per inch Adjustable mounting bracket for 2 3 4 and 6 row coils Full coverage 3 way sloping 409 stainless SS a AI steel drain pan Right or left hand coil 1 stubbed drain header access to connection match gas controls For Both Chilled Water and Direct Expansion Coils The condensate drain line needs to include a P trap immediately downstream of the connection to the unit This trap should extend at least two inches below the connection to prevent air pressure from forcing air into the unit The trap should be primed with a water glycol solution to prevent freezing All points where refrigerant water or condensate lines enter the structure should be sealed and vibration dampened Include s
38. must be derated to 90 of the rating listed above For Variable Air Movement Applications see page 17 Air Temperature Limits The maximum allowable discharge air temperature is 150 F The maximum allowable air temperature rise per furnace for Low Air Temperature Rise Units is 60 F All system units are designed for a maximum allowable total static pressure of 3 0 W C 5 562 8 27 UNIT SELECTION Selection Procedure In order to properly select an indirect fired heating ventilating cooling or make up air unit it is necessary to have the following basic information 1 9 Required air handling capacity CFM The air capacity of the unit is usually determined by the ventilation air requirements exhaust load of the building infiltration losses or the air turns changes of the space Outdoor and indoor design temperature The outdoor design temperature is determined by using the ASHRAE Guide design temperatures for the city where the equipment is to be installed For heating and ventilating units the desired room temperature would be used as the indoor design temperature In the case of 100 make up air units the discharge air temperature should be at least equal to the temperature of the air being exhausted Required heating output capacity Btu Hr The heating output capacity of the unit is determined by using the formula BTU HR CFM x Temp Rise F x 1 08 External static pressure to unit The exter
39. natural gas 10 W C for propane gas 5 Timed Freeze Protection OPT The timed freeze protection system is factory installed in the duct furnace electrical junction box with the sensor 30 75 F adjustable factory installed in the discharge air stream On initial start up the timed delay in the system allows the unit to go through the normal ignition sequence The timed delay is an automatic reset switch and adjustable for 1 10 minutes In the event that the unit fails to fire after this period the discharge air sensor will sense the cold air and will shut down the entire unit Figure 19 5 Timed Freeze Protection Module na TNO i o zl o o LU O O Og Go En Owm OW2 OW3 O oo M n M n NO c NC N L TB1 C no NC N T 5 562 8 19 OPTIONS 6 Ignition Controller OPT The ignition controller is factory installed in the duct furnace electrical junction box with the spark ignitor and sensor located on the burner For both natural and propane gas units the ignition controller is 100 shut off with continuous retry On a call for heat the system will attempt to light the pilot for 70 seconds If the pilot is not sensed for any reason the ignition control will wait for approximately six minutes with the
40. of piping must conform with local building codes GAS or in the absence of local codes with the National Fuel Gas En SN Code ANSI Z223 1 NFPA 54 Latest Edition In Canada z WZSKAS installation must be in accordance with CAN CGA B149 1 MANUAL GAS SEAT for natural gas units and CAN CGA B149 2 for propane GAS o dej ad units SUPPLY LINE g 2 Piping to units should conform with local and national Mego JIO requirements for type and volume of gas handled and 8 Ao pressure drop allowed in the line Refer to Table 14 1 gt ELUGGED to determine the cubic feet per hour cfh for the type of MIN GAGE CONNECTION gas and size of unit to be installed Using this cfh value and the length of pipe necessary determine the pipe SEDIMENT diameter from Table 8 1 Where several units are served by the same main the total capacity cfh and length of Manual shut off valve is in the OFF position when handle is perpendicular main must be considered Avoid pipe sizes smaller than to pipe Table 8 1 Gas Pipe Capacities Gas Pipe Capacities Up to 14 W C Gas Pressure through Schedule 40 Pipe Cubic Feet per Hour with Pressure Drop of 0 3 W C Natural Gas Specific Gravity 0 60 Propane Gas Specific Gravity 1 50 Pipe Diameter 1 2 3 4 1 1 1 4 1 1 2 Natural Propane Natural Natural Natural Propane Natural Propan
41. openings one near the top of the confined space and one near the bottom Each opening should have a free area of not less than one square inch per 1 000 BTU per hour of the total input rating off all units in the enclosure freely communicating with interior areas having in turn adequate infiltration from the outside For further details on supplying combustion air to a confined tightly sealed space or unconfined space see the National Fuel Gas Code ANSI 2223 1 of CAN CGA B149 1 or 2 Installation Code latest edition Sound and Vibration Levels All standard blower mechanical equipment generates some sound and vibration that may require attenuation Libraries private offices and hospital facilities will require more attenuation and in such cases an acoustical consultant may be retained to assist in the application Locating the equipment away from the critical area is desirable within ducting limitations Generally a unit should be located within 15 feet of a primary support beam Smaller deflections mean lesser vibration and noise transmission UNIT LOCATION UNIT LIFTING UNIT MOUNTING UNIT LIFTING All standard blower system units are shipped fully crated with skid supports below the unit The unit may be lifted from the bottom by means of a fork lift or other lifting device only if the shipping support skids are left in place DO NOT attempt to lift the unit from the bottom unless the shipping skid supports are still in place Wh
42. or the unit access doors in blower package units If the bottom of the tubes become red while blower and duct furnace are in operation check to be sure the blower has been set to the proper rpm for the application Refer to page 15 for Blower Adjustments 4 Start up and adjustment procedures should be performed by a qualified service agency 5 To check most of the Possible Remedies in the trouble shooting guide listed in Table 50 1 refer to the applicable sections of the manual Table of Contents Inspection on Arrival 200 00 1 Special Precautions 2000 cece eee 2 SI Metric Conversion Factors 00 eee eee ee 3 U itLOoCation a ri seid dos deed ba li holga nila s haa eae 3 Combustible Material and Service Clearances 3 Unit Lifting and Unit Mounting 20 00 000 nn 4 Duct Installation 0 0 0 0 aa e ai nR tee 5 Unit Installation s s sa ada s e do E AREA ata a 6 MENUNG sw cod ZW An A EWA OE hf I 6 Gas Connections aaaaaaa ekora gearen twi 8 Electrical Connections 0 00 9 Cooling Coil Specifications and Installation 10 Start Up Procedure 20 0 12 Pilot Burner and Main Burner Adjustment 13 Blower Adjustment 0 0 0 0 eee eee eee eee 15 Lubrication Recommendations 15 Damper Linkage Adjustment 15 Control Operating Sequence 15
43. section See description of Option 8 for additional details 15 Blower Low Voltage Terminal Strip STD The blower low voltage terminal strip is located in the electrical section The terminal strip is labeled to match the electrical wiring diagram provided with the unit Low voltage labeling ranges from terminal numbers 1 to 79 All field wiring connections should be made to the right side of the terminals to prevent miswiring by modifying the factory wiring which is made to the left side of the terminal strip 16 Dead Front Disconnect Switch OPT WARNING When the dead front disconnect switch is in the OFF position supply power remains energized at the blower supply power terminal strip and the top of the dead front disconnect switch When providing service on or near these terminals building supply power to the unit should be de energized Figure 20 1 Dead Front Disconnect Switch Assembly Supply Power Terminals See Warning Handle opening instruction table Pinch handle latch A 8 handle B together when opening and closing door To override turn shaft 90 C W with door open Blower Electrical Section Stand off Panel The dead front disconnect switch is factory installed in the electrical section The disconnect switch is designed so that it must be turned OFF before entry to the electrical control cabinet can be obtained See Figure 20 1 When in the OFF
44. size of the outlet on the appliance The pipe should be suitable corrosion resistant material Follow the National Fuel Gas Code for minimum thickness and composition of vent material The minimum thickness for connectors varies depending on the pipe diameter Limit length of horizontal runs to 75 of vertical height Install with a minimum upward slope from unit of 1 4 inch per foot and suspend securely from overhead structure at points no greater than 3 feet apart For best venting put as much vertical vent as close to the unit as possible Fasten individual lengths of vent together with at least three corrosion resistant sheet metal screws Vent pipes should be fitted with a tee with a drip leg and a clean out cap to prevent against the possibility of any moisture in the vent pipe from entering the unit The drip leg should be inspected and cleaned out periodically during the heating season The National Fuel Gas Code requires at least 6 inches from combustible materials for single wall vent pipe The minimum distance from combustible materials is based on the combustible material surface not exceeding 160 F Clearance from the vent pipe or the top of the unit may be required to be greater than 6 inches if heat damage other than fire such as material distortion or discoloration could result Avoid venting through unheated space When venting does pass through an unheated space insulate runs greater than 5 feet to minimize con
45. type which is at least 12 high 3 Move the field installed manual gas shut off valve to the ON position 4 Create a high fire call for heat from the thermostat 5 Determine the correct high fire manifold pressure For natural gas 3 5 W C for propane gas 10 W C Adjust the main gas pressure regulator spring to achieve the proper manifold pressure for location see the combination gas control literature supplied with unit 6 Ifthe unit has Electronic Modulation gas controls determine from the Model Identification Digit 12 the low fire gas pressure needs to be adjusted Using Figure 14 2 for item number locations this is accomplished as follows a Disconnect power b Remove all wires from Maxitrol Amplifier terminal 3 or duct furnace terminal 43 if available c Turn on power at the disconnect switch d Remove the maximum adjustment screw 4 spring 5 and plunger 8 A small magnet is useful for this purpose CAUTION The plunger is a precision part Handle carefully to avoid marring or picking up grease and dirt Do not lubricate e Using minimum adjusting screw 9 adjust low fire manifold pressure to 0 56 W C for natural gas and 1 6 W C for propane gas f Replace plunger and spring retainer spring and maximum adjusting screw in proper order g Using maximum adjustment screw 4 adjust high fire manifold pressure to 3 5 W C for natural gas and 10 W C for propane gas h
46. velocities and proper filtering of the fluid will help to satisfy this goal B Automatic air vents must be utilized to remove accumulated air C Freeze Protection During the winter chilled water coils need to be protected against freezing The two predominant protective measures are 1 Blowing out the coils with air or 2 Flushing coils with inhibited glycol It is recommended to use inhibited glycol designed for HVAC applications for corrosion protection Select an inhibited glycol solution that will protect the coil from the lowest possible temperatures that can occur at the particular coil s locality Start Up Procedure 10 11 12 13 14 15 16 17 18 5 562 8 IMPORTANT 1 To prevent premature heat exchanger failure observe heat exchanger tubes by looking at the heat exchanger through the field installed access openings in connecting ductwork in blower package units or the unit access doors in cooling package units If the bottom of the tubes become red while blower and duct furnace are in operation check to be sure the blower has been set to the proper rpm for the application Refer to page 15 for Blower Adjustments Start up and adjustment procedures should be performed by a qualified service agency 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 Remov
47. 0 1197 1 03 1295 1 16 1388 1 30 1477 1 59 1645 1 89 1802 2 20 1950 2300 0 94 1104 1 08 1200 1 22 1292 1 37 1380 1 52 1465 1 67 1547 1 98 1703 2 31 1850 2 65 1990 2778 1 59 1296 1 75 1377 1 92 1456 2 09 1532 2 26 1606 2 44 1679 2 80 1818 741 0 15 808 0 23 962 0 30 1093 0 38 1212 0 47 1320 0 60 1514 0 86 1686 1 07 1840 926 0 13 670 0 21 846 0 29 993 0 38 1121 0 47 1236 0 56 1342 0 77 1532 0 99 1702 1 22 1856 1200 0 22 758 0 31 916 0 41 1052 0 52 1173 0 62 1282 0 74 1384 0 97 1568 1 22 1733 1 48 1884 1400 0 30 828 0 41 975 0 53 1103 0 64 1218 0 76 1323 0 89 1422 1 15 1600 1 42 1762 1 70 1910 1800 0 55 982 0 69 1108 0 83 1220 0 98 1325 1 12 1422 1 27 1513 1 58 1681 1 90 1834 2 23 1976 2200 0 93 1145 1 10 1254 1 27 1354 1 44 1449 1 61 1537 1 79 1621 2 15 1778 2 52 1923 2 90 2057 2600 1 45 1315 1 65 1410 1 85 1500 2 05 1585 2 25 1666 2 46 1744 1 35 1638 3000 2 16 1489 2 39 1573 2 61 1654 2 84 1731 1800 0 28 497 0 41 622 0 56 735 0 72 837 2200 0 43 553 0 58 662 0 75 762 0 93 855 1 12 942 1 33 1025 2600 0 63 614 0 81 710
48. 0 875 5 2 0 75 A35 3H35125B10 5 6 0 625 4 5 0 75 A34 3H35125B11 5 6 0 875 4 5 0 75 A34 3H35126B1 2 9 0 5 5 0 75 A33 3H35126B2 2 9 0 625 5 0 75 A34 3H35126B3 4 4 0 5 6 0 75 A37 3H35126B4 4 4 0 625 6 0 75 A38 3H35126B5 4 4 0 875 6 0 75 A38 3H35126B6 3 8 0 625 4 2 0 75 A34 3H35126B7 3 8 0 875 4 2 0 75 A34 3H35126B8 3 8 1 125 4 2 0 75 A36 3H35126B9 5 6 0 625 5 2 0 75 A38 3H35126B10 5 6 0 875 5 2 0 75 A38 3H35126B11 5 6 1 125 5 2 0 75 A40 3H35126B12 5 6 0 625 4 5 0 75 A37 3H35126B13 5 6 0 875 4 5 0 75 A37 3H35126B14 5 6 1 125 4 5 0 75 A39 3H35127B1 2 9 0 5 7 1 A42 3H35127B2 2 9 0 625 7 1 A43 3H35127B3 3 8 0 625 7 5 1 A46 3H35127B4 3 8 0 875 7 5 1 A45 3H35127B5 3 8 1 125 7 5 1 A47 3H35127B6 5 0 625 8 1 A48 3H35127B7 0 875 8 1 A48 3H35127B8 1 125 1 A50 3H35127B9 4 4 0 875 5 7 1 A43 3H35127B10 4 4 1 125 5 7 1 A45 3H35127B11 5 2 1 375 6 7 1 A49 3H35127B12 5 0 875 6 1 A45 3H35127B13 5 1 125 6 1 A47 3H35127B14 5 2 1 375 6 2 1 A49 3H35127B15 5 1 125 5 2 1 A45 3H35127B16 5 6 1 375 5 7 1 A48 3H35127B17 4 4 0 625 5 7 1 A43 3H35128B1 2 9 0 5 8 1 A47 3H35128B2 2 9 0 625 8 1 A48 3H35128B3 2 9 0 875 8 1 A48 3H35128B4 3 8 0 625 8 5 1 A50 3H35128B5 3 8 0 875 8 5 1 A50 3H35128B6 3 8 1 125 8 5 1 A52 3H35128B7 0 625 9 1 A53 3H35128B8 0 875 9 1 A52 3H35128B9 5 1 125 9 1 A54 3H35128B10 5 6 0 875 8 5 1 A53 3H35128B11 5 6 1 125 8 5 1 A54 3H35128B12 5 2 1 375 8 1 A54 3H35128B13 5 6 1 125 7 1 A52 3H35128B14 5 2 1 375 6 5 1 A52 3H35128B15 5 6 0 625 8 5 1 A53
49. 00 DeKoven Ave Racine WI 53403 Phone 800 828 4328 t1stE 9900100 LisSTEP GQ 9900100 34764118 Rev B Figure 53 2 Model DFG Serial Number Designations SERIAL NUMBER PREFIX lt blank gt if standard S if Special Product Order SERIES IDENTITY NUMBER CONTROL SUPPLIER 01 Robertshaw 09 White Rodgers 05 Honeywell 17 United Technologies 08 Fenwal GAS VALVE SUPPLIER 01 Robertshaw 09 White Rodgers 05 Honeywell 09 17 0123 10000 SPO NUMBER lt blank gt if standard HHHHH if Special Product Order SEQUENTIAL NUMBER Varies 0000 TO 9999 Each unit in a week has a unique number YEAR PRODUCED WEEK PRODUCED Figure 53 3 Model DBG DCG Serial Number Designations 01 10 201 01 02 1000 MOTOR SEQUENCE VENDOR CODE NUMBER 01 Century 15 Marathon etc Razz YEAR OF FAN OR BLOWER MANUFACTURE VENDOR CODE 01 2001 10 Lau 02 2002 20 Morrison etc etc m SERIES IDENTITY NUMBER WEEK OF Identifies which series MANUFACTURE of controls were 01 1st week of year furnished on the unit 26 26th week of year 5 562 8 53 START UP CHECKLIST INDIRECT GAS FIRED HEATING EQUIPMENT Job Name Date Address Model No City 8 State Order No Start Up Check List ALL ITEMS MUST BE CHECKED Serial No All shipping straps braces tie downs removed Unit installed le
50. 1 00 800 1 20 885 1 41 965 1 63 1042 3000 0 91 680 1 11 766 1 32 847 1 54 1731 1 77 997 2 01 1068 2 51 1202 3 04 1328 3 60 1446 3400 1 26 748 1 48 825 1 72 899 1 96 970 2 21 1038 2 47 1104 3 01 1229 3 58 1347 4 17 1459 3704 1 58 802 1 83 873 2 08 942 2 34 1008 2 60 1072 2 88 1135 3 45 1254 4 04 1367 4 67 1474 4100 2 09 873 2 35 938 2 63 1001 2 91 1062 3 20 1122 3 49 1180 4 10 1291 4 74 1398 4630 2 93 969 3 23 1028 3 53 1085 3 84 1140 4 16 1194 4 48 1247 1111 0 19 727 0 28 884 0 38 1023 0 48 1148 0 59 1262 0 70 1369 0 94 1563 1 21 1738 1 48 1899 1296 0 27 793 0 37 937 0 47 1066 0 59 1184 0 71 1293 0 83 1395 1 09 1582 1 37 1752 1 66 1909 1400 0 32 832 0 42 970 0 54 1093 0 66 1208 0 78 1313 0 91 1412 1 18 1596 1 47 1763 1 78 1917 1800 0 59 994 0 72 1109 0 86 1216 1 00 1316 1 15 1410 1 30 1500 1 62 1667 1 95 1823 2 29 1967 2200 1 00 1166 1 16 1264 1 32 1356 1 49 1444 1 66 1529 1 84 1610 2 20 1762 2 57 1906 2 96 2041 2600 1 58 1344 1 76 1429 1 95 1510 2 14 1589 2 34 1664 2 54 1737 2 95 1877 3000 2 35 1526 2 57 1600 2 78 1673 3 00 1743
51. 33 1 Unit Performance Tables Total Static Pressure Inches W C 500 600 120 F 106 F Start 600 100 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 500 600 120 F Start 600 100 F 120 F 93 F 111 F 74 F 89 F 62 F 74 F 53 F 63 F 46 F 56 F End 500 41 F 49 F 744 F 743 F 740 F 740 F 500 600 62 F 74 F 53 F 63 F 46 F 56 F Start 500 SITE 49 F 44 F 43 F 40 F 40 F 700 800 120 F 115 F Start 800 105 F 120 F 104 F 119 F 94 F 108 F 86 F 99 F 80 F 91 F 700 800 120 F Start 800 104 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 700 800 65 F 74 F 58 F 66 F 52 F 59 F 47 F 54 F 47 F 54 F 43 F 49 F End 700 40 F 46 F 42 F 41 F 840 960 120 F 11 F End 840 105 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 840 960 Soe 78 F 89 F 70 F 80 F 65 F 74 F End 840 60 F 68 F 63 F Total static pressure should include external static pressure and accessory option static pressure from Table 30 1 Unit interna
52. 4 1 44 ty 2 B75 3H35130B20 7 1 875 8 4 1 44 2 B75 3H36622B1 41 0 875 10 9 1 44 B75 3H36622B2 41 1 125 10 9 1 44 BX73 3H36622B3 41 0 875 8 9 1 44 B72 3H36622B4 41 1 125 8 9 1 44 B70 3H36622B5 5 5 1 375 12 4 1 44 BX78 3H36622B6 4 7 1 125 8 9 1 44 B74 3H36622B7 5 5 1 375 10 4 1 44 BX75 3H36622B8 6 1 625 11 4 1 44 Qty 2 BX82 3H36622B9 6 1 625 11 4 1 44 Qty 2 BX82 3H36622B10 7 1 875 13 4 1 44 Qty 2 B86 3H36622B11 7 1 875 13 4 1 44 Qty 2 B86 3H36622B12 5 3 1 125 8 4 1 44 B71 3H36622B13 5 9 1 375 9 4 1 44 BX74 3H36622B14 6 1 625 9 4 1 44 Qty 2 BX79 3H36622B15 6 1 625 9 4 1 44 Qty 2 BX79 3H36622B16 7 1 875 11 4 1 44 Qty 2 B83 3H36622B17 7 1 875 11 4 1 44 Qty 2 B83 3H36622B18 7 1 375 10 4 1 44 B77 3H36622B19 7 1 625 10 4 1 44 ty 2 B82 3H36622B20 7 1 625 10 4 1 44 ty 2 B82 3H36622B21 7 1 875 10 4 1 44 ay 2 B81 3H36622B22 7 1 875 10 4 1 44 ty 2 B81 3H36622B23 7 1 625 9 4 1 44 oy 2 B80 3H36622B24 7 1 625 9 4 1 44 a y 2 B80 3H36622B25 7 1 875 9 4 1 44 ty 2 B80 3H36622B26 7 1 875 9 4 1 44 oy 2 B80 5 562 8 37 ELECTRICAL DATA MOTOR DATA Total Unit Amp Draw The total unit amp draw is a combination of the motor and the control step down transformer The control step down transformer includes damper actuators ignition controllers gas valves control relays amplifiers and motor starters Motor Amp Draw Tables 38 2 to 42 1 Control Step Down Transformer Amp Draw Table 38 1 y Total Amp Draw
53. 5 7 5 87 0 82 0 E6 or Q6 TE HE 86 5 K1 or Y1 ODP 19 3 91 0 E7 or Q7 TEFC 18 9 83 0 71 0 K2 or Y2 ODP HE 18 9 93 0 E8 or Q8 TEFC 18 12 80 0 72 0 K3 or Y3 ODP 18 9 19 3 7 8 88 5 81 5 F1 or R1 ODP 84 0 K4 or Y4 ODP 18 12 18 0 9 5 86 0 81 0 F2 or R2 ODP 89 5 K5 or Y5 TE 20 0 91 0 F3 or R3 ODP 18 9 79 0 62 0 K6 or Y6 TE HE 19 0 92 4 F4 or R4 ODP 18 12 80 0 70 0 K7 or Y7 TE 18 9 19 5 7 5 88 0 82 0 F5 or R5 TE 84 0 K8 or Y8 TE 18 12 19 5 11 0 1 88 0 84 0 F6 or R6 TE HE 85 5 V1 or Z1 ODP 25 0 i 91 0 F7 or R7 TEFC 18 9 84 0 70 0 v2 or Z2 ODP HE 24 5 93 6 F8 or R8 TE 18 12 81 0 77 0 V3 or Z3 ODP 18 9 25 2 10 0 1 89 5 82 5 G1 or S1 ODP i 86 5 V4 or Z4 ODP 18 12 24 0 13 0 1 90 0 84 0 G2 or S2 ODP HE i 89 5 V5 or Z5 TEFC 25 5 91 0 G3 or S3 ODP 18 9 80 0 66 0 V6 or Z6 TE HE 24 1 93 0 G4 or S4 ODP 18 12 82 5 NA V7 or Z7 TE 18 9 26 0 8 7 89 0 88 0 G5 or S5 TE 87 5 V8 or Z8 TE 18 12 24 7 14 0 90 0 86 0 G6 or S6 TE HE i 89 5 G7 or S7 TE 18 9 84 0 70 0 G8 or S8 TE 18 12 82 5 75 5 H1 or T1 ODP i 87 5 H2 or T2 ODP HE i 89 5 H3 or T3 ODP 18 9 84 0 73 0 H4 or T4 ODP 18 12 78 0 71 0 H5 or T5 TE 87 5 N O1 Gt
54. 5129B7 3H35129B10 3H35129B12 3H35129B16 3H35129B19 254 3H35129B13 3H35129B17 3H35129B20 256 3H35129B14 Table 35 4 Digit 16 K 18 18 Blower Units with 15 Hp motor amp up RPM Range Motor Frame 3H35129B18 826 1009 995 1161 1101 1285 1232 1438 Size Digit 19 Sheave Assembly 3H35130B1 Digit 19 Sheave Assembly 3H35130B3 Digit 19 Sheave Assembly 3H35130B5 Digit 19 Sheave Assembly 3H35130B2 3H35130B4 3H35130B6 3H35130B13 3H35130B15 3H35130B17 3H35130B19 Motor Frame 3H35130B14 3H35130B16 3H35130B18 RPM Range 3H35130B20 3H35129B21 491 649 626 765 765 901 901 1059 995 1161 1101 1285 Size 143 or 145 Sheave Assembly 3H36622B1 Sheave Assembly 3H36622B3 Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly 182 to 184 3H36622B2 3H36622B4 3H36622B6 3H36622B12 213 or 215 3H36622B5 3H36622B7 3H36622B13 3H36622B18 254 3H36622B8 3H36622B14 3H36622B19 3H36622B23 256 3H36622B9 3H36622B15 3H36622B20 3H36622B24 284 3H36622B10 3H36622B16 3H36622B21 3H36622B25 286 3H36622B11 Q 3H36622B17 3H36622B22 3H36622B26 5 562 8 35 BLOWER SHEAVE ASSEMBLY DATA Ta
55. 7 1 Minimum Height from Roof to Lowest Discharge Opening Rise Roof Pitch Min Height X in Flat to 6 12 6 12 to 7 12 7 12 to 8 12 8 12 to 9 12 9 12 to 10 12 10 11 10 12 to 11 12 11 12 11 12 to 12 12 12 12 to 14 12 14 12 to 16 12 16 12 to 18 12 18 12 to 20 12 20 12 to 21 12 Size according to expected snow depth Figure 7 1 Gravity Vented Duct Furnace Venting pitched roof Listed PE Terminal Zx H Roof mg Flashing 12 Roof Pitch is x 12 Use Thimble 4 4 Through Ceiling a i o Slope 1 4 to us Drip Leg with The Foot Cleanout Cap Unit Figure 7 2 Gravity Vented Duct Furnace Venting obstructed Approved Terminal Roof Flashing i N Use Thimble Through Ceiling X hae Drip Leg with 1 0 ja Cleanout Cap Slope 1 4 to The Foot Unit Size according to expected snow depth lt 10 Min To wall or adjoining building ADDITIONAL VENTING REQUIREMENTS FOR CATEGORY II UNITS Vent system must provide for drainage of condensate At the low point of the vent system install a tee fitting with a connector and attach flexible tubing minimum 3 8 inch I D and run to a drain Tee fitting and associated condensate disposal system must be periodically cleaned ADDITIONAL VENTING REQUIREMENTS FOR VENTING INTO AN EXISTING MASONRY CHIMNEY OR COMMON
56. 74 863 1078 1029 1332 1150 1438 1327 1659 Digit 19 Sheave Assembly 3H35127B1 Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly 56 3H35127B2 3H35127B3 3H35127B6 3H35127B17 143 to 145 3H35127B4 3H35127B7 3H35127B9 3H35127B12 182 or 184 3H35127B5 3H35127B8 3H35127B10 3H35127B13 3H35127B15 213 or 215 Motor Frame Size 48 RPM Range 3H35127B11 3H35127B14 568 771 767 958 934 1136 1136 1380 3H35128B1 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly 56 3H35128B2 3H35128B4 3H35128B7 3H35128B15 143 to 145 3H35128B3 3H35128B5 3H35128B8 3H35128B10 182 or 184 3H35128B6 3H35128B9 3H35128B11 3H35128B13 213 or 215 Motor Frame Size 56 RPM Range 3H35128B12 3H35128B14 3H35127B16 491 649 586 744 682 821 821 1009 995 1161 1101 1285 Sheave Assembly 3H35129B1 Digit 19 Sheave Assembly 3H35129B4 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly 143 or 145 3H35129B2 3H35129B5 3H35129B8 182 to 184 3H35129B3 3H35129B6 3H35129B9 3H35129B11 3H35129B15 213 or 215 3H3
57. 79 F 69 F 56 F 46 F 40 F 35 F 31 F 69 F 56 F 46 F 40 F 35 F 31 F 28 F 24 F 20 F 100 125 C D _100 F Start 125 80 F 100 F 62 F 77 F 53 F 66 F 41 F 51 F 34 F 42 F 28 F 36 F 25 F 31 F 100 125 E F 41 F 51 F 34 F 42 F 28 F 36 F 25 F 31 F 22 F 27 F End 100 gt 20 F 25 F 23 F 20 F 150 175 c p OFE Start 175 86 F 100 F 79 F 93 F 62 F 72 F 51 F 59 F 43 F 50 F 37 F 43 F 86 F 100 F 79 F 93 F 62 F 72 F 51 F 59 F 43 F 50 F 37 F 43 F 33 F 38 F 29 F 34 F 26 F 31 F 24 F 28 F 21 F 25 F 200 225 C D 100F113F Start 225 89 F 100 F 85 F 95 F 74 F 83 F 66 F 74 F 59 F 67 F 54 F 61 F 49 F 56 F 85 F 95 F 74 F 83 F 59 F 67 F 49 F 56 F 42 F 48 F 37 F 42 F 33 F 37 F 30 F 33 F 85 F 95 F 74 F 83 F 59 F 67 F 49 F 56 F 42 F 48 F 37 F 42 F 33 F 37 F 30 F 33 F 27 F 30 F 75 c D 150 175 E F 200 225 E F 200 225 G H Total Static Pressure 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
58. 89 F 62 F 74 F 53 F 63 F 46 F 56 F 41 F 49 F 37 F 44 F 34 F 40 F 00 F 120 F Start 300 83 F 100 F 74 F 89 F 62 F 74 F 53 F 63 F 46 F 56 F 41 F 49 F 37 F 44 F 34 F 40 F 31 F 37 F 28 F 34 F l 46 F 56 F 37 F 44 F 31 F 37 F 26 F 32 F 23 F 28 F gt 20 F 24 F 22 F 20 F 100 F 96 F 87 F 100 F 74 F 85 F 65 F 74 F 58 F 66 F 52 F 59 F 47 F 54 F GH JK E F GH 100 F F 74 F 85 F 65 F 74 F 58 F 66 F 52 F 59 F 47 F 54 F 43 F 49 F 40 F 46 F 100 F F 100 F 65 F 74 F 52 F 59 F 43 F 49 F 37 F 42 F 32 F 37 F 29 F 33 F 26 F 30 F 24 F 27 F 23 F 26 F 12 09 14 34 Total static pressure should include external static pressure and accessory option static pressure from Table 30 1 Unit interna included in the unit performance tables resistance has been Brake Horsepower and RPM values are approximate values only Please consult the AccuSpec selection software for values at other than listed CFM static pressures 32 5 562 8 BLOWER PERFORMANCE DATA Table
59. Blower Model Size Digits 4 6 Btu Hr Input 75 000 10 0000 125 000 150 000 175 000 Btu Hr Output 60 000 80 000 100 000 120 000 140 000 Blower Style Digit 16 Letter AorB CorD CorD EorF CorD EorF CorD E orF CorD EorF Max Temp Rise F 100 100 100 85 100 100 100 100 100 100 Min Temp Rise F 28 20 21 20 27 20 33 20 39 23 Max CFM 1980 2778 3450 3450 4630 3350 5556 3350 5556 Min CFM 556 556 741 926 926 1111 1111 1296 1296 Model Size Digits 4 6 Btu Hr Input 200 000 225 000 250 000 Btu Hr Output O 160 000 180 000 200 000 Blower Style Digit 16 Letter EorF EorF GorH Max Temp Rise F 85 95 100 Min Temp Rise F Max CFM Min CFM Model Size Digits 4 6 Btu Hr Input 300 000 350 000 400 000 Btu Hr Output 240 000 280 000 320 000 Blower Style Digit 16 Letter GorH I J orK GorH GorH Max Temp Rise F 100 100 100 100 Min Temp Rise F 31 20 37 42 Max CFM 12000 5700 Min CFM 2593 2963 Model Size Digits 4 6 Btu Hr Input 500 000 600 000 700 000 Btu Hr Output 400 000 480 000 560 000 Blower Style Digit 16 Letter I J or K l J or K l J or K Max Temp Rise F 120 120 120 Min Temp Rise F 40 40 40 Max CFM 11111 6850 Min CFM 3704 4321 Model Size Digits 4 6 Btu Hr Input 800 000 1 050 000 1 200 000 Btu Hr Outp
60. Connections in direction of airflow Second Inlet on Dual Circuit Coils Table 46 1 DX Coil Dimensions Cooling MBH 75 All DX Single Circuit DX Dual Circuit Suction Line Qt 1 1 625 Liquid FL Line A FL Suction Line Qt 2 1 625 Liquid Line Qt 100 125 All 1 1 625 2 1 625 150 175 All 1 1 625 2 1 625 Below 185 MBH 185 MBH amp Up Below 185 MBH 185 MBH amp Up Below 185 MBH 185 MBH amp Up 200 225 250 300 350 400 1 1 625 Liquid line dimensions vary by configuration Refer to the original order for configured dimensions Figure 46 2 Chilled Water Coil Drawing All dimensions in inches 2 1 625 Airflow Direction 1 S TOP VIEW al L af Coil for Right Hand Units Digit 9 R Headers on opposite side for Left Hand Units 1 5 A FL si FRONT VIEW IM o a Rows 4 6 w 7 5 10 W ee r 1 8 gt lt Return Water Line Connection turned 90 in 4 direction of airflow 2 25 i Airflow Direction ADENWEW 2 25 Supply Water Line p Connection turned 90 in 4 direction of airflow s 1 8 Table 46 2 Chilled Water Coil Dimensions Model Size 75 1 50 MPT Supply Line Return Line 1 50 MPT 100 125 1 50 MPT 1 50 M
61. DED 7 GREASE LINE ZERK FITTINGS 1 4 PERIMETER GASKETED BLOWER CONNECTION CONVENIENCE OUTLET BLOWER DOOR BOTTOM DIRECT SAFETY SWITCH SUPPORTED DRIVE BLOWER AND DAMPER MOTOR ACTUATOR Blower Sheave Assembly Numbers Table 34 1 Digit 16 A or B 9 7 Blower Units RPM Range Motor Frame 656 1001 978 1265 1150 1561 1526 1858 1763 2147 Size Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly 48 A 3H35125B1 C 3H35125B3 56 B 3H35125B2 D 3H35125B4 F 3H35125B6 H 3H35125B8 J 3H35125B10 143 or 145 E 3H35125B5 G 3H35125B7 I 3H35125B9 K 3H35125B11 Table 34 2 Digit 16 C or D 9 9 Blower Units Motor Frame Size 48 RPM Range 656 1001 978 1265 1150 1561 1526 1858 1763 2147 Digit 19 3H35126B1 Sheave Assembly Digit 19 Sheave Assembly 3H35126B3 Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly 56 3H35126B2 3H35126B4 3H35126B6 3H35126B9 3H35126B12 143 or 145 3H35126B5 3H35126B7 3H35126B10 3H35126B13 182 or 184 34 3H35126B8 5 562 8 3H35126B11 3H35126B14 BLOWER SHEAVE ASSEMBLY DATA Blower Sheave Assembly Numbers Con t Table 35 1 Digit 16 E or F 12 12 Blower Units Motor Frame Size 48 RPM Range 468 715 644 8
62. Do not fire unit until blower adjustment has been made or unit may cycle on high limit control 8 Check motor amps Do not exceed nameplate amps shown on motor nameplate Lubrication Recommendations The blower can be provided with either spider or pillow block bearings Spider bearings are permanently lubricated and do not require lubrication Pillow block bearings are shipped greased from the factory but will require lubrication The bearings should be checked and lubricated before each heating season but a more frequent lubrication schedule may be required based on the environment in which the unit is installed and the frequency of the equipment operation Shell Alvania 2 lubricant is recommended Damper Linkage Adjustment If the unit is provided with a return air damper to prevent shipping damage the return air damper linkage is disconnected and the damper closed Before operating the unit the fresh and return air dampers must be connected This is accomplished by the following 1 The damper actuator should be de energized and the fresh air damper in a fully closed position 2 Open the return air damper in a fully open position 3 Slide the connecting rod into the ball joint on the blade arm with the return air damper fully open See Figure 15 3 4 Tighten the 5 16 hex head screw on the ball joint Figure 15 3 Damper Linkage Adjustment CONNECTING ROD BLADE ARM DAMPER BLADE Contro
63. E F G or H 350 400 J or K 5 562 8 Insulation Double Wall All Sections 47 MAINTENANCE All heating equipment should be serviced before each heating season to assure proper operations The following items may be required to have more frequent service schedule based on the environment in which the unit is installed and the frequency of the equipment operation Blower Assembly The blower assembly includes the bearings drive sheaves and belts Blower bearings should be checked and lubricated based on the blower manufacturer s recommendations Bearings should also be checked for any unusual wear and replaced if needed Drive sheaves should be checked at the same time the bearings are inspected Check to make sure the sheaves are in alignment and are securely fastened to the blower and motor shafts Belt tension should be rechecked shortly after the unit has been installed to check for belt stretching After the initial start up monthly checks are recommended Filters If the unit is supplied with a dirty filter switch and light clean or replace the filters any time the dirty filter light comes on Units which do not have a dirty filter warning light should have the filters checked monthly Clean or replace if necessary In dirty atmospheres filter maintenance may be required more often Figure 48 1 Filter Replacement Arrangement for Blower Size Digit 16 A B C D E F Gand
64. ENT TERMINATION CLEARANCE FROM GAS AND ELECTRIC METERS REGULATORS AND RELIEF EQUIPMENT REQUIRED LIGHTING INSTRUCTIONS FOR UNITS WITH INTERMITTENT PILOT SET THERMOSTAT TO LOWEST SETTING HOVE GAS CONTROL KNOB OR LEVER TO OFF AND WAIT 5 HINUTES HOVE GAS CONTROL KNOB OR LEVER TO ON SET THERMOSTAT TO DESIRED SETTING PILOT AND HAIN BURNER WILL LIGHT AUTOKATICALLY WHEN THERMOSTAT CALLS FOR HEAT FOR UNITS WITH STANDING PILOT SET THERMOSTAT TO LOWEST SETTING MOVE GAS CONTROL KNOB OR LEVER TO OFF AND WAIT 5 MINUTES HOVE GAS CONTROL KNOB TO PILOT OR MOVE GAS CONTROL LEVER TO SET AND DEPRESS RESET BUTTON WHILE LIGHTING THE PILOT AND HOLD FOR 1 MINUTE AFTER PILOT IS LIT HOVE GAS CONTROL KNOB OR LEVER TO ON SET THERMOSTAT TO DESIRED SETTING SHUT DOWN INSTRUCTIONS TURN OFF POWER amp CLOSE ALL GAS VALVES Modine Manufacturing Company GAS FIRED DUCT FURNACE FOR INDUSTRIAL COMMERCIAL USE nm SEEM ZE in be S A 1500 DeKoven Avenue GENERATEUR D AIR CHAUD A GAINE POUR Racine WI 53403 2552 Phone 800 828 4328 USAGE INDUSTRIEL COMHERCIAL MODEL NUMBER MIN INPUT BTU H wero oe oee DFGI25AFRNN14A1 nesir core Ge D Id HIN BTU HEURE SERIAL MUMBER HIN INLET PRESS FOR PURPOSE OF nero oe ski 0905092010 4877 ineur sme pression 6 muc gt kusqe0 US D ALIMENTATION EN GAZ MIN ADMISE PO CD E 9909100 We OF 5 MANIFOLD PRESSURE DESIGN COMPLIES WITH DUCT FURNACE STANDARD DESIGN CONFORMS TO UL STD 1995 nec oraz Natural e
65. H FILTER SPACER Nye 250 300 500 600 200 225 350 400 A 20 X 25 FILTER 700 800 B 16 X 25 FILTER C 15 X 25 FILTER Filter Spacer to be inserted on non access side of unit Figure 48 2 Filter Replacement Arrangement for Blower Size Digit 16 I J K and L NON ACCESS SIDE NON ACCESS IDE FILTER SPACER lt A FILTER SPACER 350 400 700 800 840 960 Og UO0UWU gt uuu 1 O x N ol Manifold Assembly Removal To remove the manifold 1 Shut off gas and electric supply 2 Disconnect gas manifold at ground union joint 3 Remove the two screws holding the manifold to the heat exchanger support Slide the manifold through the manifold bracket Clean the orifices and adjust the air shutters as necessary Follow steps 3 6 in reverse order to install the manifold assembly 7 Turn onthe electric and gas supply 8 Check the ground union joint for leaks with a soap solution Tighten if necessary Figure 48 3 Manifold Assembly Removal o OT R ELECTRICAL JUNCTION BOX MANIFOLD SERIAL PLATE BURNER SIDE ACCESS PANEL Burner and Pilot Assembly Removal To remove the burner 1 Shut off gas and electric supply 2 Disconnect the pilot supply line from the gas valve 3 Disconnect the ignition cable from the ignition controller located in the electrical junction box Feed the cable through the bushing in the bo
66. OJO TE 18 12 Motors have no thermal overload Refer to page 42 for Motor Type abbreviations 40 5 562 8 MOTOR DATA Table 41 1 Motor Data for Digit 14 F 460V 60Hz 3Ph Digits Service Weight Efficiency Digits Si Frame Service Weight Efficiency 17 amp 18 Factor Ibs 17 amp 18 Size Factor Ibs A1 or L1 ODP i N A H6 or T6 TE HE 6 5 90 2 A3 or L3 TE N A H7 or T7 TE 18 9 7 0 2 5 86 0 83 0 B1 or M1 ODP N A H8 or T8 TE 18 12 6 9 4 1 85 0 75 5 B5 or M5 TEFC N A 11 or W1 ODP 9 8 88 5 C1 orN1 ODP i N A 12 or W2 ODP HE 9 7 91 7 C5 or N5 TEFC N A 13 or W3 ODP 18 9 11 8 4 2 i 85 0 72 0 D1 or P1 ODP 3 82 5 14 or W4 ODP 18 12 10 0 6 0 87 0 80 0 D2 or P2 ODP HE i 84 0 15 or W5 TE 10 0 89 5 D3 or P3 ODP 18 9 76 0 59 0 16 or W6 TE HE 9 6 91 7 D4 or P4 ODP 18 12 74 0 60 0 I7 or W7 TE 18 9 10 0 4 1 84 0 74 0 D5 or P5 TEFC N A 18 or W8 TE 18 12 10 3 5 6 85 0 80 0 D6 or P6 TE HE 85 5 J1 or X1 ODP 13 4 89 5 D7 or P7 TEFC 18 9 73 0 58 0 J2 or X2 ODP HE 12 6 91 7 D8 or P8 TEFC 18 12 A 74 0 60 0 J3 or X3 ODP 18 9 15 0 5 3 83 0 71 0 E1 or Q1 ODP 84 0 J4 or X4 ODP 18 12 12 0 6 3 87 0 82 0 E2 or Q2 ODP 89 5 J5 or X5 TE 13 0 89 5 E3 or Q3 ODP 18 9 80 0 65 0 J6 or X6 TE HE 12 5 90 2 E4 or Q4 ODP 18 12 75 0 71 0 J7 or X7 TE 18 9 13 0 5 4 86 5 77 0 E5 or Q5 TEFC N A J8 or X8 TE 18 12 13
67. Others Follow the expansion valve manufacturer s recommendations for installation to avoid damaging the valve 5 The expansion valve s remote sensing bulb should be securely strapped to the horizontal run of the suction line at the 3 or 9 o clock position and insulated 6 Connect the liquid line to the expansion valve Pressurize the coil expansion valve assembly and suction connection to 100 psig with dry nitrogen or other suitable gas The coil should be left pressurized for a minimum of 10 minutes 7 Ifthe coil holds pressure the hook up can be considered leak free If the pressure drops by 5 psi or less repressurize the coil and wait another 10 minutes If the pressure drops again there are more than likely one or more small leaks which should be located and repaired Pressure losses greater than 5 psi would indicate a larger leak which should be isolated and repaired Be sure to check valves and fittings as potential sites for leakage or bleed If the coil is found to be leaking contact your local factory representative 0 10 5 562 8 UNIT INSTALLATION Table 11 1 Cooling Coil Performance Limits DX Single Circuit Coil Area Sq Ft DX Dual Circuit Coil Area Sq Ft Chilled Water Max CFM O Min CFM Coil Area Sq Ft Max CFM O Max CFM O All Units Max Cooling Tons DX Chilled Coils Water Coils Based on 550 feet
68. PT 150 175 1 50 MPT 1 50 MPT 200 225 1 50 MPT 1 50 MPT 250 300 1 50 MPT 1 50 MPT 350 400 46 1 50 MPT 5 562 8 1 50 MPT DIMENSIONS WEIGHTS Figure 47 1 Remote Panel Dimensions Remote Panel Type Light and Switch Panels Only Table 47 3 Remote Panel Dimensions All dimensions in inches Light and Switch Panels with Single Stage Thermostat or Electronic Set Point Adjustor NOTES 1 Holes visable on right side are also on left side in the same location 2 Holes on top are also on the back in the same location horizontally 1 down vertically Table 47 1 Blower Package Unit Operating Weights All weights in pounds Light and Switch Panels with Two Stage Thermostat Model Blower Type Mot i Dampers Dampers i Double Wall Digit 16 otor Filters Fresh Air F amp RA SU 20 AII Sections All All All E F G or H I J or K E F G or H I J or K See Motor Data GorH I J K orL GorH I J K orL u aaa alla Ng A jaja I J K orL Table 47 2 Cooling Package Unit Operating Weights AII weights in pounds Blower Dampers Type Dampers Fresh amp Digit 16 Filters Fresh Air Return Air 75 All 100 125 All 150 175 All 200 225 All 250 300 E F G or H See Motor 250 300 I J or K Data 350 400
69. R EXPRESS OR IMPLIED WHETHER ARISING FROM LAW COURSE OF DEALING USAGE OF TRADE OR OTHERWISE THERE ARE NO OTHER WARRANTIES INCLUDING WARRANTY OF MERCHANTABILITY OR FITNESS FOR PURPOSE WHICH EXTEND BEYOND THE PRODUCT DESCRIPTION CONFIRMED BY BUYER AND SELLER AS OF THE DATE OF FINAL AGREEMENT This warranty is void if the input to the product exceeds the rated input as indicated on the product serial plate by more than 5 on gas fired and oil fired units or if the product in the judgment of SELLER has been installed in a corrosive atmosphere or subjected to corrosive fluids or gases been subjected to misuse negligence accident excessive thermal shock excessive humidity physical damage impact abrasion unauthorized alterations or operation contrary to SELLER S printed instructions or if the serial number has been altered defaced or removed BUYER S REMEDY FOR BREACH OF WARRANTY EXCLUSIVE OF ALL OTHER REMEDIES PROVIDED BY LAW IS LIMITED TO REPAIR OR REPLACEMENT AT THE FACTORY OF SELLER ANY COMPONENT WHICH Component Applicable Models SHALL WITHIN THE APPLICABLE WARRANTY PERIOD DEFINED HEREIN AND UPON PRIOR WRITTEN APPROVAL BE RETURNED TO SELLER WITH TRANSPORTATION CHARGES PREPAID AND WHICH THE EXAMINATION OF SELLER SHALL DISCLOSE TO HAVE BEEN DEFECTIVE EXCEPT THAT WHEN THE PRODUCT IS TO BE USED BY BUYER AS A COMPONENT PART OF EQUIPMENT MANUFACTURED BY BUYER BUYER S REMEDY FOR BREACH AS LIMITED HEREIN SHALL BE LIMITED
70. Replace defective controller IMPORTANT To check most of the Possible Remedies in the troubleshooting guide listed in Table 50 1 refer to the applicable sections of the Troubleshooting manual Figure 49 1 Blocked Vent Safety Switch BVSS Troubleshooting Flow Chart Is vent blocked or restricted YES YES Can negative pressure be corrected YES NO Install power vent accessory Correct negative pressure YES Is there a negative pressure in space see note 2 NO Is vent in compliance with NFGC YES NO Is there spillage after 5 minutes see note 1 NO Replace blocked vent switch Does switch still trip YES NO NO YES Note 1 To determine spillage place lit match stick 6 8 match stick if possible 2 3 into diverter relief opening and determine direction of the flame or direction of smoke if flame goes out If flame or smoke comes back at you there is spillage The flame or smoke should be pulled in One indication of negative pressure is that outside doors tend to be pulled toward inside of space 5 562 8 YES Install power exhauster accessory Can one or more of the following be done e Lengthen vertical vent run e Insulate vent e Use larger diameter vent e Use less restrictive weather cap YES NO Does unit still trip Install power vent accessory NO 49 SERVICE 8 TROUBLESHOOTING Table 50 1 Troubleshooting 50 Trouble Pilot
71. TO ONE YEAR FROM DATE OF SHIPMENT FROM SELLER FOR GAS FIRED PRODUCTS INSTALLED IN HIGH HUMIDITY APPLICATIONS AND UTILIZING STAINLESS STEEL HEAT EXCHANGERS BUYER S REMEDY FOR BREACH AS LIMITED HEREIN SHALL BE LIMITED TO TEN YEARS FROM DATE OF SHIPMENT FROM SELLER These warranties are issued only to the original owner user and cannot be transferred or assigned No provision is made in these warranties for any labor allowance or field labor participation Seller will not honor any expenses incurred in its behalf with regard to repairs to any of Seller s products No credit shall be issued for any defective part returned without proper written authorization including but not limited to model number serial number date of failure etc and freight prepaid OPTIONAL SUPPLEMENTAL WARRANTY Provided a supplemental warranty has been purchased Seller extends the warranty herein for an additional four 4 years on certain compressors Provided a supplemental warranty has been purchased Seller extends the warranty herein for an additional four 4 years or nine 9 years on certain heat exchangers EXCLUSION OF CONSUMABLES amp CONDITIONS BEYOND SELLER S CONTROL The above referenced warranty shall not be applicable to any of the following items refrigerant gas belts filters fuses and other items consumed or worn out by normal wear and tear or conditions beyond Seller s control including without limitation as to generality poll
72. VEILLEUSE APPUYER SUR LE BOUTON DE REENCLENCHEMENT ET LE MAINTENIR ENFONC PENDANT 1 MINUTE APR S ALLUHAGE DE LA VEILLEUSE TOURNER LA MOLETTE OU LE LEVIER DE COMMANDE DU GAZ SUR ON REGLER LE THERMOSTAT SUR LE DEGRE DESIRE INSTRUCTIONS DE FER METURE COUPER LE COURANT ET FERMER TOUTES LES ROBINETS A GAZ Had w no w 52 5 562 8 MODEL DESIGNATIONS Figure 53 1 Model Identification Plate MODEL IDENTIFICATION PLATE Model Number DBG 75AFRHN10A1AA1AAA1A MOTOR DATA Votago Horz Phase 115 208 230 60 1 Amps SYSTEM DATA Supply Voltage Hortz Phase Max System Amps 115 60 1 8 47 Mopine Sonal Number 01101010199 0002 6 6 3 0 3 3 COMMON REPLACEMENT PARTS For parts ordering contact the parts wholesaler or the manufacturer s representative serving your area A complete listing of both can be found in your instalation and Service Manual When inquiting about parts always provide model number serial number description and part number When ordering parts provide part number isted For service contact your local qualified installation and service contractor or appropriate utllty company Blower Sheave 5H63081 20 Motor Sheave 5H58064 3 Blower Beit 5H76183 31 Blower Motor 9F20218 Time Delay Relay 5H71790 Fuse Sizo Timo Dolay 10 00 Design conforms to UL Std 1995 Certified to CAN CSA C22 2 No 236 Modine Manufacturing Company c 15
73. akage 2 Provide uniform air distribution over the heat exchanger Use turning vanes where required to obtain uniform air distribution See Figure 5 2 3 Provide removable access panels on the downstream side of the ductwork See Figure 5 1 This opening should be large enough to view smoke or reflect light inside the casing to indicate leaks in the heat exchanger and to check for hot spots on heat exchangers due to poor air distribution or lack of sufficient air CFM Figure 5 1 Furnace Discharge Duct Connection Figure 5 2 Recommended Field Installed Discharge Duct Configurations for Blower Package Units STRAIGFIT DUCTWORK Dimension B should never be less than 1 2 of dimension A Provide leak tight access panels in discharge duct for heat exchanger Tuning inspection Vanes SIDE VIEW Dimension B should never be less than 1 2 of dimension A Provide leak tight access panels in discharge duct for heat exchanger inspection Turning Vanes TOP VIEW Blower section and cooling cabinet discharge duct connections The blower section back and bottom and cooling cabinet section discharge are designed to accept 90 flanged ductwork See Figure 5 3 Provide an airtight seal between the ductwork and the unit Seams with cracks in the ductwork should be caulked and or taped and be of permanent type All duct connections MUST be airtight to prevent air leakage Figure 5
74. al Electric Code or CSA code based on the power supply voltage amp draw and length of run Refer to Table 9 1 for maximum wire lengths Once the wire gauge has been determined refer to Table 9 2 for the number of wires for which the low voltage terminal blocks in the unit are rated Table 9 1 Low Voltage 24V Maximum Wire Length Feet NEC 1996 Table 310 17 Copper wire with 90 C insulation conductors in free space not in conduit 86 F ambient For other wire types refer to the NEC of CSA code Digit 15 VA 18GA 16Ga 14Ga 12Ga 10 Ga 0 4 75 150 250 Table 9 2 Number of Wires Per Terminal Wire Gauge Number of Wires per Terminal 10 AWG 12 AWG 14 AWG 16 AWG 18 AWG 22 AWG 4 Make sure all multi voltage components motors transform ers etc are wired in accordance with the power supply voltage 5 562 8 Figure 9 1 Recommended Accessory Field Installed Disconnect Switch Mounting Locations ELECTRIC SUPPLY COMPONENTS MUST BE CLEAR OF SERVICE DOORS LEFT HAND ACCESS DISCONNECT UNIT SHOWN ELECTRI SWITCH WIRING AND CONNECTOR SUPPLY 5 5 The power supply to the unit must be protected with a fused or circuit breaker disconnect switch Refer to the Factory Mounted Option Locations Figure 18 1 for the factory mounted disconnect switch location and then review the unit to determine if a factory installed dead front disconne
75. al shut off valve external of the unit casing i A i i and adjacent to the unit for emergency shut off and easy sea level input to the appliance as indicated on the serial SE A late must not be less than 5 below the rated input or 5 SS Veng or controisnneluding amp ue NPT plugged tapping p ate accessible for test gauge connection below the minimum rated input of dual rated units See Figure 8 1 Verify the manual shut off valve is gas 4 CAU T i O N tight on an annual basis 4 Provide a sediment trap before each unit in the line where Purging of air from gas supply line should be performed as low spots cannot be avoided See Figure 8 1 described in ANSI Z223 1 latest edition National Fuel Gas EEN A Code or in Canada in CAN CGA B149 codes 3 To reduce the opportunity for condensation the minimum 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 M PO RTAN T testing pressures 14 W C 1 2 psi or below close the manual shut off valve on the appliance before testing 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 Figure 8 1 Recommended Sediment Trap Manual Shut off Valve Installation Side or Bottom Gas Connection 1 Installation
76. and Blower Vibration Isolation 52 Burner Box 18 Step Down Transformer 36 Blower Support 56 Blocked Vent Safety Switch 19 Factory Installed Minimum Positioner 37 Convenience Outlet 58 Energy Cut off Switch All units include the standard STD features The unit must be reviewed to determine the optional OPT features that may have been supplied with the unit 1 Discharge Thermostat OPT Figure 18 2 Two stage Capillary Type Thermostat The discharge thermostat is factory installed in the discharge air stream of the unit For additional information refer to the thermostat vendor literature provided in the literature packet with the unit NOTE Model Sizes 500 960 contain multiple furnaces so multiple thermostats sensors may be included The thermostat s provided can be one of the following a Two stage Capillary Type Thermostat The thermostat includes a thermostat body that is factory installed for cooling package units below the unit junction box For blower package units the thermostat is factory wired and capillary is to be field installed in duct work The thermostat body contains the discharge air set point adjuster that must be field set 18 or Capillary Right o Duct Furnace Electrical Control Box PG Setpoint Adjuster Thermostat body Shown with cover removed
77. ave 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 ONO OR Customer Owner instructed in operation and maintenance of unit Yes No Name of Person s Instructed Comments Start Up Company Name Phone Signature Date 54 5 562 8 MODEL NOMENCLATURE FOR SYSTEM UNITS Indoor Duct Furnace Model Nomenclature 456 7 8 9 10 11 12 13 14 15 16 17 18 19 2021 22 23 PT UC V MBH HE DS AS ATR GT 1 Product Type PT D Indoor HVAC Unit 2 Unit Configuration UC B Blower Package Furnace amp Blower C Cooling Package Furnace Blower amp Cooling Coil Cabinet 3 Venting V G Gravity 4 5 6 Furnace Input Rating MBH Output on 840 amp 960 100 100 000 Btu Hr Input 500 500 000 Btu Hr Input 175 175 000 Btu Hr Input 600 600 000 Btu Hr Input 250 250 000 Btu Hr Input 840 1 050 000 Btu Hr Input 400 400 000 Btu Hr Input 960 1 200 000 Btu Hr Input 7 Heat Exchanger Burner Drip Pan Material HE A Aluminized Steel S 409 Stainless Steel Heat Exchanger Burner T 409 Stainless Steel Heat Exchanger Burner Drip Pan 8 Development Sequence Designation DS F Single Stage M 2 stage or Modulating 9 Access Side AS R Right Hand L Left hand 10 Air Temperature Rise ATR H High 60 100 F 11 Gas Type
78. ble 36 1 Blower Sheave Assembly Settings Turns Open Sheave Assembly i 2 2 5 Blower R 3H35125B1 2 3H35125B3 5 3H35125B6 7 3H35125B8 9 3H35125B10 11 3H35126B1 2 3H35126B3 5 3H35126B6 8 3H35126B9 11 3H35126B12 14 3H35127B1 2 3H35127B3 5 3H35127B6 8 3H35127B9 11 3H35127B12 14 3H35127B15 16 3H35127B17 3H35128B1 3 3H35128B4 6 3H35128B7 9 3H35128B10 12 3H35128B13 14 3H35128B15 3H35129B1 3 3H35129B4 7 3H35129B8 10 3H35129B11 14 3H35129B15 18 3H35129B19 21 3H35130B1 2 3H35130B3 4 3H35130B5 6 3H35130B13 14 3H35130B15 16 3H35130B17 18 3H35130B19 20 3H36622B1 2 3H36622B3 5 3H36622B6 11 3H36622B12 17 3H36622B18 22 3H36622B23 26 36 5 562 8 BLOWER SHEAVE ASSEMBLY DATA Table 37 1 Blower Sheave Assembly Numbers and Size Motor Sheave Blower Sheave Sheave Browning Assembly Pitch Pitch Belt No Diameter Bore Diameter Bore 3H35125B1 2 9 0 5 5 0 75 A30 3H35125B2 2 9 0 625 5 0 75 A31 3H35125B3 4 4 0 5 6 0 75 A34 3H35125B4 4 4 0 625 6 0 75 A35 3H35125B5 4 4 0 875 6 0 75 A35 3H35125B6 3 8 0 625 4 2 0 75 A31 3H35125B7 3 8 0 875 4 2 0 75 A31 3H35125B8 5 6 0 625 5 2 0 75 A35 3H35125B9 5 6
79. blower RPM refer to Blower Adjustments 26 Filters OPT When filters are supplied with the unit a rack and the filters are factory installed in the blower section The unit can be supplied with 1 or 2 permanent filters 2 FARR Aeropleat MERV 7 or 2 FARR 30 30 MERV 8 filters For filter replacement refer to Maintenance 27 Fresh Air Damper OPT When a fresh air damper is supplied with the unit the damper is factory installed in the blower section The fresh air damper is used as an outside air shut off damper so ultra low leak Class II leakage resistance less than 10 CFM ft2 at 1 W C dampers with self compensating stainless steel side seals and santoprene and galvanized steel blade seals are used 30 Direct Drive Damper Actuator OPT The direct drive damper actuator is factory installed in the blower section on the side of the fresh air damper The actuator controls the position of the fresh air damper The return air damper if provided is controlled by the damper linkage between the two dampers All damper actuators are low voltage 24V For Right Hand units Digit 9 R during operation the actuator should rotate in the counterclockwise direction when viewed from the service side of the unit For Left Hand units Digit 9 L during operation the actuator should rotate in the clockwise direction when viewed from the service side of the unit Three different types of dampers actuators can be pro
80. combination gas control closed and no spark After six minutes the cycle will begin again After three cycles some ignition controllers lockout for approximately one hour before the cycle begins again This will continue indefinitely until the pilot flame is sensed or power is interrupted to the system 8 Control Relay OPT The control relay is factory installed in the duct furnace electrical junction box The relay has a 24V coil with double pole double throw DPDT contacts Refer to the unit wiring diagram for the function of the switching operation of the relay The two normally open and two normally closed contacts are rated for a maximum of 30 amps 115V 1Ph 9 Time Delay Relay STD The time delay relay is factory installed in the duct furnace electrical junction box The time delay relay allows the gas controls to operate for approximately 30 seconds before the blower starts This allows the heat exchanger a warm up period so that the initial delivered air coming out of the ductwork is not cool The time delay relay also keeps the motor running for approximately 30 seconds after the call for heat has been satis fied to remove the residual heat from the heat exchanger For single phase units below 2 Hp the time delay relay controls the motor directly For single phase units 2 Hp and greater and all three phase units the time delay relay controls the motor starter 10 Furnace Low Voltage Terminal Strip STD
81. ct switch was provided Accessory field installed disconnect switches should be mounted where shown in Figure 9 1 For fusible disconnect switches refer to the Model Identification plate for the fuse size and type 6 The power supply must be within 5 of the voltage rating and each phase must be balanced within 2 percent of each other If not advise the utility company 7 External electrical service connections that must be installed include a Supply power connection 120 208 240 480 or 600 volts b Connection of thermostats remote monitoring panels building pressure sensors CO detectors time clocks or any other accessory control devices that may be supplied 24 volts 8 Refer to the unit dimensional drawings on Figures 43 1 through 44 1 for the electrical knock out locations 9 All supply power electrical connections are made in the electrical section of the unit The low voltage thermostat and accessory control devices can be wired to either the electrical section or the duct furnace electrical junction box Refer to the wiring diagram for the terminal location of all low voltage wiring Cooling Coil Units Models with a cooling section can be provided with either a factory installed direct expansion DX evaporator a chilled fluid for use with water ethylene glycol or propylene glycol fluids coil or the coil can be field supplied and installed by others For units equipped with a factory installed cooling co
82. d For this reason two identification plates are used on these models The Serial Plate is used to identify the duct furnace and its components The Model Identification Plate is used to identify the complete model including blower and cooling sections Figure 52 1 Serial Plate Ordering When servicing repairing or replacing parts on these units locate the model identification plate of the unit and always give the complete Model Number and Serial Number from the model identification plate The model identification plate is located on the door of the electrical control box or on the side of unit The part number for some common replacement parts are listed on the serial plate See Figure 52 1 and the model identification plate See Figure 53 1 For a complete description of the model number see Model Identification TOW 2000 TO 4500 FT 610 ET 1370 H ka 100000 90000 0 TO 2000 FT 0 ET 610 M DEBIT CALORIFIQUE BTU HEURE RENDEMENT BTU HEURE ORIFICE SIZE KIN om OE L INJECTI 28 vari 695 SPEED CFH RECOMMENDED SERVICE CLEARANCES DEGAGEMENT DE SERVICE RECOMMENDE ACCESS SIDE 0 NON ACCESS SIDE bs led sw 10 COTE D ACCES 2 0 Cure NON ACCES PO COMMON REPLACEMENT PARTS For parts ordering contact the parts wholesaler or the manufacturer s representative serving your area When inquiring about parts always provide model number serial number description and part numbe
83. densation Inspect for leakage prior to insulating and use insulation that is noncombustible with a rating of not less than 350 F Install a tee fitting at the low point of the vent system and provide a drip leg with a clean out cap as shown in Figure 7 1 When the vent passes through an interior wall or floor a metal thimble 4 inches greater than the vent diameter is necessary If there is 6 feet or more of vent pipe in the open space between the appliance and where the vent pipe passes through the wall or floor the thimble need only Table 6 1 ANSI Venting Requirements Appliance Category Venting Description Requirements Negative vent pressure Non condensing Follow standard venting requirements Condensate must be drained Negative vent pressure Condensing Positive vent pressure Non condensing Vent must be gastight 10 11 12 13 14 15 16 IT 5 562 8 Positive vent pressure Condensing Vent must be liquid and gastight Condensate must be drained be 2 inches greater than the diameter of the vent pipe If a thimble is not used all combustible material must be cut away to provide 6 inches of clearance Any material used to close the opening must be noncombustible Do NOT use dampers or other devices in the vent or combustion air pipes Precautions must be taken to prevent degradation of building materials by flue products The outlet of the vent should extend
84. ditions If unit is undersized an additional unit s or other heat source must be added Check replace thermostat a Check unit wiring against the wiring diagram b Check for loose or worn wires Adjust to a maximum of 14 W C Replace gas valve Automatic Reset High Limit Figure 51 1 Lifting Flame Condition The duct furnace comes standard with an automatic reset high limit switch that will shut off the gas should the discharge air temperature become excessive See Figure 18 1 indicator 9 for the location of either the standard automatic or optional manual reset high limit switch The switch should operate only when something is seriously wrong with the unit operation Anytime the switch operates correct the difficulty immediately or serious damage may result If the switch cuts off the gas supply during normal operation refer to the Not Enough Heat section of Service amp Troubleshooting Figure 51 2 Figure 51 3 Floating Flame Condition Flame Rollout Appearance 5 562 8 51 MODEL DESIGNATIONS Model Identification Duct furnace make up air units contain an CSA and ETL ETL Canada certified indoor duct furnace This duct furnace is combined with either a blower section or a blower and cooling section to make a complete make up air or heating ventilating cooling unit that is ETL ETL Canada certifie
85. does not light Main burners do not light Pilot is lit Lifting Flames See Figure 51 1 Yellow Tipping With propane gas some yellow tipping is always present Possible Cause Main gas is off Power supply is off Air in gas line Dirt in pilot orifice Gas pressure out of proper range Pilot valve does not open a Defective ignition controller b Defective gas valve No Spark at ignitor a Loose wire connections b Pilot sensor is grounded c Defective ignition controller Safety device has cut power Pilot valve is off Dirty thermocouple contact Excessive drafts Pilot orifice Fitting leak Defective valve Loose wiring Defective pilot sensor Defective ignition controller Improper thermostat wiring Blocked vent safety switch trippped Too much primary air Main pressure set too high Orifice too large Insufficient primary air Dirty orifice Misaligned orifice 5 562 8 Possible Remedy Open manual gas valve Turn on main power Purge gas line Check for plugged pilot orifice and clean with compressed air if necessary Adjust to a maximum of 14 W C Minimum for Natural Gas 6 W C Minimum for Propane Gas 11 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 Check all safety devices High l
86. e 16 5 562 8 START UP PROCEDURE Electronic Modulating Gas Controls Building Management Control 0 10 Vdc or 4 20 mA Signal Utilizes an electronic modulating regulating gas control combination gas valve an ignition control modulating signal conditioner and an inverted 0 Vdc or 4 mA being high fire and 10 Vdc or 20 mA being low fire 0 10 Vdc or 4 20 mA input signal provided by a Building Management System BMS The signal conditioner can modulate the gas flow between 40 through 100 full fire When the BMS thermostat field supplied is satisfied the BMS heat contact field supplied opens to cut power to the combination gas valve which prevents gas flow to both the main and pilot burners 1 The BMS thermostat field supplied calls for heat and closes the BMS heat contact field supplied 2 The pilot valve opens and the spark ignitor sparks in an attempt to light the pilot If the unit was not provided with a time delay relay the blower starts at this time 3 Oncethe pilot is lit the flame sensor proves the pilot and stops the spark ignitor from sparking 4 The main gas valve is opened and the main burner is lit to 100 full fire 5 Ifthe unit was provided with a time delay relay the blower starts after 30 to 45 seconds 6 The modulating gas valve is controlled by the BMS thermostat The thermostat can modulate the firing rate between 40 through 100 full fire by modulating the input signal between either
87. e Natural 8 5 562 8 UNIT INSTALLATION Electrical Connections 1 Disconnect power supply before making wiring connections to prevent electrical shock and equipment damage 2 All appliances must be wired strictly in accordance with wiring diagram furnished with the appliance Any wiring different from the wiring diagram could result in a hazard to persons and property 3 Any original factory wiring that requires replacement must be replaced with wiring material having a temperature rating of at least 105 C 4 Ensure that the supply voltage to the appliance as indicated on the serial plate is not 5 greater than rated voltage A CAUTION Ensure that the supply voltage to the appliance as indicated on the serial plate is not 5 greater than rated voltage 1 Installation of wiring must conform with local building codes or in the absence of local codes with the National Electric Code ANSI NFPA 70 Latest Edition Unit must be electri cally grounded in conformance to this code In Canada wiring must comply with CSA C22 1 Part 1 Electrical Code 2 Two copies of the job specific wiring diagram are provided with each unit one located in the duct furnace electrical junction box and one in the electrical section of the unit Refer to this diagram for all wiring connections 3 The wire gauge must be sized according to the Nation
88. e of the standard automatic reset high limit switch located in the duct furnace electrical junction box In case of a failure of the blower motor blockage of the inlet air etc the manual reset switch prevents the unit from cycling on the high limit If the limit temperature is exceeded a service person must inspect the unit for the cause of the high discharge temperature take corrective action and then reset the switch 50 Supply Air Fire Stat OPT The supply air fire stat is factory installed in the duct furnace electrical junction box with the sensor in the discharge air stream In case of elevated temperatures in the supply air stream the manual reset switch shuts down the entire unit If the limit temperature is exceeded a service person must inspect the unit for the cause of the high discharge temperature take corrective action and then reset the switch For single phase units 1 1 2 HP and less the fire stat de energizes a relay that controls blower motor operation For three phase units and single phase units 2 HP and greater the fire stat de energizes the motor starter that controls blower motor operation 51 Main Gas Valve STD The main gas valve is factory installed in the duct furnace gas train The main gas valve provides the pilot regulator main gas and manual shutoff functions For additional information see the supplier literature included with the unit 52 Burner Box STD The burner box i
89. e keep the bottom of the unit at least 7 above the floor unless the unit is properly guarded to provide user protection from moving parts In parking garages the unit must be installed in accordance with the standard for parking structures ANSI NFPA 88A and in repair garages the standard for repair garages NFPA 88B In Canada installation of heaters in airplane hangars must be in accordance with the requirements of the enforcing authority and in public garages in accordance with the current CAN CGA B149 codes 9 Do not install units in locations where gas ignition system is exposed to water spray rain or dripping water 5 562 8 Figure 3 1 Combustible Material and Service Clearances 3 minimum clearance i to combustible material c is required from the vent collar Access Side B 2 4 A A 3 minimum clearance to combustible material is required from the vent collar Table 3 2 Combustible Material Clearances Model Access Side Non Access Side Size A B 75 175 6 1 200 960 6 2 Table 3 3 Recommended Service Clearances Model Access Side Non Access Side Size A B 75 18 6 100 125 20 150 175 25 200 225 at 250 300 30 350 400 500 600 700 800 840 960 Combustion Air Requirements Units installed in tightly sealed buildings or confined spaces must be provided with two permanent
90. e cross hair location through the slot of the limiter This is the screw mounting location 4 Pierce through the label material to allow easy fastening of the retaining screw 5 Position the limiter back to the desired position making sure the locating teeth on the limiter are engaged into the locating holes on the actuator 6 Fasten the limiter to the actuator using the self tapping screw provided 7 Test the damper rotation either manually with the manual crank or apply power and if required a control signal Re adjust if necessary Figure 21 1 Two position damper actuator and limiter Lock down with screw as shown Adjustable end switch set to angle of rotation _ Actuator clamp at 50 rotation limit 5 562 8 21 OPTIONS Modulating Damper Actuator A modulating damper actuator is provided with Air Control options GA GB GC GD GE GF GG GH GJ GK GM and GN Digits 20 amp 21 The modulating damper actuator provides incremental operation of the fresh air damper The return air damper is controlled by the fresh air damper position Full 90 rotation of the modulating actuator requires 150 seconds All modulating damper actuators operate using a 0 10 Vdc input signal Air Control GB utilizes a resistor to convert from a 4 20 mA to 0 10 Vdc from a damper controller All modulating damper actuators are spring return so when the damper is de energized the fresh air dampe
91. e main gas valve is opened completely and the main burner is lit to 100 full fire 8 The unit continues to operate until the high stage of the thermostat is satisfied at which time the main valve closes to 50 fire 9 The unit continues to operate until the low stage thermostat is satisfied at which time both the main and pilot valves close 100 If the unit was not provided with a time delay relay the blower stops at this time 10 If the unit was provided with a time delay relay the blower stops after 30 to 45 seconds Electronic Modulating Gas Controls Electronic Modulating Gas Controls Single Furnace Model Sizes 75 400 Utilizes an electronic modulating regulating gas control combination gas valve an ignition control modulating amplifier and either a modulating room thermostat or modulating duct thermostat with remote temperature set point adjuster The thermostat controls can modulate the gas flow between 40 through 100 full fire When the thermostat is satisfied the amplifier cuts power to the combination gas valve which prevents gas flow to both the main and pilot burners When duct sensing is utilized a room override thermostat can be added When calling for heat the room override thermostat provides full fire operation until the space temperature is satisfied Control is then returned to the duct sensing control In this situation either the duct sensor or the room override thermostat can call for heat
92. e the blower exterior panels and open the electrical compartment door 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 Check to insure that the venting system is installed and free from obstructions Check to see that there are no obstructions to the intake and discharge of the unit Check the belt tension and sheave alignment Refer to Blower Adjustments for proper belt tension Check bearings for proper lubrication For units provided with pillow block bearings See Model Nomenclature refer to Lubrication Recommendations for lubrication requirements Check to make sure that all filters are in place and that they are installed properly according to direction of air flow Perform a visual inspection of the unit to make sure no damage has occurred during installation 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 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 For units with a return air damper the return air damper linkage needs to be adjusted Refer to Damper Linkage Ad
93. en drip proof motor will be used so the Motor Type 1 Determine the Sheave Arrangement To establish the Sheave Arrangement the motor frame size must be determined The Motor Data tables on pages 38 to 42 contain the motor frame size A Using the Supply Voltage 460V 60Hz 3Ph enter the correct Motor Data table Table 41 1 Using Model Nomenclature Digits 17 and 18 G1 determined in steps 13 and 14 find the motor frame size 182T e Using the Motor Frame Size enter the Sheave Selection table for the selected blower determined by step 13 Table 35 2 Using the rpm calculated in step 12 870 rpm select the sheave range that contains the required rom Find the intersection with the Motor Frame Size to determine the Sheave Selection For this example with a 182T frame with 870 rpm from Table 35 2 the Sheave Arrangement I Determine the Air Control The Air Control option is selected based on the required damper configuration The available damper selections are detailed on page 21 For this selection a 100 fresh air unit without return air was required so the Air Control DA Determine the Evaporative Cooler An evaporative cooler is not available so for purposes of this selection the Evaporative Cooler 0 Determine the Cooling Coil A cooling coil cabinet was not specified so for purposes of this selection the Cooling Coil 0 Based on the previous steps the model number for the base unit is the followi
94. en lifting units make sure the load is balanced All extended cabinet systems are shipped without a crate and cannot be lifted with a fork truck Use a crane or other overhead lifting device in conjunction with the lifting holes refer to page 45 for base rail lifting hole locations for safe unit relocation If the unit must be lifted from the bottom for final installation of the unit be sure to properly support the unit over its entire length to prevent damage UNIT MOUNTING Be sure the method of unit support Suspension or floor mounting is adequate to support the weight of the unit see Weights for base unit and factory installed option weights For proper operation the unit must be installed in a level horizontal position Combustible material and service clearances as specified in Figure 3 1 and Tables 3 2 and 3 3 must be strictly maintained To assure that flames are directed into the center of the heat exchanger tubes the unit must be level in a horizontal position Use a spirit level to ensure that the unit is suspended or floor mounted correctly Unit Suspension 3 4 diameter suspension hanging locations are provided in the base rail assembly of the unit Refer to Figure 45 1 for Suspension Hanging Locations and Figure 4 1 demonstrates how the unit should be suspended and the suspension rods fastened to the unit base rail If required vibration isolators may be added Floor Mounted Units For floor installations the floor s
95. er Housing STD The blower housing is factory installed in the blower section The blower housing contains a double width double inlet DWDI blower wheel so both sides of the blower must be free from obstructions for proper operation For Right Hand units Digit 9 R during operation the blower wheel should rotate in the clockwise direction when viewed from the service side of the unit For Left Hand units Digit 9 L during operation the blower wheel should rotate in the counterclockwise direction when viewed from the service side of the unit If necessary interchange supply power wiring to reverse blower rotation 24 Pillow Block Bearings OPT The blower bearings are factory installed in the blower section The blower can be provided with either spider or pillow block bearings Spider bearings are permanently lubricated and do not require lubrication Pillow block bearings are shipped non greased from the factory and require lubrication before start up For lubrication recommendations see Lubrication Recommendations 25 Blower Motor STD The blower motor is factory installed in the blower section The blower motor can be provided in a variety of supply voltages frame types and motor horsepowers Refer to the model nomenclature to determine the type of motor provided The blower motor is supplied with an adjustable sheave that can be used to increase decrease the blower RPM For instructions on changing the
96. g Air Vent gt ger Vent Plug Gate Valve gt gt Tee Supply LU x Drain Plug Union Dirt Leg gt Cap gt Chilled Fluid Piping To prevent noise within a system an air vent is necessary to bleed off the accumulated air in the system The vent should be located on the top of the inlet manifold where the air collects This vent should be opened twice a year Air in the system will generate noise and may cause water hammer than can damage the joints of the piping and the cooling coil The outlet manifold should have a drain installed on the bottom of the manifold to allow for periodic flushing of the system to remove sediments and corrosion products from the cooling coil This drain should be opened to allow some fluid to drain twice a year Check coloration and viscosity of the effluent for 2 indications of corrosion in the system The lines between the unit and the structure should be insulated to prevent freezing of the water 5 562 8 Once installed the coil should be pressurized to 100 psig with dry nitrogen or other suitable gas The coil should be left pressurized for a minimum of 10 minutes If the coil holds the pressure the hook up can be considered leak free If the pressure drops by 5 psig or less re pressurize the coil and wait another 10 minutes If the pressure drops again there is more than likely one or more small leaks which should be located and repaired Pressure losses greater t
97. g Switch Positive pressure connector Negative pressure connector a Pressure adjustment set screw 5 562 8 23 OPTIONS 40 Motor Starter OPT The motor starter is factory installed in the electrical section A motor starter is required for all three phase motors and single phase motors 2 Hp and greater The motor starter current set point dial is factory set to the motor full load amp draw listed on the motor nameplate 40 Variable Frequency Drive OPT The VFD controller adjusts the motor rpm to vary the unit air flow The minimum air flow may be varied between 30 and 100 of the full speed air flow depending on the controls selection of the unit The control changeover options are two speed floating building pressure sensing and building management control The overload module of the motor starter is designed to trip to protect the motor from exceeding the nameplate amps If the motor exceeds the amp draw on the current set point dial the trip condition is indicated by a red color in the trip indicator window The motor starter can be placed in the automatic or manual reset positions Automatic reset is accomplished by depressing the RESET button and turning the button 1 4 turn When in the automatic reset position if the overload module trips the module will reset itself once the overload relay has cooled In t
98. han 5 psig would indicate a larger leak that should be isolated and repaired If the coil itself is found to be leaking contact your local factory representative All field brazing and welding should be performed using high quality materials and an inert gas purge such as nitrogen to reduce oxidation of the internal surface of the coil All field piping must be self supporting System piping should be flexible enough to allow for thermal expansion and contraction of the coil 11 UNIT INSTALLATION START UP PROCEDURE Operation General All coils 1 Proper air distribution is vital to coil performance Air flow anywhere on the coil face should not vary by more than 20 Air velocities should be maintained between 200 and 550 feet per minute For chilled fluid coils fluid velocities should be maintained within the recommended values of 1 to 8 fps for Water and 1 to 6 fps for Glycol solutions Chilled fluid coils Initial Start Up 1 Open all air vents so that air is eliminated from within the coil circuitry and headers Verify that all vents and drains are not obstructed and do discharge a stream of water Fill the coil with water then close all vents Perform an initial hydrostatic leak test of all brazed threaded or flanged joints valves and interconnecting piping Recheck the coil level and correct if necessary When the setup is found to be leak free discharge and discard initial water charge It is important
99. he main and pilot valves close 100 If the unit was not provided with a time delay relay the blower stops at this time 8 If the unit was provided with a time delay relay the blower stops after 30 to 45 seconds Electronic Modulating Gas Controls Two amp Three Furnaces Model Sizes 500 960 One Master furnace is provided with up to two Slave furnaces that utilize electronic modulating regulating gas controls combination gas valves ignition controls one multiple furnace modulating amplifier and either a modulating room thermostat or modulating duct thermostat with remote temperature adjuster The thermostat controls can modulate the gas flow of all the furnaces between 40 through 100 full fire The amplifier sends a signal to all of the gas valves so that they modulate at the same percentage When the thermostat is satisfied the amplifier cuts power to the combination gas valves which prevents gas flow to both the main and pilot burners When duct sensing is utilized a room override thermostat can be added When calling for heat the room override thermostat provides full fire operation until the space temperature is satisfied Control is then returned to the duct sensing control In this situation either the duct sensor or the room override thermostat can call for heat The sequence of operation for Electronic Modulating Gas Controls Two amp Three Furnaces is the same as Electronic Modulating Gas Controls Single Furnac
100. he manual reset position if the overload module trips the RESET button must be depressed before the blower can operate The contractor module includes one 1 normally open auxiliary contact The contact rating is 10 amps If the factory installed motor starter option was not ordered with a unit that has a three phase motor or single phase motor 2 Hp or greater a motor starter must be field supplied and installed Figure 24 1 Motor Starter PH 1 z L Ei 5 8 CONTACTOR MODULE a TRIP INDICATOR CURRENT m WINDOW SET POINT DIAL i y 8 RESET gt EP OVERLOAD D S MODULE i B Q Q 8 8 g 42 Proportional Temperature Controller OPT A proportional temperature controller is provided with Air Control options GF GG GH GK GM or GN Digits 20 8 21 and factory installed in the electrical section The controller compares the mixed air temperature set point and the mixed air temperature from the Proportional Temperature Controller Sensor The controller sends a 2 10 Vdc signal to the modulating damper actuator in order to maintain the set point The controller includes a set point dial that must be field set to the desired mixed air temperature typically 55 F 43 Warm Up Stat OPT A warm up stat i
101. hut off valves to isolate the cooling coil from the system in order to remove the coil for service or replacement without draining the entire system For additional guidelines refer to the ASHRAE Fundamentals Handbook section of piping recommendations Direct Expansion DX Piping The refrigerant lines should be insulated to prevent warming or cooling of the refrigerant If the suction line is allowed to be cooled liquid will condense in the line and can severely damage the compressor If the liquid line is warmed the refrigerant can flash into a gas This will cause erratic operation of the expansion device and impair the heat transfer ability of the cooling coil Long runs of piping need to be periodically supported to prevent excess vibration that can damage the piping and joints It is recommended to provide dampening supports at intervals of length equivalent to 15 tube diameters Figure 10 2 General DX Piping Suction Header Distributor Equalizer Line Coil Expansion Valve By Others Suction Line Straps Remote Sensing Bulb Suction Connection 1 Inspect the refrigerant distributor and verify that the nozzle is in place 2 All field brazing and welding should be performed using high quality materials and an inert gas purge such as nitrogen to reduce oxidation of the internal surface of the coil Connect the suction line and suction connection 4 Install the expansion valve By
102. il Digit 23 1 refer to the packing slip to determine the coil type provided The cooling section is located downstream of the duct furnace heat exchanger in a blow through configuration preventing condensation on the heat exchanger in the cooling mode Thus a stainless steel heat exchanger is not required when a cooling section is used However a stainless steel heat exchanger is still recommended when the combined entering return air to the unit is below 40 F UNIT INSTALLATION The cooling section includes a full coverage 3 way sloping 409 stainless steel drain pan to remove condensate from coil headers thermal expansion valves and refrigerant piping Insulation is standard on outdoor units and optional on indoor units and double wall construction is optional on all units The cabinet includes two doors a removable upper door for service access to the coil once the plumbing has been installed and a lower door which includes a factory supplied 1 stubbed drain connection to the exterior of the cabinet Field connections for coil inlet and outlet piping can be made through the cabinet corner post or back of the unit The cooling section duct transition includes 1 1 2 flanges for fastening the sides of the coil The bottom duct transition is angled to remove any condensation that may be entrained in the supply air stream For field supplied coils do not exceed the maximum coil dimensions listed in Literature 82 135 The dimensions
103. imit air flow proving switch differential pressure switch gas pressure switches etc Determine and correct problem Reset if necessary Turn gas control knob or lever on combination gas control to pilot position Be sure thermocouple contact is clean If problem persists replace thermocouple Find source and re direct airflow away from unit Tighten pilot orifice Flame impingment on thermocouple may cause thermocouple to become inoperative Replace valve Check wiring to gas valve Replace pilot sensor Replace ignition controller Verify wiring compared to wiring diagram Refer to Figure 49 1 Reduce primary air Adjust to a maximum of 14 W C Check orifice size with those listed on the serial plate Increase primary air Check orifices and clean with compressed air if necessary Check manifold replace if necessary SERVICE 8 TROUBLESHOOTING Trouble Possible Cause Flashback Too much primary air Main pressure set too high Orifice too large Floating Flames See Figure 51 2 Insufficient primary air Main pressure set too high Orifice too large Blocked vent Flame Rollout See Figure 51 3 Main pressure set too high Orifice too large Blocked vent Not Enough Heat Unit cycling on high limit a Obstructions leaks in duct system b Main pressure set too high c Blower motor not energized d Loose belt e Blower speed too low f Blocked damaged venti
104. in the atmosphere Location Recommendations 1 When locating the furnace consider general space and heating requirements availability of gas and electrical supply and proximity to vent locations 2 Unit must be installed on the positive pressure side of the circulating blower 3 Be sure the structural support at the unit location site is adequate to support the weight of the unit For proper operation the unit must be installed in a level horizontal position 4 Do not install units in locations where the flue products can be drawn into the adjacent building openings such as windows fresh air intakes etc 5 Be sure that the minimum clearances to combustible materials and recommended service clearances are maintained Units are designed for installation on non combustible surfaces with the minimum clearances shown in Figure 3 1 and Tables 3 2 and 3 3 6 Units installed downstream of refrigeration systems or exposed to inlet air temperatures of 40 F or less may experience condensation therefore provisions should be made for disposal of condensate Means have been provided in the bottom pan of the unit to accommodate a condensate drain line connection flange 7 When locating units it is important to consider that the exhaust vent piping must be connected to the outside atmosphere 8 In garages or other sections of aircraft hangars such as offices and shops that communicate with areas used for servicing or storag
105. increase or decrease primary combustion air Prior to flame adjustment operate duct furnace for about fifteen minutes The main burner flame can be viewed after loosening and pushing aside the gas designation disc on the side of the burner box To increase primary air loosen the air shutter set screws and move the air shutters closer to the manifold until the yellow tipped flames disappear See Figure 48 4 for air shutter and 14 5 562 8 START UP PROCEDURE Blower Adjustments If blower fan speed changes are required adjust motor sheave as follows 1 Refer to page 34 to determine correct blower speed according to job requirements then proceed with steps 2 through 8 2 Loosen motor base and take belt off of motor sheave 3 Loosen set screw on outer side of adjustable motor sheave Figure 15 1 Motor Sheave Adjustment Set Screw Toward Motor Adjustable Half of Sheave 4 Turn outer side of motor sheave clockwise until motor sheave is fully closed 5 From fully closed position turn outer side of motor sheave counterclockwise until the proper number of turns open are achieved 6 Retighten motor sheave set screw replace belt and retighten motor base Motor base should be shifted for proper belt tension which is 3 4 deflection with about 5 Ibs of force Figure 15 2 Belt Tension Adjustment 3 4 deflection with 5 Ibs of force 7 Recheck blower rpm after adjustment NOTE
106. ion of A CAU T oO N product ordered including specifications where applicable To prevent premature heat exchanger failure do not locate ANY gas fired units in areas where chlorinated halogenated or acid vapors are present in the atmosphere THIS MANUAL IS THE PROPERTY OF THE OWNER PLEASE BE SURE TO LEAVE IT WITH THE OWNER WHEN YOU LEAVE THE JOB SPECIAL PRECAUTIONS TABLE OF CONTENTS SPECIAL PRECAUTIONS THE INSTALLATION AND MAINTENANCE INSTRUCTIONS IN THIS MANUAL MUST BE FOLLOWED TO PROVIDE SAFE EFFICIENT AND TROUBLE FREE OPERATION IN ADDITION PARTICULAR CARE MUST BE EXERCISED REGARDING THE SPECIAL PRECAUTIONS LISTED BELOW FAILURE TO PROPERLY ADDRESS THESE CRITICAL AREAS COULD RESULT IN PROPERTY DAMAGE OR LOSS PERSONAL INJURY OR DEATH THESE INSTRUCTIONS ARE SUBJECT TO ANY MORE RESTRICTIVE LOCAL OR NATIONAL CODES HAZARD INTENSITY LEVELS 1 DANGER Indicates an imminently hazardous situation which if not avoided WILL result in death or serious injury 2 WARNING Indicates a potentially hazardous situation which if not avoided COULD result in death or serious injury 3 CAUTION Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury 4 IMPORTANT Indicates a situation which if not avoided MAY result in a potential safety concern A DANGER Appliances must not be installed where they may be exposed to a potentially explosive or flammable atmo
107. justment Check to make sure that the damper opens properly without binding 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 Check the blower speed rpm Refer to Blower Adjustments for modification Check the motor speed rpm Check the motor voltage On three phase systems check to make sure all legs are in balance 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 UNIT INSTALLATION START UP PROCEDURE 19 Recheck the gas supply pressure at the field installed manual shut off valve The minumum inlet pressure should be 6 W C on natural gas and 11 W C on propane gas The maximum inlet pressure for either gas is 14 W C If inlet pressure exceeds 14 W C a gas pressure regulator must be added upstream of the combination gas valve 20 Open the field installed manual gas shut off valve 21 Open the manual main gas valve on the combination gas valve Call for heat with the thermostat and allow the pilot to light for intermitent pilot ignition If the pilot does not light purge the pilot line If air purging is required disconnect the pilot line at outlet of pilot valve In no case should line be
108. l 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 Indoor gravity vented duct furnaces are supplied with intermittent pilot systems with continuous retry as standard For intermittent pilot systems both the main burner and pilot burner are turned off 100 when the thermostat is satisfied On a call for heat the system will attempt to light the pilot for 70 seconds If the pilot is not sensed for any reason the ignition control will wait for approximately six minutes with the combination gas control closed and no spark After six minutes the cycle will begin again After three cycles some ignition controllers lockout for approximately one hour before the cycle begins again This will continue indefinitely until the pilot flame is sensed or power is interrupted to the system NOTE Gas Control Options see page 16 could change the listed sequence of operation based on their function The descriptions given are for the basic duct furnace 5 562 8 15 START UP PROCEDURE Single Stage Gas Controls Utilizes a single stage combination gas control an ignition control and a single stage low voltage thermostat 1 The thermostat calls for heat 2 The pilot valve opens and the spark ignitor sparks in an attempt to light the pilot If the unit
109. l resistance has been included in the unit performance tables Brake Horsepower and RPM values are approximate values only Please consult the AccuSpec selection software for values at other than listed CFM static pressures 5 562 8 33 BLOWER SHEAVE ASSEMBLY DATA Adjusting the Blower Drive Setting 2 Locate the unit Model Identification Plate and note Digit 16 and Digit 19 of the model number Digit 16 is the Blower Based on the Sheave Arrangement Tables 34 1 through 35 5 Size and Type and Digit 19 is the Sheave Arrangement give the Sheave Assembly numbers used on units that include a 3 Once the Blower Size and Type Digit 16 is known enter blower The Sheave Arrangement is Digit 19 and is found on the the proper Sheave Arrangement table unit Model Identification Plate The Sheave Assembly describes 4 Use the Sheave Arrangement Digit 19 to determine the ee and blower sheave size and bore as well as the belt Sheave Assembly provided p i 5 Use Table 36 1 and the Sheave Assembly number to To determine how many turns open the motor sheave should be determine the required turns open to achieve the s t for desired blower rpm 6 Set the motor sheave as described in Blower Adjustments 1 Follow the Selection Procedure found on pages 28 and 29 to determine what blower rpm is required to meet the job specifications Figure 34 1 Blower Section EXTENDED ADJUSTABLE 5 HP FILTER GREASE MOTOR TWO SPEED RACK LINES SHEAVE MOTOR EXTEN
110. ll switches need to be reset to the OFF position after testing otherwise the components will remain energized Figure 24 3 Service Switches SYSTEM OVERRIDE SWITCH POSITIONS DAMPERS ONLY on OFF DFF R oo os a fnr f ha A AAA EOB DAMPERS amp BLOWER ONLY on OH OFF m n r J A Am AS id a a 3 DAMPERS BLOWER amp FURNACE ONLY GN on GH DE SEE DOG UD RESET SWATCHE TQ OFF POSITION AFTER TESTING OM ON on KJ GEE DER ns FF 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 Digit 12 4 or 5 The amplifier processes the thermostat temperature and set point signals to modulate the firing rate between 40 to 100 full fire For additional information refer to Control Operating Sequence 24 5 562 8 OPTIONS 47 Electronic Modulating Gas Valve OPT An electronic modulating gas valve is provided factory installed in the duct furnace gas train when the unit is equipped with Electronic Modulating Gas Controls Digit 12 4 5 6 7 or 8 The gas valve modulates the firing rate between 40 to 100 full fire based on the input signal from the Electronic Modulation Amplifier or Signal Conditioner For additional information refer to Control Operating Sequence 48 Air Flow Proving Switch OPT The
111. n 2 A call for cooling from the space thermostat brings on mechanical cooling The enthalpy controller is used in conjunction with the Enthalpy Sensor not shown and field installed and a mixed air temper ature sensor not shown The mixed air temperature sensor is factory installed in the blower section to sense the combined temperature of the fresh and return air streams The sensor is non adjustable and when in the free cooling mode modulates the dampers to maintain between 50 F and 56 F at the sensor The enthalpy controller contains a minimum position adjustment and an enthalpy changeover set point that must be field set Figure 22 1 Enthalpy Controller ENTHALPY CHANGEQVER SETPOINT MINIMUM DAMPER POSITION SETTING W710 A 1001 LEO LIGHTS WHEN SUTOOGA AIH 15 SUITABLE FOR FREE COOLING M1625 Minimum Position Adjustment The minimum position adjustment keeps the outdoor air damper from closing completely during system operation to provide ventilation in both the heating and cooling modes To set the minimum position adjustment 1 Disconnect mixed air sensor from terminals T and T1 on the enthalpy controller 2 Make sure the factory installed jumper is in place across terminals P and P1 3 Connect 24 Vac across terminals TR and TR1 4 Adjust the minimum position adjustor with a screwdriver for the desired minimum position
112. nal static pressure E S P is determined using the ASHRAE Guide for duct losses or may be provided by the design engineer Unit configuration with options and accessories Filters or dampers The unit configuration is determined by the location where the unit is to be installed The critical options and accessories are those that add internal static pressure I S P to the unit Once these items are determined the pressure drop curves would be used to calculate the total pressure drop T S P Total Static Pressure Internal External Static Pressure Heat exchanger material The heat exchanger type is determined by the application The standard heat exchanger material is aluminized steel A 409 stainless steel heat exchanger and burner is recommended when the unit is installed downstream of a cooling coil or evaporative cooler and when the combined entering return air to the unit is below 40 F Type of fuel Either natural or propane gas determined by the design engineer Gas control staging method Either single stage two stage mechanical modulation or electronic modulation determined by the design engineer Main power supply voltage to unit 10 Altitude at which unit is to be installed With this information a basic unit can be selected as shown in the following example 28 Selection Example Conditions Select an indirect fired 100 make up air unit to meet the following conditions 1 CFM at sea level
113. ng DBG400SMRLN40F2GG1IDA00 Once the basic model has been determined the additional options and accessories outlined on page 18 to 25 can be added to the unit 5 562 8 29 OPTION 8 ACCESSORY PRESSURE DROP DATA Table 30 1 Option amp Accessory Pressure Drop Tables in W C All Units Weatherproof Unit Only 75 A B C D 100 125 150 175 C D E F 5 i 7 i E Max CEM 0 12 0 17 0 22 0 27 0 33 200 225 C D E F G H 7 5 5 5 E 0 40 0 47 0 55 0 63 Max CFM for Evap Permanent Permanent 2 Farr 30 30 Evap Cooler Evap Cooler Evap Cooler Evap Cooler ainhood and irdscreen ischarge Downturn 0 24 0 29 0 35 0 48 0 63 Max CEM 250 300 500 600 0 10 0 05 0 15 0 09 0 20 0 14 0 26 0 20 0 34 0 27 0 41 0 35 0 50 0 45 0 64 0 60 10400 Max CFM for Evap 350 400 700 800 840 960 10000 0 13 11050 0 15 13000 0 20 Accesssory Option static pressure losses are approximate values only Please consult the Accuspec selection software for static pressure losses at other than listed CFM 30 5 562 8 BLOWER PERFORMANCE DATA Table 31 1 Unit Performance Tables Air Digit Temp Unit Size 16 Rise 75 A B 100 F
114. ng motor w Space Pressure Controller JA Manual FA amp RA Dampers KA Manual FA Damper with Return Air Opening 22 Evaporative Cooling EC 0 None 23 Cooling Coil CC 0 None 1 Factory Installed Coil 5 562 8 55 COMMERCIAL WARRANTY Seller warrants its products to be free from defects in material and workmanship EXCLUSIVE HOWEVER of failures attributable to the use of materials substituted under emergency conditions for materials normally employed This warranty covers replacement of any parts furnished from the factory of Seller but does not cover labor of any kind and materials not furnished by Seller or any charges for any such labor or materials whether such labor materials or charges thereon are due to replacement of parts adjustments repairs or any other work done This warranty does not apply to any equipment which shall have been repaired or altered outside the factory of Seller in any way so as in the judgment of Seller to affect its stability nor which has been subjected to misuse negligence or operating conditions in excess of those for which such equipment was designed This warranty does not cover the effects of physical or chemical properties of water or steam or other liquids or gases used in the equipment BUYER AGREES THAT SELLER S WARRANTY OF ITS PRODUCTS TO BE FREE FROM DEFECT IN MATERIAL AND WORKMANSHIP AS LIMITED HEREIN SHALL BE IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES EITHE
115. ng system g Air distribution baffle removed high temperature rise units only h Defective high limit switch Main pressure set too low Too much outside air Thermostat malfunction Gas controls wired incorrectly Unit undersized Too Much Heat 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 Possible Remedy Reduce primary air Adjust to maximum of 14 W C Check orifice size with those listed on the serial plate Increase primary air Adjust to a maximum of 14 W C Check orifice size with those listed on the serial plate Clean correct venting system Adjust to a maximum of 14 W C Check orifice size with those listed on the serial plate Clean correct venting system Clean correct duct system Adjust to a maximum of 14 W C Check correct to insure blower motor operates within 45 seconds of when gas controls are energized Adjust belt tension Check correct blower drive settings for proper rpm Check correct venting system g Replace air distribution baffle h Replace high limit switch Adjust main gas pressure Minimum for Natural Gas 6 W C Minimum for Propane Gas 11 W C Adjust outside air damper to decrease outside air percentage if possible Check replace thermostat Check unit wiring against the wiring diagram Check design con
116. nized Steel drip pan will be used Thus the Heat Exchanger Burner Drip Pan Material S 4 Determine the Development Sequence From item 8 in Selection Example Conditions the modulating gas controls result in the Development Sequence M 5 Determine the Access Side From item 5 in Selection Example Conditions the Right Hand Gas controls result in the Access Side R 6 Determine the Air Temperature Rise From item 2 in Selection Example Conditions the Air Temperature Rise is 60 F 70 F 10 F However using the output capacity of the DBG400 5000 cfm the resulting temperature rise is 59 3 F 320 000 5000 x 1 08 Since the rise is less than 60 F the air baffle must remain in place 7 Determine the Gas Type From item 7 in Selection Example Conditions the Natural Gas results in the Gas Type N 8 Determine the Gas Valve From item 8 in Selection Example Conditions the Electronic Modulating with Duct Sensing results in the Gas Valve 4 9 Determine the Additional Safety Switches Since no additional safety switches were specified the Additional Safety Switches 0 5 562 8 UNIT SELECTION 10 11 12 Determine the Supply Voltage From item 9 listed above the 460V 60Hz 3Ph results in the Supply Voltage F Determine the Transformer For DBG DCG models a 75VA Transformer is required Thus the Transformer 2 Determine the Blower Size and Bearing Type Using Table 26 1 the M
117. odel Size 400 has three available blowers for which the performance tables are shown on pages 30 33 Since all of the blower performance curves can provide the required 5000 cfm the total static pressure must be determined A The Pressure Drop of an option or accessory is determined by entering the right of the table at the desired cfm and reading up the table until the cfm intersects the desired item For this example in table 30 1 the 2 Permanent Filter line is used At the point of intersection read across the table to the left and read the pressure drop in inches of water column for the filters For this example the pressure drop is 0 06 W C As a result For the Model Size 400 with Digit 16 E F G or H 2 Permanent Filters 0 06 W C Internal Static Pressure Drop 0 06 W C The Total Static Pressure for the system is determined by Internal Static External Static Total Static Pressure For this example 0 06 0 65 0 71 W C T S P From page 30 for the Model Size 400 with Digit 16 I J or K 2 Permanent Filters 0 04 W C Internal Static Pressure Drop 0 04 W C The Total Static Pressure for the system is determined by Internal Static External Static Total Static Pressure For this example 0 04 0 65 0 69 W C T S P D Using the total static pressure T S P calculated in step 12a use blower performance tables for the Model Size 400 Table 32 1 Using Table 32 1 enter the table at the
118. or Data for Digit 14 E 230V 60Hz 3Ph Frame Service Weight Efficiency Digits i Frame Service Weight Efficiency Factor 17818 Size 19 6 8 88 5 19 4 91 7 22 5 8 2 85 0 72 0 19 5 12 3 1 89 0 85 0 20 0 89 5 19 2 91 7 21 0 8 8 z 87 0 75 0 TE 18 12 20 0 12 4 1 86 0 80 0 A i ODP 26 8 E 89 5 ODP 18 12 4 2 i ODP HE 25 2 A 91 7 TEFC i ODP 18 9 32 4 11 6 1 88 0 77 0 TE HE i ODP 18 12 24 0 13 0 _ 1 88 0 80 0 TEFC 18 9 4 1 26 0 89 5 TEFC 18 12 Ale 25 0 90 2 ODP 29 0 11 5 1 87 0 77 0 ODP K TE 18 12 28 0 17 5 1 88 0 80 0 ODP 18 9 8 2 ODP 38 6 E 91 0 ODP 18 12 9 2 ODP HE 37 8 a 93 0 TEFC 40 0 17 0 _ 1 90 2 84 0 TE HE 40 0 E 91 0 TEFC 18 9 0 1 38 0 i 92 4 TEFC 18 12 9 2 A 39 0 15 0 1 88 0 82 0 ODP 38 0 22 0 1 88 0 84 0 ODP 89 5 50 0 z 91 0 ODP 18 9 4 2 81 0 67 0 49 0 8 93 6 ODP 18 12 3 3 81 0 NA 51 0 21 5 1 90 2 82 5 T i 84 0 ODP 18 12 48 0 26 0 _1 89 0 86 0 TE HE i i 85 5 TEFC 51 0 91 0 TEFC 18 9 4 2 i 84 0 70 0 TE HE 48 2 TE 18 12 4 4 84 0 77 0 TE 18 9 52 0 18 0 ODP i 86 5 ODP HE ODP 18 9 ODP 18 12 a OT On OT OT A a a w w w w w w w w N N JO JNJN J
119. p R 2 Hp Hp with Motor Starter G 3Hp S 3 Hp with Motor Starter H 5Hp T 5Hp with Motor Starter 7 1 2 Hp W 7 1 2 Hp with Motor Starter J 10Hp 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 5 TE 2 ODP High Eff 6 TE High Eff 3 ODP 1800 900 RPM 7 TE 1800 900 RPM 4 ODP 1800 1200 RPM 8 TE 1800 1200 RPM 19 Sheave Arrangement SA A See Sheave Tables 34 1 to 35 5 20 21 Air Control AC AA RA Opening BA FA Opening CA FA 8 RA Openings DA FA Dampers w 2 pos motor No RA EA FA amp RA Dampers w 2 pos motor EQ ASHRAE Cycle EA with Warm up Stat FA FA Damper amp RA Opening w 2 pos motor GA FA 8 RA Mod motor w 0 10 Vdc External Input GB FA 8 RA Mod motor w 4 20 mA External Input GC FA 8 RA Mod motor w Minimum Position GD FA 8 RA Mod motor w Remote Position On Remote Panel GE FA 8 RA Mod motor w 3 pos damper 100 RA Variable 100 OA GF FA8 RA Mod motor w A350P Proportional Temp Controller GG FA amp RA Mod motor w Minimum Position amp Prop Temp Controller GH FA8 RA Mod motor w Remote Position amp Prop Temp Controller GJ FA 8 RA Mod motor w FA Enthalpy Controller GK ASHRAE Cycle II GG with Warm up Stat GM ASHRAE Cycle II GH with Warm up Stat GN ASHRAE Cycle III GF with Warm up Stat HP FA8 RA Floati
120. per minute FPM coil face velocity 1 Ton 12 000 Btu Hr Based on 95 F Entering Dry Bulb 75 F Entering Wet Bulb 8600 o Use a vacuum pump to evacuate the coil and any interconnecting piping that has been open to atmosphere Model Size 75 CFM listed for Chilled Water DX Single Circuit CFM minimum is 688 and DX Dual Circuit CFM min is 621 Model Size 100 CFM listed for Chilled Water DX Single Circuit CFM minimum is 802 and DX Dual Circuit CFM min is 745 Figure 11 1 General Chilled Fluid Piping Measure the vacuum in the piping using a micron gauge located as far from the pump as possible the vacuum at the pump will be greater than the rest of the system Evacuate the coil to 500 microns or less then close the valve between the pump and the system If the vacuum holds to 500 microns or less for one minute the system is ready to be charged or refrigerant pumped down in another portion of the system can be opened to the coil A steady rise in microns would indicate that moisture is still present and that the coil should be further vacuumed until the moisture has been removed 9 Failure to obtain a high vacuum is indicative of a great deal of moisture or a small leak Break the vacuum with a charge of dry nitrogen or other suitable gas and recheck for leaks soapy water works well If no leaks are found continue vacuuming the coil until the desired vacuum is reached 10 All field piping must be self supportin
121. r When ordering parts provide part number listed For service contact your local qualified installation and service contactor or appropriate utility company COMBUSTIBLE MATERIALS AND SERVICE CLEARANCES MATERIAUX COMBUSTIBLES ET DEGAGEMENTS D ENTRETIEN 5H080681 Comb Gas Valve 5H080689 Ignition Control 5H77892 1 Wiring Diagram 5H71956 1 Ctrl Transformer 3H37454 3 Pilot Replace Kit 3H36508 5 Heat Exch Kit PP ZE 3H35628 2 Burner Kit MATERIAL 15 FROM OUTSIDE SURFACE OF 5H71790 Optional TOR 2 pasa INSTALLATION ON NON COMBUSTIBLE FLOORS 1 LA DISTANCE MINIMUM DE MAT RIAU COMBUSTIBLE DE 3 PO EST DETERMINEE PARTIR DE L EXTERIEUR DU CONDUIT DE VENTILATION 2 POUR L INSTALLATION SUR LES 5477929 Rev 0 PLANCHERS INCOMBUSTIBLES en gt gt 1 INSTALLATION INSIDE OUTDOOR WEATHERIZED ENCLOSURE ACCEPTABLE ON NFG MODEL TYPE ONLY INSTALL ON THE POSITIVE PRESSURE SIDE OF AIR CIRCULATING BLOWER FOR INSTALLATION DOWNSTREAM OF REFRIGERATION SYSTEMS IN USA FOR INSTALLATIONS ABOVE 2000 FEET DERATE 4 PERCENT FOR EACH 1000 FEET OF ELEVATION ABOVE SEA LEVEL INSTALLATIONS IN AIRCRAFT HANGARS PARKING STRUCTURES AND REPAIR GARAGES SHALL BE IN ACCORDANCE WITH THE STANDARD ON AIRCRAFT HANGARS ANSI NFPA 409 THE STANDARD FOR PARKING STRUCTURES ANSI NFPA 88A THE STANDARD FOR REPAIR GARAGES ANSI NFPA 668 AND IN CANADA WITH THE CAN1 B149 CODES 4 FOOT HORIZONTAL V
122. r will spring closed Floating Damper Actuator A floating damper actuator is provided with Air Control option HP Digits 20 amp 21 The floating damper actuator provides forward and reversing damper operation in response to contact closures from the space pressure controller When the space pressure is above the desired set point a high pressure contact on the space pressure controller energizes the damper to drive the fresh air damper closed When the space pressure is below the desired set point a low pressure contact on the space pressure controller energizes the damper to drive the fresh air damper open When the space pressure is between the high and low set points the damper floats at the fresh air percentage that satisfied the space pressure controller Full 90 rotation of the floating actuator requires 150 seconds For additional information on the space pressure controller refer to Literature 5 585 The damper actuator is designed to float and therefore it is not spring return When the unit is de energized under normal operation the fresh air damper is closed by a relay contact closure which electrically drives the damper closed If the supply power to the unit is interrupted before the damper actuator can drive closed the fresh air damper will remain open The damper can be manually closed through the use of the manual override switch on the floating damper actuator 31 Enthalpy Controller OPT An
123. required 5000 cfm for E F blowers and follow the cfm line up the right until it intersects with the T S P line of 0 75 W C which is shown at the top of the table At the point of intersection of these two columns read the required horsepower and blower rpm Repeat this process for 1 00 T S P and literate to determine the BHP and rpm for 0 89 W C For this example the horsepower is 5 and the blower rpm is 1280 Following this procedure for G H blowers Using 5000 cfm and 0 89 W C T S P the horsepower is 5 hp and 920 rpm Following this procedure for I J H blowers Using 5000 cfm and 0 87 W C T S P the horsepower is 3hp and 700 rpm Although I J H blowers results in a 3 hp motor this blower requires the use of the extended cabinet length As a result for purposes of this selection example G H will be used Since the Bearing Type was not specified the standard spider bearings will be used Thus using Table 32 1 with spider bearings the Blower Size and Bearing Type G 13 14 15 16 17 18 Determine the Motor Horsepower The motor horsepower determined in step 12 was a 3 Hp Since the supply voltage is 460V 60Hz 3Ph a motor starter will need to be provided either with the unit or by others For purposes of this selection a motor starter by others will be used so the Motor Horsepower G Determine the Motor Type The motor type was not specified so for purposes of this selection the standard op
124. rictions of the controller all selections must be performed with the AccuSpec configuration software Within AccuSpec three variable frequency drive speed control changeover options are available 1 Two speed which may be controlled by a manual high low switch which may be factory mounted on the control panel or shipped loose for field installation or by exhaust fan interlocks 2 Floating building pressure sensing which utilizes a photohelic pressure controller to adjust the building pressure by varying the amount of makeup air supplied to the the space 3 Building management control which allows for an external signal of 0 10VDC of 4 20mA to adjust the unit airflow Additionally when the air mover supplied by others can provide variable air movement i e 2 speed or variable frequency drive units the allowable minimum CFM of the duct furnace can be 66 of the minimum listed CFM in Table 26 1 if the unit is applied as follows 1 The unit is provided with 2 stage or electronic modulating gas controls see Model Identification 2 The unit is provided with a factory installed discharge air controller 3 The system does not include a room thermostat The factory installed discharge air thermostat will prevent the unit from firing above the allowable 100 F rise when the unit is at or above the minimum CFM by monitoring the discharge air and going to low fire A room thermostat because it is located remote from the unit could
125. s of Dimensions G H 100 125 150 175 200 225 250 300 E F G or H 350 400 EF G or H 500 600 GorH 700 800 GorH For Right Hand Access Units Drill Locator Dimples for Field Drilled Electrical Conduit Entry Holes spaced 2 0 apart For Left Hand Access Units Drill Locator Dimples for Field Drilled Electrical Conduit Entry Holes spaced 2 0 apart 5 562 8 43 DIMENSIONS UNIT Figure 44 1 DBG Indoor Gravity Vented Blower Package Unit Dimensions with Blower Type I J K orL J Over Roof 33 22 47 36 36 68 L 3 86 N Vent Dia EL X Blower Hat Field Drilled Electrical Conduit Return Air Entry Holes spaced 2 0 apart Duct Connection s 500 800 Model Shown Z 34 00 z x 4 43 23 23 07 Height Outside OKS 24 00 24 00 C Width Outside a inside S NEDE Inside 44 80 dasz 5 9784 mid Fresh Air z RE SE q Duct Gonnection a R H L Z tL m m o H c 9 21 9 21 LU 529 s2 a E L zk pag L 1 50 3 00 Ll 5 65 Min approx Qty 4 Drill Locator Dimples for Gnade 4 35 RB i Figure 44 2 DCG Indoor Gravity Vented Cooling Package Unit Dimensions with Blower Type I
126. s located in the duct furnace section and contains the burner and pilot assembly The burner box includes an access panel for removal of the burner for inspection and servicing 56 Blocked Vent Safety Switch A manual reset BVSS is supplied on all gravity vented duct furnaces and is designed to prevent operation of the main burner in the event there is spillage of flue producs into the space This spillage may occur due to a restricted vent inadequate vent draw uninsulated vent pipe in cold ambient or long vent runs excessive vent diameter restricitve vent terminal negative pressure within space etc After the cause of the spillage has been corrected depressing the button of the BVSS found on top of the unit may reset the BVSS See trouble shooting section for more information Not Shown Circuit Analyzer OPT The circuit analyzer is factory installed on the door of the electrical section The circuit analyzer is used to quickly assist service personnel in troubleshooting by monitoring the unit firing sequence and vital operating steps Lights will come on as a point of electrical operation is passed and proven If any light is not lit that is the point where failure occurred Figure 25 1 Circuit Analyzer Circuit analyzer tagging will vary based on the unit ordered Circuit analyzer shown is for reference only Ka 5 562 8 25 GENERAL PERFORMANCE DATA Table 26 1 General Performance Data Models With
127. s provided with Air Control options GK GM or GN Digits 20 amp 21 and factory installed in the electrical section with the sensor in the return air stream The warm up thermostat monitors the return air temperature to the unit and prevents the fresh air dampers from opening until the temperature of the return air has reached the desired set point typically 65 F or 5 F below the room temperature Figure 24 2 Proportional Temperature Controller r N o SET POINT DIAL A350 P VOLTS 2468 10 ON 48 12 16 25 MILLIAMPS JOHNSON CONTROLS SS 44 Blower Supply Power Terminal Strip STD The blower supply power terminal strip is located in the electrical section The terminal strip is labeled to match the electrical wiring diagram provided with the unit Supply power labeling ranges from terminal numbers 80 to 99 All field wiring connections should be made to the bottom side of the terminals to prevent miswiring by modifying the factory wiring which is made to the top of the terminal strip 45 Service Switches OPT The service switches are factory installed in the electrical section The service switches allow for service personnel to independently test operation of the damper blower and furnace without using jumper wires The switches override the remote monitoring panel and or thermostats to energize each compo nent directly A
128. sphere A WARNING 1 Gas fired heating equipment must be vented do not operate unvented 2 Abuilt in draft diverter is provided additional external diverters are not required or permitted 3 Gas fired heating equipment which has been improperly vented or which experiences a blocked vent condition may have flue gases accidentally spilled into the heated space See page 25 for specific information about the blocked vent safety switch supplied on the unit 4 All field gas piping must be pressure leak tested prior to operation Never use an open flame Use a soap solution or equivalent for testing 5 Gas pressure to appliance controls must never exceed 14 W C 1 2 psi 6 Disconnect power supply before making wiring connections to prevent electrical shock and equipment damage 7 All appliances must be wired strictly in accordance with wiring diagram furnished with the appliance Any wiring different from the wiring diagram could result in a hazard to persons and property 8 To reduce the opportunity for condensation the minimum sea level input to the appliance as indicated on the serial plate must not be less than 5 below the rated input or 5 below the minimum rated input of dual rated units 9 Ensure that the supply voltage to the appliance as indicated on the serial plate is not 5 greater than the rated voltage 10 Any original factory wiring that requires replacement must be replaced with wiring material
129. stem Units PSH BSH Steam Hot Water Units Oil Fired Units Electric Units Cassettes Vertical Unit Ventilators Compressors Vertical Unit Ventilators Burners High Intensity Infrared Units Sheet Metal Parts All Products ONE YEAR FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER WITHIN ONE YEAR FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION OR WITHIN EIGHTEEN MONTHS FROM DATE OF SHIPMENT FROM SELLER WHICHEVER OCCURS FIRST As Modine Manufacturing Company has a continuous product improvement program it reserves the right to change design and specifications without notice TP gt MODINE Modine Manufacturing Company 2010 Commercial Products Group Modine Manufacturing Company 1500 DeKoven Avenue Racine WI 53403 Phone 1 800 828 4328 HEAT www modine com Litho in USA
130. that all grease oil flux and sealing compounds present from the installation be removed Maintenance General 1 12 Filters should be inspected on a regular basis and changed as needed Maintaining clean filters is a cost effective way to help maintain maximum coil performance and service life Periodic inspection of the coil for signs of corrosion and for leaks is recommended For DX coils Small leaks can be detected using a Halide torch Repair and replacement of the coil and the connecting piping valves etc should be performed as needed by a qualified individual s Should the coil surface need cleaning caution should be exercised in selecting the cleaning solution as well as the cleaning equipment Improper selection can result in damage to the coil and or health hazards Clean the coil from the leaving air side so that foreign material will be washed out of the coil rather than pushed further in Be sure to carefully read and follow the cleaning fluid manufacturer s recommendations before using any cleaning fluid For DX coils the use of filter dryers in the system piping is recommended along with a sight glass that has a moisture indicator Replace the filter dryer s as needed For chilled fluid coils A Maintain the circulated fluid free of sediment corrosive products and biological contaminants Periodic testing of the fluid followed by any necessary corrective measures along with maintaining adequate fluid
131. trical section The dirty filter pressure switch monitors the pressure differential between the two sides of the filters When the filters become dirty the differential pressure increases and trips the pressure switch which energizes a light on the remote monitoring panel The pressure differential switch must be field set because setting the switch requires the blower to be in operation and the ductwork to be installed Setting the Dirty Filter Switch The range of the dirty filter pressure switch is adjustable between 0 17 to 5 0 W C 1 Ensure that the unit filters are clean Clean or replace if necessary 2 Connect the leads of a continuity tester to the NO and C terminals of the dirty filter pressure switch See Figure 23 2 3 Set the thermostat so that there is a call for heat This should fire the burner and the blower should start 4 Turn the set screw of the pressure switch clockwise until it stops This will set the pressure at 5 0 W C and the continuity tester should be sensing an open circuit 5 Begin turning the screw counterclockwise until the continuity tester senses a closed circuit This determines the base pressure of the system 6 Turn the screw clockwise until the continuity tester senses an open circuit and then one additional full turn This is approx imately 0 25 W C This will allow for the increase in static pressure due to dirty filters Figure 23 2 Dirty Filter Pressure Switch and Air Flow Provin
132. tructure must be adequately designed to support the live weight load of the unit and any other required support structure Additional reinforcement should be provided if necessary The floor should include threaded 5 8 inch anchor bolts spaced according to Figure 4 2 for securing the unit in place Anchor bolts should extend at least 1 1 2 above the surface of the floor to allow clearance for mounting washers nuts and bolts mounting washers nuts and bolts by others Figure 4 1 Unit Suspension Method 3 4 Suspension Rods by others aura 73 LOCKWASHER FURNACE N Standard blower cabinet shown aen 2 Figure 4 2 Floor Mounted Units 5 8 Dia 4 Blower Type DBG Units DCG Units All Units DBG Units Size Digit 16 A A B 75 All 86 27 115 48 33 85 100 25 All 86 37 115 48 36 36 150 175 All 86 37 115 48 40 61 200 225 All 86 37 115 48 42 71 E F G or H I J or K E F G or H I J or K GorH I J or K GorH 1 J K or L 1 J K or L 5 562 8 DUCT INSTALLATION DUCT INSTALLATION Furnace discharge duct connection 1 The furnace discharge is designed to accept straight ductwork See Figure 5 1 Provide an airtight seal between the ductwork and the furnace Seams with cracks in the ductwork should be caulked and or taped and be of permanent type All duct connections MUST be airtight to prevent air le
133. ttom of the electrical junction box 4 Remove the screws holding the burner side access panel Attached to the panel are the burner retaining pins that align the burner 5 Slide the burner assembly out The pilot is attached to the burner assembly 6 Examine the burner and pilot assembly for cleanliness and or obstructions as necessary see Duct Furnace for cleaning instructions 7 Replace the burner assembly in reverse order In replacing the burner be certain that the rear burner slots are located properly on the burner retaining pins Do not force the burner side access panel it will not fit if the burner is not properly aligned 8 Reconnect the ignition cable and pilot gas supply line 9 Turn on the electric and gas supply Figure 48 4 Burner and Pilot Assembly Removal AIR SHUTTERS NOT SHOWN ARE LOCATED ON THE MANIFOLD PILOT ASSEMBLY IGNITION CABLE 48 5 562 8 SERVICE 8 TROUBLESHOOTING 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 A CAUTION Do not attempt to reuse any mechanical or electrical controllers which have been wet
134. ut 640 000 840 000 960 000 Blower Style Digit 16 Letter I J or K I J or K Max Temp Rise F 120 120 Min Temp Rise F 46 68 Max CFM 13000 Min CFM 4938 Ratings are shown for elevations up to 2000 ft For higher elevations the input rating should be reduced at the rate of 4 for each 1000 feet above sea level For Canada in elevations between 2000 and 4500 feet the unit must be derated to 90 of the rating listed above For Variable Air Movement Applications see page 17 26 5 562 8 GENERAL PERFORMANCE DATA Table 27 1 Air Temperature Rise Btu Hr Air Temperature Rise through Unit F Input Output 40 45 50 55 60 65 CFM 75 000 60 000 100 000 80 000 125 000 100 000 150 000 120 000 175 000 140 000 200 000 225 000 250 000 300 000 350 000 400 000 ir Temperature Rise through Unit F 65 70 75 80 85 CFM 500 000 400 000 5698 5291 600 000 480 000 6838 6349 700 000 560 000 7977 7407 800 000 640 000 9117 8466 840 000 11966 11111 960 000 13675 12698 Ratings are shown for elevations up to 2000 ft For higher elevations the input rating should be reduced at the rate of 4 for each 1000 feet above sea level For Canada in elevations between 2000 and 4500 feet the unit
135. uted or contaminated or foreign matter contained in the air or water utilized for heat exchanger condenser cooling or if the failure of the part is caused by improper air or water supply or improper or incorrect sizing of power supply APPLICABLE WARRANTY PERIOD TEN YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER WITHIN Heat Exchangers Gas Fired Units except PSH BSH OCCURS FIRST TEN YEARS FROM DATE OF RESALE BY BUYER OR ANY OTHER USER WITHIN TEN YEARS FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION OR WITHIN ONE HUNDRED TWENTY SIX MONTHS FROM DATE OF SHIPMENT FROM SELLER WHICHEVER Heat Exchangers Low Intensity Infrared Units Compressors Condensing Units for Cassettes FIVE YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER WITHIN FIVE YEARS FROM DATE OF RESALE BY BUYER OR ANY OTHER USER WITHIN FIVE YEARS FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION OR WITHIN SIXTY SIX MONTHS FROM DATE OF SHIPMENT FROM SELLER WHICHEVER OCCURS FIRST Burners Low Intensity Infrared Units Other TWO YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER WITHIN TWO YEARS FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION OR WITHIN THIRTY MONTHS FROM DATE OF SHIPMENT FROM SELLER WHICHEVER OCCURS FIRST Components excluding Heat Exchangers Coils Condensers Burners Sheet Metal Heat Exchangers Coils Indoor and Outdoor Duct Furnaces and Sy
136. vel and secure Gas burner properly located and aligned Blower and motor alignment okay Bearings aligned and tight on shaft bearing supports Electrical connections checked and secure Gas piping checked and tightened if necessary Any visible damage to unit Describe If damaged was the damage repaired Air inlet and discharge checked for obstructions Bearings checked for proper lubrication Filters in place and correct to direction of air flow Belt tension checked Electric supply to unit Volts Hz Phase Gas supply to unit Natural Propane Gas supply pressure to unit W C PSIG Inlet and or discharge dampers operating correctly Blower rotation correct Blower speed Hi Speed RPM Lo Speed RPM Motor speed Hi Speed RPM Lo Speed RPM s unit noisy Excessive vibration Motor voltage L1 V L2 V L3 V Motor amps L1 Amp L2 Amp L3 Amp High temperature limit control continuity checked 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 Gas input checked Input at maximum firing rate Btu Hr Input at minimum firing rate Btu Hr Gas piping checked for and free of leaks Has wiring been verified to match the unit wiring diagram Have all the modes of the sequence of operation been verified and tested What optional and or accessory control devices h
137. vided Two position Modulating and Floating Two position Damper Actuator A two position damper actuator is provided with Air Control options DA EA EQ and FA Digits 20 8 21 The two position damper actuator provides open closed operation of the fresh air damper When the damper is energized the fresh air damper is opened to 100 outside air in 75 seconds For units with a two position damper limiter the outside air percentage would be the set by the damper limiter See Two Position Damper Limiter below All two position damper actuators are spring return so when the damper is de energized the fresh air damper will spring closed All two position dampers include auxiliary switches one normally open and one normally closed that reverse when the damper actuator is at 85 rotation adjustable Two Position Damper Limiter The two position damper limiter is factory set to prevent the outside air damper from opening 100 The outside air percentage and the actuator end switch is set based on the unit order Field adjustment of the two position damper limiter is accomplished by the following 1 Determine the amount of damper rotation required Percentage of outside air 2 Locate the angle of rotation limiter on the actuator so that its edge lines up with the degree graduation on the actuator face which corresponds with the required rotation See Figure 21 1 which is shown at 50 rotation limit 3 Find the appropriat
138. was not provided with a time delay relay the blower starts at this time 3 Oncethe pilot is lit the flame sensor proves the pilot and stops the spark ignitor from sparking 4 The main gas valve is opened and the main burner is lit to 100 full fire 5 If the unit was provided with a time delay relay the blower starts after 30 to 45 seconds 6 The unit continues to operate until the thermostat is satisfied at which time both the main and pilot valves close 100 If the unit was not provided with a time delay relay the blower stops at this time 7 If the unit was provided with a time delay relay the blower stops after 30 to 45 seconds Two Stage Gas Controls Utilizes a two stage combination gas control an ignition control and a two stage low voltage thermostat The unit fires at 50 fire on low stage and 100 fire on high stage 1 The thermostat calls for low stage heat 2 The pilot valve opens and the spark ignitor sparks in an attempt to light the pilot If the unit was not provided with a time delay relay the blower starts at this time 3 Once the pilot is lit the flame sensor proves the pilot and stops the spark ignitor from sparking 4 The main gas valve is opened and the main burner is lit to 50 fire 5 Ifthe unit was provided with a time delay relay the blower starts after 30 to 45 seconds 6 If the temperature at the thermostat continues to fall the thermostat will call for high stage heat 7 Th
139. y ME 3 5 woel ANSI Z83 8 2006 CERTIFIED TO CAN CSA C22 2 NO 236 TEMPERATURE RISE RANGE o MAXIMUM EXTERNAL STATIC PRESSURE CSA 2 6 2006 APPROVED FOR USE IN MASSACHUSETTS IN WC evevarion DE rem _ 20 100 F Pression statique TERIER mmm 3 0 Ca ACCEPTED BY CITY ar ai Vo Eit tig a osa CATEGORY HORIZ VERT VENT CONNECTOR SIZE rap FOR INDOOR INSTALLATIONS ONLY SEULEMENT POUR INSTALLATION INT RIEURE L APPAREIL DE CHAUFFAGE NFG EST HOMOLOGUE POUR MONTAGE DANS UNE ENCEINTE ETANCHE SEULEMENT POUR EXT RIEUR INSTALLER DU COTE DE LA PRESSION POSITIVE OU VENTILATEUR POUR L INSTALLATION QUE SUIVE LES SYSTEMS REFRIGERANTS L INSTALLATION DANS LES HANGERS D AERONEFS DOIT CONFORHER AUX EXIGENCES DES AUTORITES COMPETENTES ET DANS LES GARAGES PUBLICS DOIT CONFORMER AUX CODES CAN 1 8149 INSTRUCTIONS D ALLUMAGE POUR UNITE EQUIPEE D UNE VEILLEUSE INTERMITTENTE R GLER LE THERMOSTAT SUR LE DEGR LE PLUS BAS TOURNER LA MOLETTE OU LE LEVIER DE COMMANDE DU GAZ SUR OFF ET ATTENDRE 5 TOURNER LA MOLETTE QU LE LEVIER DE COMHANDE DU GAZ SUR ON LA VETLLEUSE ET LE BR LEUR PRINCIPAL ALLUME RONT AUTOMATIQUEMENT QUAND LE THERMOSTAT LES DECLENCHERA POUR UNITE EQUIPEE 0 UNE VEILLEUSE PERMANENTE REGLER LE THERMOSTAT SUR LE DEGRE LE PLUS BAS TOURNER LA MOLETTE OU LE LEVIER DE COMMANDE DU GAZ SUR OFF ET ATTENDRE 5 TOURNER LA HOLETTE DE COMMANDE DU GAZ SOR PILOT OU TOURNER LE LEVIER DE COMMANDE SUR SET ET TOUT EN ALLUMANT LA

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