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1. 36 67 29 36 48 08 J Over Roof 12 67 N Vent Dia 2 200 200 4 Outlet Air I B E L E Duct 1 RRN Connection i 19 28 E F Height H Inside G INSIDE 24 00 P X i Inside K Width Inside I usi aaaamananan L o 7 65 10 26 921 i 5223 529 Eun 5 29 B r 8 n 24 00 34 27 Min approx Qty 4 Drill Locator Dimples for Inside 435 1 3 00 Field Drilled Electrical Conduit Return Air Duct Connection 150 L Entry Holes spaced 2 0 apart 116 98 Table 42 1 IBG ICG Indoor Gravity Vented Unit Dimensions All dimensions in inches Blower Type Qty of Dimensions Digit 16 Furnaces G H 75 All 1 2 100 125 All 1 2 150 175 All 1 2 200 225 All 1 2 1 3 4 250 300 E F or H 3 4 350 400 E F G orH 3 4 500 600 Gor H 3 4 700 800 GorH 3 4 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 42 AIR 5 565 2 DIMENSIONS UNIT Figure 43 1 IBG Indoor Gravity
2. Lf 9 MIN 9 EU STEEL ANGLE VENT TERMINATION SUPPORT BRACKET WHERE REQUIRED TEE WITH DRIP LEG AND CLEANOUT CAP 2 UNIT INSTALLATION Gas Connections A WARNING 1 All field gas piping must be pressure leak tested prior to operation Never use an open flame Use a soap solution or equivalent for testing 2 Gas pressure to appliance controls must never exceed 14 W C 1 2 psi 3 To reduce the opportunity for condensation the minimum Sea level input to the appliance as indicated on the serial plate must not be less than 5 below the rated input or 5 below the minimum rated input of dual rated units CAUTION Purging of air from gas supply line should be performed as described in ANSI Z223 1 latest edition National Fuel Gas Code or in Canada in CAN CGA B149 codes IMPORTANT To prevent premature heat exchanger failure the input to the appliance as indicated on the serial plate must not exceed the rated input by more than 5 1 Installation of piping must conform with local building codes or in the absence of local codes with the National Fuel Gas Code ANSI Z223 1 NFPA 54 Latest Edition In Canada installation must be in accordance with CAN CGA B149 1 for natural gas units and CAN CGA B149 2 for propane units 2 Piping to
3. Total static pressure should include external static pressure and accessory option static pressure from Tab 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 AIR 5 565 2 e 32 1 Unit internal resistance has 33 BLOWER PERFORMANCE DATA Table 34 1 Unit Performance Tables Total Static Pressure 030 975 10 1285 150 20 250 300 RPM RPM BHP RPM BHP RPM RPM BHP RPM BHP RPM BHP RPM Start 300 83 F 100 F 74 F 89 F 62 F 74 F 53 F 63 F 46 F 7 56 F 41 F 49 F 37 F 44 F 34 F 40 F Sao 9 83 F 100 F 2222 0 28 424 0 43 1123 2 67 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 I J K 46 F 56 F 37 F 44 F 31 F 37 F 26 F 32 F 23 F 28 F 20 F 24 F 100 96 F 74 F 85 F 65 F 74 F 58 F 66 F 52 F 59 F 350 400 G H 100 F Start 400 87 100 F 74 F 85 F 65 F 74 F 58 F 7 66 F 52 F 59 F 47 F 54 F 43 F 49 F 40 F 46 F
4. 2 Low Gas Pressure Switch OPT The low gas pressure switch is factory installed in the duct furnace above the gas train The switch monitors the gas pressure upstream of all the gas controls and shuts off the electric supply to the ignition controller and combination gas valve if low gas pressure is experienced This will shut off all gas flow to the burner The switch has an automatic reset so that if the gas pressure is interrupted and then is returned the Switch will automatically allow the unit to operate when gas conditions are returned to the allowable range of the pressure Switch The pressure switch range is 2 to 14 W C and should be set to insure that the minimum inlet gas pressure is available 6 W C for natural gas 11 W C for propane gas 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 Figure 20 3 Low or High Gas Pressure Switch the gas controls have been damaged by the high gas pressure and then reset the switch to
5. E A A mk oa Qty 2 BX82 Qty 2 BX82 Qty 2 B86 Qty 2 B86 B71 BX74 Qty 2 BX79 Qty 2 BX79 Qty 2 B83 Qty 2 B83 B77 E N 3H36622 oj o o mi 3H35128 Qty NIN SIUS ov olo t AIR 5 565 2 39 ELECTRICAL DATA MOTOR DATA Total Unit Amp Draw The total unit amp draw is a combination of the motor the control step down transformer and the power exhauster amp draw The control step down transformer includes damper actuators ignition controllers gas valves control relays amplifiers and motor starters Unit Amp Draw Table 40 1 Motor Amp Draw Tables 40 2 to 41 2 H ll Total Amp Draw Table 40 1 Unit Amps ah mor mpi Draw Power Exhauster Amp Draw Supply Voltage Digit 15 Transformer Model Size did I 00 1 2 4 75 175 200 400 500 800 840 960 3 A 115 60 1 1 3 1 4 2 4 4 8 7 2 208 60 1 0 72 i 1 4 Unit controls amp draw is included in master unit amp draw 230 60 1 0 65 1 8 Requires a 250 VA transformer 208 60 3 0 72 1 4 G Requires a 500 VA transformer 230 60 3 0 65 1 3 i i Requires a 750 VA transformer Requires a 1000 VA transformer 460 60 3 0 33 0 30 0 65 For Digits F 460V and G 575V amp draw shown is on 575 60 3 0 2
6. NOTE For units equipped with two stage or modulating gas controls only the high fire manifold pressure needs to be adjusted No adjustments to the low fire manifold pressure are necessary on these units Selection of the Proper High Altitude Kit All units installed at elevations greater than 2000 feet above sea level require a kit in addition to potential manifold pressure adjustment outlined in the previous step To determine the proper kit to use refer to Table 10 2 Table 10 3 shows the contents of the kit For more information refer to the latest revision of Modine Bulletin 75 530 Table 10 2 High Altitude Kit Selection Table Model Elevation Above Sea Level ft Size 2 001 5 500 5 501 6 500 6 501 7 500 IBG Item 67248 67248 75 350 Item 500 700 Code 67248 67248 67248 IBP 840 ICP 400 goo Hem 67248 68409 68411 Code 960 Applies to both installations in the U S and Canada Applies to both natural and propane gas Sizes 75 400 require a kit qty of 1 sizes 500 800 require a kit qty of 2 sizes 840 960 require a kit qty of 3 Table 10 3 High Altitude Kit Contents Kit Contents Pressure Switch High Altitude Conversion Label Installation Instructions If a unit is to be installed at higher elevations AND converted from natural gas to propane gas operation a propane conversion kit must be used in conjunction with the manifold pressure adjustment and high altitude kit lis
7. ODP 1 5 TE 5 ODP 1 ODP 1 TE 5 5 ODP 1 d ODP 1 TE 5 5 ODP HE 2 d ODP HE 2 TE HE 6 TE HE 6 ODP HE 2 f ODP HE 2 TE HE 6 TE HE 6 ODP HE 2 ODP HE 2 TE HE 6 TE HE 6 ODP HE 2 ODP HE 2 TE HE 6 TE HE 6 ODP HE 2 ODP HE 2 TE HE 6 TE HE 6 ODP HE 2 ODP HE 2 TE HE 6 TE HE 6 ODP HE 2 ODP HE 2 TE HE 6 TE HE 6 ODP HE 2 ODP HE 2 TE HE 6 TE HE 6 ODP HE 2 ODP HE 2 TE HE 6 TE HE 6 ODP 1 k ODP 1 TE 5 j TE 5 ODP 1 ODP 1 5 f TE 5 ODP 1 ODP 1 TE 5 5 ODP HE 2 ODP HE 2 TE HE 6 d TE HE 6 ODP HE 2 ODP HE 2 TE HE 6 f TE HE 6 ODP HE 2 ODP HE 2 TE HE 6 TE HE 6 ODP HE 2 ODP HE 2 TE HE 6 TE HE 6 ODP HE 2 ODP HE 2 TE HE 6 TE HE 6 ODP HE 2 ODP HE 2 TE HE 6 TE HE 6 ODP HE 2 ODP HE 2 TE HE 6 TE HE 6 ODP HE 2 ODP HE 2 TE HE 6 TE HE 6 ODP HE 2 ODP HE 2 TE HE 6 TE HE 6 208V 60Hz 3ph D 460V 60Hz 3ph F 230V 60Hz 3ph E 575V 60Hz 3ph G Motors rated 1hp and larger are inverter duty rated as standard Three phase motors do not ha
8. LJ K 100 F 1 66 Start 400 1 81 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 32 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 34 AIR 5 565 2 BLOWER PERFORMANCE DATA Table 35 1 Unit Performance Tables Total Static Pressure Inches W C 025 oso 075 100 125 150 200 250 300 Cru EE RPA SPP BHEISEM BHPIREM EHEIEEM EHE eat PIP eM 500 600 120 F 06 F Start 600 100 F 120 F 93 F 111 F 82 F 7 99 F 74 F 89 F 67 F 81 F 62 F 74 F 57 F 1 68 F 500 600 120 F Start 600 100 F 120 F H 93 F 111 F E 74 F 89 F 62 F 74 F 2 53 F 63 F 46 F 56 F End 500 41 F 49 F 3 1 44 F 10000 9 62 975 43 F 10 77 1011 40 F 12 66 1065 40 F 13 04 1075 500 600 62 F 74 F 53 F 63 F 46 F 56 F 41 F 49 F 44 F 10000 7 04 793
9. Morrison etc etc um 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 AIR 5 565 2 55 START UP CHECKLIST INDIRECT GAS FIRED HEATING EQUIPMENT Job Name Date Address Model No City amp State Order No Start Up Check List ALL ITEMS MUST BE CHECKED Serial No All shipping straps braces tie downs removed Unit installed level 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 Is unit noisy Excessive vibration Motor voltage L1 V L2 V L3 V Motor amps L1 _Amp L2_ Ampl3 Amp High temperature limit control continuity checked Burner
10. Max Temp Rise F 100 100 100 100 100 100 Min Temp Rise F 27 20 33 20 39 23 Max CFM 3450 4630 3350 5556 3350 5556 Min CFM Model Size Digits 4 6 Btu Hr Input 200 000 926 225 000 926 1111 1111 250 000 1296 1296 Btu Hr Output 160 000 180 000 200 000 Blower Style Digit 16 Letter EorF EorF GorH Max Temp Rise F Min Temp Rise F 85 95 100 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 GorH GorH Max Temp Rise F 100 100 100 Min Temp Rise F Max CFM 31 37 42 12000 5700 Min Model Size Digits 4 6 Btu Hr Input 500 000 600 000 2593 2963 700 000 Btu Hr Output 400 000 480 000 560 000 Blower Style Digit 16 Letter I J or K l J or K I J or K Max Temp Rise F 120 120 120 Min Temp Rise F 40 40 40 Max CFM Min CFM 2 Model Size Digits 4 6 Btu Hr Input 800 000 1 050 000 1 200 000 Btu Hr Output 640 000 840 000 960 000 Blower Style Digit 16 Letter I J orK I J or K I
11. 36 68 G 30 5 HEIGHT 24 00 43 23 E WIDTH 921 765 5 20 529 P 3 00 BOTTOM DRILL LOCATOR QTY 4 DRILL LOCATOR DIMPLES FOR DIMPLES FOR FIELD DRILLED FIELD DRILLED ELECTRICAL CONDUIT ENTRY HOLES SPACED 2 0 APART HOLES SPACED 2 0 APART ONLY ON ACCESS SIDE Table 45 1 IBP ICP Indoor Power Vented Unit Dimensions with Blower Type l J K or L All dimensions in inches Blower Type Qty of Dimensions Digit 16 Furnaces L N 250 300 I J or K 123 35 350 400 l J or K 123 35 500 600 I J K or L 156 76 700 800 1 J K or L 156 76 840 960 J K or L 185 99 Applies to units with Digit 16 L only AIR 5 565 2 45 DIMENSIONS BASE Figure 46 1 Unit Base Dimensions C To end of unit nH gt gt 0 63 5 0 75 Suspension Hanging Locations Typical 4 Corners E Inside Suspension Doint 24 00 Inside a Lifting Liftin i Doint Return Air gt bt Opening 145 la N Table 46 1 Indoor Power Vented Blower Package Units All dimensions in inches 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 1 J K or L 700 8
12. 43 F 10400 7 88 ES 288 11000 9 27 700 800 GorH 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 657 2 04 Start 800 104 F 119 F 86 99 731 65 F 74 F 845 6 30 888 58 F 66 F i Start 500 52 F 59 F 47 F 1 54 F 43 F 49 F 40 F 46 F 120 F 111 F 105 F 120 F 97 F 111 F 86 F 99 F 78 F 89 F 70 F 80 F 65 F 74 F 62 F 71 F 60 F 68 F 840 960 End 840 840 960 End 840 700 800 65 F 74 F i 58 F 66 52 F 59 F j 7 B 47 F 54 F I 47 F 54 F j j i i i 43 F 49 F End 700 40 I 1 10 E 41 E 14500 n 02 968 D A 994 x 21 1019 T 82 1045 Total static pressure should include external static pressure and accessory option static pressure from Table 32 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 AIR 5 565 2 35 BLOWER SHEAVE ASSEMBLY DATA Adjusting the Blower Drive Setting Based on the Sheave Arrang
13. Inside 7 65 21 kus L 34 27 Min approx Return Air Inside 4 35 Qty 4 Drill Locator Dimples for Duct Connection Field Drilled Electrical Conduit Entry Holes spaced 2 0 apart 152 84 Table 43 1 IBG ICG Indoor Gravity Vented Unit Dimensions with Blower Type I J K or L All dimensions in inches Blower Type Qty of Dimensions Digit 16 Furnaces L N 250 300 I J or K 27 13 30 00 123 35 350 400 I J or K 38 63 42 00 123 35 500 600 I J K or L 156 76 700 800 1 J K or L 156 76 840 960 I J K or L 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 AIR 5 565 2 DIMENSIONS UNIT Figure 44 1 IBP Indoor Power Vented Blower Package Unit Dimensions J OVER ROOF 30 07 6 VENT I CONNECTOR 23 07 HEIGHT x 43 23 C WIDTH 17 40 H pese QTY 4 DRILL LOCATOR DIMPLES FOR BOTTOM DRILL LOCATOR FIELD DRILLED ELECTRICAL CONDUIT DIMPLES FOR FIELD DRILLED ENTRY HOLES SPACED 2 0 APART ELECTRICAL CONDUIT ENTRY HOLES SPACED 2 0 APART 120 90 ONLY ON ACCESS SIDE 500 800 Model Shown 9 21 3 00 Figure
14. It is important that all grease oil flux and sealing compounds present from the installation be removed Figure 13 1 General Chilled Fluid Piping Air Vent ees Vent Plug Gate Valve Te e gt a Drain Plug Dirt Leg Union Cap Table 13 1 Cooling Coil Performance Limits Single Circuit Dual Circuit Max Cooling Max Area Max Area ft ft2 Tons Chilled Water Based on 550 feet per minute FPM coil face velocity Based on 95 F 75 F Entering Dry Bulb Wet Bulb Model Size 75 minimum CFM for DX Dual Circuit is 621 Model Size 100 minimum CFM for DX Dual Circuit is 745 AIR 5 565 2 13 START UP PROCEDURE Start Up Procedure IMPORTANT 1 To prevent premature heat exchanger failure observe heat exchanger tubes by looking at the heat exchanger through the field installed access openings in connecting ductwork in blower package units or the unit access doors in cooling package units If the bottom of the tubes become red while blower and duct furnace are in operation check to be sure the blower has been set to the proper rpm for the application Refer to page 16 for Blower Adjustments 2 Start up and adjustment procedures should be performed by a qualified service agency 1 Turn off power to the unit at the disco
15. 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 Excessive drafts Pilot orifice fitting leak Defective valve Loose wiring Defective pilot sensor Defective ignition controller Improper thermostat wiring Blocked vent safety switch tripped Too much primary air Main pressure set too high Orifice too large Insufficient primary air Dirty orifice Misaligned orifice Too much primary air Main pressure set too high Orifice too large Insufficient primary air Main pressure set too high Orifice too large Blocked vent Main pressure set too high Orifice too large Blocked vent AIR 5 565 2 Bowl 10 N 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 safe
16. RA Mod motor w 0 10 Vdc External Input GB FA amp RA Mod motor w 4 20 mA External Input GC FA amp RA Mod motor w Minimum Position GD FA amp RA Mod motor w Remote Position On Remote Panel GE FA amp RA Mod motor w 3 pos damper 10096 RA Variable 10096 OA GG FA amp RA Mod motor w Minimum Position amp Prop Temp Controller GH amp RA Mod motor w Remote Position amp Prop Temp Controller GJ amp RA Mod motor w FA Enthalpy Controller ASHRAE Cycle II GG with Warm up Stat GM ASHRAE Cycle II with Warm up Stat HP amp Floating motor w Space Pressure Controller JA Manual FA amp RA Dampers 22 Evaporative Cooling EC 0 None 23 Cooling Coil CC 0 None 1 Factory Installed Coil AIR 5 565 2 57 58 THIS PAGE INTENTIONALLY LEFT BLANK AIR 5 565 2 THIS PAGE INTENTIONALLY LEFT BLANK AIR 5 565 2 59 COMMERCIAL WARRANTY Seller warrants its products to be free from defects in material and workmanship EXCLUSIVE HOWEVER of failures attributable to the use of materials substituted under emergency conditions for materials normally employed This warranty covers replacement of any parts furnished from the factory of Seller but does not cover labor of any kind and materials not furnished by Seller or any charges for any such labor or materials whether such labor materials or charges thereon are due to replacement of parts adjustments
17. SECTION DUCT FURNACE DISCONNECT SWITCH WIRING AND CONNECTOR a ELECTRIC SUPPLY BLOWER COMPONENTS MUST BE SECTION CLEAR OF SERVICE DOORS DOOR 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 pages 42 45 for the electrical entry 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 AIR 5 565 2 11 UNIT INSTALLATION Cooling Coil Units Models with a cooling section can be provided with either a factory installed direct expansion DX evaporator a chilled fluid for use with water ethylene glycol or propylene glycol fluids coil or the coil can be field supplied and installed by others For units equipped with a factory installed cooling coil Digit 23 1 refer to
18. 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 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 or the unit access doors in blower package units If the bottom of the tubes become red while blower and du
19. condition should be observed periodically to assure trouble free operation To Adjust the Pilot Flame 1 Create a call for heat from the thermostat 2 Remove the cap from the pilot adjustment screw For location see the combination gas control literature supplied with unit 3 Adjust the pilot length by turning the screw in or out to achieve a soft steady flame 3 4 to 1 long and encompassing 3 8 1 2 of the tip of the thermocouple or flame sensing rod See Figure 14 1 4 Replace the cap from the pilot adjustment screw Figure 14 1 Correct Pilot Flame P 3 4 to 1 ae JU i 14 AIR 5 565 2 START UP PROCEDURE 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 15 1 To Adjust the Manifold Pressure 1 Move th
20. repairs or any other work done This warranty does not apply to any equipment which shall have been repaired or altered outside the factory of Seller in any way so as in the judgment of Seller to affect its stability nor which has been subjected to misuse negligence or operating conditions in excess of those for which such equipment was designed This warranty does not cover the effects of physical or chemical properties of water or steam or other liquids or gases used in the equipment BUYER AGREES THAT SELLER S WARRANTY OF ITS PRODUCTS TO BE FREE FROM DEFECT IN MATERIAL AND WORKMANSHIP AS LIMITED HEREIN SHALL BE IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES EITHER EXPRESS OR IMPLIED WHETHER ARISING FROM LAW COURSE OF DEALING USAGE OF TRADE OR OTHERWISE THERE ARE NO OTHER WARRANTIES INCLUDING WARRANTY OF MERCHANTABILITY OR FITNESS FOR PURPOSE WHICH EXTEND BEYOND THE PRODUCT DESCRIPTION CONFIRMED BY BUYER AND SELLER AS OF THE DATE OF FINAL AGREEMENT This warranty is void if the input to the product exceeds the rated input as indicated on the product serial plate by more than 5 on gas fired and oil fired units or if the product in the judgment of SELLER has been installed in a corrosive atmosphere or subjected to corrosive fluids or gases been subjected to misuse negligence accident excessive thermal shock excessive humidity physical damage impact abrasion unauthorized alterations or operation contrary to SELLER S p
21. 1 Determine the Sheave Arrangement To establish the Sheave Arrangement the motor frame size must be determined The Motor Data tables on pages 40 41 contain the motor frame size A Using the Supply Voltage 460V 60Hz SPh enter the correct Motor Data table Table 41 2 Using Model Nomenclature Digits 17 and 18 G1 determined in steps 13 and 14 find the motor frame size 182T Using the Motor Frame Size enter the Sheave Selection table for the selected blower determined by step 13 Table 37 2 Using the rpm calculated in step 12 870 rpm select the sheave range that contains the required rpm Find the intersection with the Motor Frame Size to determine the Sheave Selection For this example with a 182T frame with 870 rpm from Table 37 2 the Sheave Arrangement 1 Determine the Air Control The Air Control option is selected based on the required damper configuration The available damper selections are detailed on pages 22 23 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 following IBP400SMRLNAOF2GG1IDAOO Once the basic mo
22. 1 E 230 60 8 C 230 60 1 F 460 60 8 G 575 60 3 15 Transformer TR 1 40 VA 4 250 VA 2 75 VA 0 None 3 150 VA 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 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 2Hp M 1 2 Hp with Motor Starter C 3 4 Hp N 3 4 Hp with Motor Starter D 1Hp P 1 Hp with Motor Starter E 1 1 2 Hp Q 1 1 2 Hp with Motor Starter F 2Hp R 2 Hp Hp with Motor Starter G 3Hp S 3 Hp with Motor Starter H 5Hp T 5 Hp with Motor Starter 7 1 2 Hp W 7 1 2 Hp with Motor Starter J 10 Hp X 10 Hp with Motor Starter K 15 Hp Y 15 Hp with Motor Starter V 20Hp Z 20 Hp with Motor Starter 18 Motor Type MT 1 ODP 2 ODP High Eff 5 6 High Eff 19 Sheave Arrangement SA A See Sheave Tables 34 1 to 35 5 20 21 Air Control AC AA RA Opening BA FAOpening CA amp 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 GA FA amp
23. 1001 978 1265 1150 1561 1526 1858 1763 2147 Size 48 Digit 19 Sheave Assembly 3H35125B1 Digit 19 Sheave Assembly 3H35125B3 Digit 19 Sheave Assembly Digit 19 Sheave Assembly Digit 19 Sheave Assembly 56 3H35125B2 3H35125B4 3H35125B6 3H35125B8 3H35125B10 143 or 145 3H35125B5 RPM Range 3H35125B7 3H35125B9 3H35125B11 Motor Frame 656 1001 978 1265 1150 1561 1526 1858 1763 2147 Size 48 Digit 19 Sheave Assembly 3H35126B1 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 145 182 or 184 3H35126B5 36 3H35126B7 3H35126B8 3H35126B10 3H35126B11 3H35126B13 K 3H35126B14 AIR 5 565 2 BLOWER SHEAVE ASSEMBLY DATA Blower Sheave Assembly Numbers Con t Table 37 1 Digit 16 E or F 12 12 Blower Units Motor Frame Size 48 RPM Range 468 715 644 874 863 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 3H35127
24. 2 DUCT INSTALLATION VENTING Discharge Duct Connection refer to Figure 5 1 1 The furnace discharge is designed to accept straight ductwork Provide an airtight seal between the ductwork and the furnace to prevent leakage Seams with cracks in the ductwork should be caulked and or taped and be of permanent type 2 Provide removable access panels on the downstream side of the ductwork 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 3 Provide uniform air distribution over the heat exchanger Use turning vanes where required to obtain uniform air distribution see Figure 5 1 Figure 5 1 Recommended Field Installed Discharge Duct Configurations PROVIDE LEAK TIGHT ACCESS PANELS IN SIDE OF DISCHARGE DUCT FOR HEAT EXCHANGER INSPECTION TURNING VANES 3 MINIMUM 3 MAXIMUM 12 MINIMUM SIDE VIEW B 4 DIMENSION SHOULD NEVER LESS THAN 1 2 OF DIMENSION A PROVIDE LEAK TIGHT ACCESS PANELS IN SIDE OF DISCHARGE DUCT FOR HEAT EXCHANGER INSPECTION TURNING VANES 3 MAXIMUM PA 3 MINIMUM 4 12 MINIMUM TOP VIEW DIMENSION B SHOULD NEVER BE LESS THAN 1 2 OF DIMENSION A Blower Section and Cooling Cabinet Duct Con
25. 3 27 1511 3 86 1632 42 48 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 37 F 42 F 4000 2 40 1091 2 65 1157 2 91 1221 318 1284 3 46 1345 3 75 1404 4 35 1518 4 98 1628 33 F 37 F 4500 3 34 1211 3 62 1270 3 91 1329 4 21 1385 4 51 1441 4 82 1495 30 F 33 F 5000 4 52 1332 4 82 1387 200 225 G H 85 F 95 F 1750 0 20 425 0 33 546 0 48 653 74 F 83 F 2000 0 26 449 0 40 562 0 56 662 0 74 754 59 F 67 F 2500 0 42 507 0 58 603 0 75 692 0 94 774 1 16 851 1 38 925 49 F 56 F 3000 0 65 571 0 83 654 1 02 732 1 23 807 1 45 877 1 69 944 2 21 1071 42 F 48 F 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 37 42 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 33 F 37 F 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 30 33 5000 2 54 858 2 81 911 3 08 963 3 37 1014 3 67 1064 3 98 1112 4 62 1206 27 30 5500 3 32 933 3 61 982 3 91 1030 4 22 1077 4 54 1123 4 87 1168 25 F 28 F 6000 4 25 1009 4 57 1054 4 89 1099
26. 44 2 ICP Indoor Power Vented Cooling Package Unit Dimensions J OVER ROOF BOTTOM DRILL LOCATOR QTY 4 DRILL LOCATOR DIMPLES FOR DIMPLES FOR FIELD DRILLED FIELD DRILLED ELECTRICAL CONDUIT ENTRY HOLES SPACED 2 0 APART ELECTRICAL CONDUIT ENTRY HOLES SPACED 2 0 APART 116 98 ONLY ON ACCESS SIDE Table 44 1 IBP ICP Indoor Power Vented Unit Dimensions All dimensions in inches Blower Type Qty of Dimensions Digit 16 Furnaces G H 75 All 100 125 All 150 175 All 200 225 All 250 300 E F G orH 350 400 E F G orH 500 600 G or H 700 800 G or H NIN 44 AIR 5 565 2 DIMENSIONS UNIT Figure 45 1 IBP Indoor Power Vented Blower Package Unit Dimensions with Blower Type I J K or L J OVER ROOF 6 23 07 HEIGHT 24 00 4323 C WIDTH 921 897 10 26 APPROX 9 21 5 29 5 29 5 65 APPROX BOTTOM DRILL LOCATOR DIMPLES FOR FIELD DRILLEI ELECTRICAL CONDUIT ENTRY HOLES SPACED 2 0 APART ONLY ON ACCESS SIDE FIELD DRILLED ELECTRICAL CONDUIT QTY 4 DRILL LOCATOR DIMPLES FOR ENTRY HOLES SPACED 2 0 APART 156 76 500 800 Model Shown Figure 45 2 ICP Indoor Power Vented Cooling Package Unit Dimensions with Blower Type l J K or L J OVER ROOF
27. 622 0 56 735 0 72 837 34 F 42 F 2200 0 43 553 0 58 662 0 75 762 0 93 855 1 12 942 1 33 1025 28 F 36 F 2600 0 63 614 0 81 710 1 00 800 1 20 885 1 41 965 1 63 1042 25 F 31 F 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 22 F 27 F 3400 1 26 748 1 48 825 1 72 899 1 96 970 2 21 1038 2 47 1104 3 01 1229 3 58 1347 4 17 1459 End 100 20 25 3704 1 58 802 1 83 873 2 08 942 2 34 1008 2 60 1072 2 88 1135 3 45 1254 4 04 1367 4 67 1474 23 F 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 20 F 4630 293 969 3 23 1028 3 53 1085 3 84 1140 4 16 1194 4 48 1247 150 175 C D 1009 1179 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 Start 175 86 100 1296 0 27 793 0 37 937 0 47 1066 0 59 1184 0 71 1293 0 83 1395 1 09 1582 1 37 1752 1 66 1909 79 F 93 F 1400 0 32 832 0 42 970 0 54 1093 0 66 1208 0 78 1313 0 91 1412 1 18 1596 1 47 1763 1 78 1917 62 F 72 F 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 51 F 59 F 2200 1 00 1166 1 16 1264 1 32 1356 1
28. 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 or electronic modulation determined by the design engineer Main power supply voltage to unit Altitude at which unit is to be installed With this information a basic unit can be selected as shown in the following example 30 Selection Example Conditions Select an indirect fired 100 make up air unit to meet the following conditions 1 CFM at sea level 5 000 cfm 2 Outdoor design temp 10 F Indo
29. Sheave Assembly 3H35130B3 Digit 19 Sheave Assembly 3H35130B5 Digit 19 5 Assembly 3H35130B2 3H35130B4 3H35130B6 3H35130B13 3H35130B15 3H35130B17 3H35130B19 Motor Frame Size 143 or 145 3H35130B14 3H35130B16 3H35130B18 RPM Range 3H35130B20 3H35129B21 626 765 765 901 901 1059 995 1161 1101 1285 3H36622B1 Digit 19 Sheave Assembly 3H36622B3 Digit 19 Sheave Assembly Digit 19 5 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 AIR 5 565 2 3H36622B17 3H36622B22 3H36622B26 37 BLOWER SHEAVE ASSEMBLY DATA Table 38 1 Blower Sheave Assembly Settings Turns Open Sheave Assembly I 2 2 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
30. The power exhauster pre purge time delay relay then closes after 20 to 40 seconds and energizes the gas control circuit 3 The pilot valve opens and the spark igniter sparks in an attempt to light the pilot If the unit was not provided with a time delay relay the blower starts 4 Once the pilot is lit the flame sensor proves the pilot and stops the spark igniter from sparking 5 The main gas valve is opened and the main burner is controlled as follows a Single Stage Units The main burner is lit to 100 full fire b Two Stage Units The main burner is lit to 5096 fire If the temperature at the thermostat continues to fall the thermostat will call for high stage heat and the main burner is lit to 100 full fire c Modulating Thermostat Room or Duct The main gas valve is opened 10096 and the burner firing rate is modulated between 40 and 100 full fire A resistance signal 8000 to 12000 ohms in the thermostat is converted 6 by the modulating amplifier to an inverted DC voltage OVDC for high fire to 12 VDC for low fire The output voltage is applied to the modulating gas valve to control the gas flow to the main burner The modulating valve is modulated open or closed based on the voltage from the amplifier less gas flow required higher voltage more gas flow required lower voltage Note When modulating duct sensing is utilized a room override thermostat can be added When the room override calls for heat t
31. Vented Blower Package Unit Dimensions with Blower Type I J K or L 3322 47 36 36 68 J Over Roof Y _ nNr 2 00 u 3 86 X Blower Hat nn go N Vent Dia ee sss I et y er E 3 3 00 w 2 32 i l 34 00 gt T3400 N 2 23 07 Height Outside Ik 24 00 G INSIDE 24 00 C Width Outside Inside SS 42 37 i Z M MORE Fresh Air 2 a Duct Connection Or Qr t 7 Nath SG fh u 1026 905 921 oe YY 9 21 529 EXE l 1 vierte epp pt sc Ig 2 08 3 00 Lol 5 65 Min approx Qty 4 Drill Locator Dimples for inside 4 35 Field Drilled Electrical Conduit Return Air 1 50 k Entry Holes spaced 2 0 apart Duct Connection 5 500 800 Model Shown Figure 43 2 ICG Indoor Gravity Vented Cooling Package Unit Dimensions with Blower Type J K or L 36 67 29 36 47 86 36 68 J Over Roof 12 67 L N Vent Dia p 2 00 2 32 Outlet Air Duct 1 Fresh Air Connection M Duct Connection 28 00 Height 00 24 00 43 42 37 inser ide G NSDE naq E Width
32. allow the unit to operate when gas conditions are returned to the allowable range of the pressure switch The pressure switch range is 2 to 16 W C and should be set to insure that the maximum manifold gas pressure is not exceeded 3 5 W C for natural gas 10 W C for propane gas 5 Timed Freeze Protection OPT The timed freeze protection system is factory installed in the duct furnace electrical junction box with the sensor 30 75 F adjustable factory installed in the discharge air stream On initial start up the timed delay in the system allows the unit to go through the normal ignition sequence The timed delay is a manual reset switch and adjustable for 1 10 minutes In the event that the unit fails to fire after this period the discharge air sensor will sense the cold air and will shut down the entire unit Figure 20 4 Timed Freeze Protection Module 60 o T 35 30975 2 0 WI 55 1 G O 4 UD 6 50 5117 B Owe L65 44 8 TIME Qi sg 40 9 MIN o Ty cm H 1 mmo Q 0 Om Ow OW Ows O ERIE o c nei N L L 6 Ignition Controller STD The ignition controller is factory installed in the duct furnace electrical junction box with the spark ignitor and sensor located on the burner For both natura
33. amp 960 75 75 000 Btu Hr Input 350 350 000 Btu Hr Input 100 100 000 Btu Hr Input 400 400 000 Btu Hr Input 125 125 000 Btu Hr Input 500 500 000 Btu Hr Input 150 150 000 Btu Hr Input 600 600 000 Btu Hr Input 175 175 000 Btu Hr Input 700 700 000 Btu Hr Input 200 200 000 Btu Hr Input 800 800 000 Btu Hr Input 225 225 000 Btu Hr Input 840 1 050 000 Btu Hr Input 250 250 000 Btu Hr Input 960 1 200 000 Btu Hr Input 300 300 000 Btu Hr Input 7 Heat Exchanger Burner Drip Pan Material HE A Aluminized Steel S 409 Stainless Steel Heat Exchanger Burner T 409 Stainless Steel Heat Exchanger Burner Drip Pan 8 Development Sequence Designation DS F Single Stage M 2 stage or Modulating 9 Access Side AS R Right Hand L Left hand 10 Air Temperature Rise ATR H High 60 100 F 11 Gas Type GT N Natural with ignition controller P Propane with ignition controller 12 Gas Valve GV 1 Single Stage 6 Electronic Modulation Slave 2 Two Stage 7 Electronic Modulation 0 10 Vdc 4 Electronic Modulation External Input 5 Electronic Modulation Master 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 D 208 60 3 B 208 60
34. 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 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 34 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 open drip proof motor will be used so the Motor Type
35. feet The following instructions are for units that will be installed over 2 000 feet elevation If this does not apply you may skip ahead to the Electrical Connections section on page 11 Manifold Pressure Adjustment The unit manifold pressure is factory set for operation at elevations up to 2000 feet as follows For Natural Gas units 3 5 W C based on a gas heating value of 1 050 BTU ft3 For Propane Gas units 10 0 W C based on a gas heating value of 2 500 BTU ft3 For higher elevations some utility companies may derate the BTU content heating value of the gas provided at altitude to a lower value to allow certain heating appliances to be used with no manifold pressure adjustments For this reason it is necessary that the supplying utility be contacted for detailed information about the gas type and BTU content heating value before operating any heater Table 10 1 shows the standard derated heating values of natural and propane gases at various elevations Table 10 1 Gas Heating Values at Altitude Btu ft 2 0 2 000 2 001 3 000 3 001 4 000 4 001 4 500 4 501 5 000 5 001 6 000 6 001 7 000 7 001 8 000 8 001 9 000 9 001 10 000 Values shown are for 3 5 W C manifold pressure for Natural Gas and 10 0 W C for Propane Gas If the local utility supplies gas with a different Btu ft value use Equation 10 1 to calculate the required manifold pressure Gas heating values
36. life The vent pipe must not pass through an unheated space or interior part of an open chimney unless the vent pipe is insulated Where the vent pipe may be exposed to extreme cold or come into contact with snow or ice the entire vent must be insulated or double wall includes outdoors It is preferred that the double wall vent is one continuous piece but a joint is allowed outside the building The heater system shall be checked at least once a year by a qualified service technician Additional Requirements for Horizontally Vented Category III Units Model IBP ICP units only 1 Seal the joints with a metallic tape or silastic suitable for temperatures up to 350 F 3M tapes 433 or 363 are acceptable Wrap tape two full turns around the vent pipe 2 Refer to Table 7 1 for total minimum and maximum vent lengths making the vent system as straight as possible The equivalent length of a 90 elbow is 5 feet for 4 diameter and 7 feet for 6 diameter Table 7 1 Horizontal Category III Vent Sizing Requirements 2 Model Vent Connector Minimum Vent Maximum Vent Size Diameter Pipe Diameter Length 75 4 4 48 100 175 200 225 250 300 500 600 350 400 800 960 Unit can be vented with 5 diameter pipe if a 6 to 5 reducer is used Otherwise use 6 pipe Per furnace 3 The vent terminal must be Modine part number 5H072285 0001 Item Code 27866 for 4 vent pipe 5H072285 0004 Item Code 2
37. light off Low Fire Does entire burner light off Hi Fire Burner pressure reading 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 have been set Device Setting __ VF psi Inches W C etc Device Setting __ ___ F psi Inches W C etc Device Setting __ F psi Inches W C etc ONOaARWN Customer Owner instructed in operation and maintenance of unit Yes No Name of Person s Instructed Comments Start Up Company Name Phone Signature Date 56 AIR 5 565 2 MODEL NOMENCLATURE FOR SYSTEM UNITS Indoor Duct Furnace Make Up Air Unit Model Nomenclature 8 9 10 11 2 13 14 15 16 17 18 19 120 21 22 23 DS AS ATR GT GV SS SV TR BB HP MT SA AC EC CC 1 Product Type PT Indoor HVAC Unit Unit Configuration UC Furnace Blower Package Furnace amp Blower Cooling Package Furnace Blower amp Cooling O DU TN 3 Venting V G Gravity P Power 4 5 6 Furnace Input Rating MBH Output on 840
38. locating units it is important to consider that the exhaust vent piping must be connected to the outside atmosphere 8 In garages or other sections of aircraft hangars such as offices and shops that communicate with areas used for servicing or storage keep the bottom of the unit at least 7 above the floor unless the unit is properly guarded to provide user protection from moving parts In parking garages the unit must be installed in accordance with the standard for parking structures ANSI NFPA 88 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 notinstall units in locations where gas ignition system is exposed to water spray rain or dripping water AIR 5 565 2 Figure 3 1 Combustible Material and Service Clearances Access Slide o Model IBP ICP Model IBGACG minimum clearance to combustible material is required from the vent collar Table 3 2 Combustible Material Clearances Access Side Non Access A Side B Model Size All 75 thru 175 6 12 4 2 3 200 thru 960 6 12 2 2 3 Table 3 3 Recommended Service Clearances Acce
39. or electrical controllers which have been wet Replace defective controller IMPORTANT To check most of the Possible Remedies in the troubleshooting guide listed in Table 51 1 refer to the applicable sections of the manual 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 oft
40. 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 2 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 blower RPM refer to Blower Adjustments 26 Filters OPT When fi
41. should the discharge air temperature become excessive See Figure 19 1 indicator 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 Lifting Flame Condition 00000000 Figure 52 2 Figure 52 3 Floating Flame Condition Flame Rollout Appearance wx BOSS gt Wu TOE A 52 AIR 5 565 2 SERVICE amp TROUBLESHOOTING Blocked Vent Safety Switch Figure 53 1 Blocked Vent Safety Switch Location A manual reset blocked vent safety switch is supplied on all Model IBG ICG units and is designed to prevent operation of the main burner in the event there is spillage of flue products into the space This spillage may occur due to a restricted vent inadequate vent draw uninsulated vent pipe in cold ambient long vent runs excessive vent diameter restrictive vent terminal negative pressure within space etc After the cause of the spillage has been corrected depressing the button of the blocked vent safety switch found on top of the unit may reset the switch See Figu
42. shown are derated 4 per 1 000 of elevation 10 between 2 000 and 4 500 elevation in Canada in accordance with ANSI Z223 1 and CSA B149 respectively 945 Btu ft for Canada amp 2 250 Btu ft for Canada When installed at altitudes above 2 000 a pressure switch may need to be changed Refer to Tables 10 2 and 10 3 to determine if a switch change is required If the utility is supplying gas with heating values SAME as shown in Table 10 1 the manifold pressure should remain set to 3 5 W C for natural gas and 10 0 W C for propane gas and you may proceed to the section on this page titled Selection of the Proper High Altitude Kit If the utility is supplying gas with heating values DIFFERENT than shown in Table 10 1 use Equation 10 1 to determine the appropriate manifold pressure for the elevation and gas heating value being supplied Note what that value is as it will be needed later for Start Up Proceed to the section on this page titled Selection of the Proper High Altitude Kit Equation 10 1 Manifold Pressure for Gas Heating Values Different Than Shown in Table 10 1 TBL MP Erg x MP ACT Where EV Manifold Pressure W C at installed elevation BTUTg BTU ff content of gas from Table 10 1 BTUACT BTU ft content of gas obtained from the utility company MPs Manifold Pressure W C at Sea Level use 3 5 W C for natural gas and 10 0 W C for propane
43. 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 Figure 25 3 Proportional Temperature Controller 43 Warm Up Stat OPT A warm up stat is provided with Air Control options GK or GM 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 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 f
44. 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 12 AIR 5 565 2 UNIT INSTALLATION 9 Failure to obtain a high vacuum is indicative of a great deal of moisture or a small leak Break the vacuum with a charge of dry nitrogen or other suitable gas and recheck for leaks soapy water works well If no leaks are found continue vacuuming the coil until the desired vacuum is reached 10 All field piping must be self supporting Chilled Fluid Piping To prevent noise and coil damage from water hammer an air vent is necessary to bleed off the accumulated air in the System The vent should be located on the top of the inlet manifold where the air collects This vent should be opened twice a year The outlet manifold should have a drain installed on the bottom to allow for periodic flushing of the system to remove sediments and corrosion products from the cooling coil This drain should be opened to allow some fluid to drain twice a year Check coloration and viscosity of the effluent for indications of corrosion i
45. unit the damper is factory installed in the blower section The return air damper is used as an air balancing damper so low leak Class III leakage resistance less than 40 CFM ft at 1 W C dampers with self 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 GG GH GK or GM Digits 20 amp 21 and factory installed in the blower section The sensor provides the mixed air temperature signal to the A350P Proportional Temperature Controller which is mounted in the electrical section 35 Motor and Blower Vibration Isolation STD 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 Figure 24 1 Blower Motor Vibration Isolation BLOWER SUPPORT BLOWER SUPPORT RAIL NEOPRENE VIBRATION ISOLATOR 36 Blower Support STD The blow
46. 0 556 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 79 700 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 699 1800 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 56 F 1000 0 29 917 0 39 1062 0 50 1192 0 60 1310 0 72 1419 0 83 1522 1 07 1709 1 32 1879 46 F 1200 0 45 1042 0 57 1171 0 69 1289 0 82 1397 0 94 1499 1 08 1595 1 35 1773 40 F 1400 0 66 1173 0 80 1288 0 94 1395 1 08 1495 1 23 1589 1 38 1680 5 1600 0 93 1308 1 09 1412 1 25 1509 1 42 1601 31 F 1800 1 28 1445 1 46 1539 75 69 F 800 0 15 795 0 21 960 56 F 1000 0 20 822 0 28 975 0 36 1112 46 F 1200 0 19 705 0 27 862 0 35 1003 0 44 1131 0 54 1250 0 65 1361 40 F 1400 0 27 770 36 00 912 0 45 1041 0 55 1161 0 66 1273 0 77 1377 1 00 1572 35 F 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 31 F 1800 0 49 912 0 60 1030 0 72 1139 0 84 1244 0 96 1343 1 09 1437 1 36 1613 1 65 1
47. 0 00 0 03 0 01 1000 0 02 0 02 0 03 0 04 0 04 0 12 0 01 0 05 0 01 1500 0 03 0 04 0 05 0 07 0 08 0 23 0 02 0 07 0 02 2000 0 05 0 06 0 07 0 10 0 15 0 36 0 04 0 10 0 03 2500 0 07 0 08 0 10 0 14 0 23 0 53 0 07 0 13 0 04 3000 0 09 0 11 0 13 0 19 0 34 0 73 0 11 0 16 0 05 3500 0 11 0 13 0 16 0 24 0 46 0 97 0 15 0 18 0 07 4000 0 14 0 16 0 20 0 30 0 60 1 28 0 19 0 22 0 09 4500 0 17 0 20 0 25 0 37 0 25 0 25 0 1 4630 0 17 021 0 26 0 38 4000 Max CFM for Evap 0 26 0 26 0 11 1111 0 01 0 02 0 03 0 04 0 03 0 09 0 02 0 02 0 01 1500 0 02 0 03 0 04 0 05 0 05 0 15 0 02 0 03 0 01 2000 0 03 0 04 0 06 0 08 0 09 0 24 0 04 0 05 0 02 2500 0 05 0 06 0 09 0 11 0 14 0 34 0 05 0 08 0 02 3000 0 06 0 08 0 1 0 15 0 20 0 46 0 07 0 10 0 04 3500 0 08 0 1 0 14 0 18 0 27 0 61 0 10 0 14 0 05 4000 0 1 0 13 0 18 0 23 0 35 0 77 0 13 0 18 0 06 4500 0 13 0 16 0 21 0 27 0 45 0 95 0 17 0 22 0 08 5000 0 16 0 19 0 25 0 32 0 55 1 15 0 21 0 27 0 10 5200 0 17 0 21 0 27 0 34 0 60 1 23 0 23 0 29 0 1 5556 0 19 0 23 0 30 0 38 4000 Max CFM for Eva 0 26 0 33 0 13 1481 0 01 0 02 0 03 0 03 0 04 0 12 0 02 0 03 0 01 2000 0 01 0 02 0 04 0 04 0 07 0 19 0 03 0 05 0 01 2500 0 02 0 04 0 05 0 06 0 10 0 27 0 04 0 08 0 02 3000 0 03 0 05 0 07 0 08 0 15 0 36 0 06 0 10 0 04 3500 0 03 0 06 0 09 0 10 0 20 0 47 0 09 0 14 0 05 4000 0 05 0 08 0 1 0 12 0 27 0 60 0 11 0 18 0 06 4500 0 06 0 10 0 18 0 15 0 34 0 73 0 14 0 22 0 08 5000 0 07 0 1 0 16 0 18 0 42 0 89 0 18 0 27 0 10 5500 0 09 0 14 0 19 0 21 0 50 1 05 0 21 0 32 0 12
48. 00 G or H 700 800 I J K or L 840 960 I J K or L Table 46 2 Indoor Power Vented Cooling Package Units All dimensions in inches Dimensions Blower Type Digit 16 75 All 100 125 All 150 175 All 200 225 All 250 300 E F or H 250 300 I J or K 350 400 E F G or H 350 400 l J or K 46 AIR 5 565 2 DIMENSIONS COOLING COILS Figure 47 1 DX Coil Drawing All dimensions in inches Airflow Direction E ns Coil for Right Hand Units Digit 9 R Headers on opposite side for Left Hand Units FRONT VIEW RR 1 5 4 Rows 2 314 6 W 7 5 6 7 5 10 TOP VIEW L lt 1 5 15 gt 765 gt W lt A Distributor Inlet Liquid 7 Line Connection s Second Inlet on Dual Circuit Coils a SIDE VIEW Airflow Direction Suction Line Connections in direction of airflow Second Inlet on Dual Circuit Coils Table 47 1 DX Coil Dimensions Model Size Cooling MBH FH H 75 All S 1 5 All 24 31 24 27 34 30 Below 185 MBH 100 125 1 5 150 175 27 5 30 5 27 5 30 5 1 5 30 200 225 185 MBH amp Up 27 34 5 Below 185 MBH 250 300 185 MBH amp Up Below 185 MBH 185 MBH amp Up Single Circuit DX coils have 1 each Suction Line and Liquid Lines Refer to A
49. 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 Start 225 89 100 1667 0 48 943 0 61 1078 0 75 1198 0 88 1309 1 03 1411 1 17 1507 1 47 1682 1 77 1842 2 09 1988 85 95 1750 0 54 975 0 68 1106 0 82 1224 0 96 1332 1 11 1433 1 26 1527 1 57 1700 1 88 1857 2 21 2003 74 F 83 F 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 66 F 74 F 2250 1 04 1181 1 21 1291 1 39 1393 1 57 1488 1 75 1577 1 94 1663 2 31 1822 2 69 1969 59 F 67 F 2500 1 38 1288 1 57 1389 1 77 1484 1 97 1573 217 1658 2 37 1739 2 78 1892 54 F 61 F 2750 1 79 1396 2 00 1490 2 22 1579 2 44 1663 2 66 1743 2 88 1820 49 F 56 F 3000 2 28 1506 2 51 1593 2 75 1677 2 98 1756 200 225 85 F 95 F 1750 0 29 594 0 43 723 0 58 838 0 75 944 0 94 1042 1 14 1134 1 58 1303 2 07 1458 2 60 1600 174 F 83 F 2000 0 40 642 0 54 759 0 71 866 0 88 966 1 08 1058 1 28 1146 1 74 1309 2 23 1458 2 78 1595 59 F 67 F 2500 0 68 746 0 85 845 1 04 938 1 23 1025 1 45 1108 1 67 1188 2 15 1337 2 67 1475 3 24 1604 49 F 56 F 3000 1 09 857 1 29 942 1 50 1024 1 72 1101 1 95 1176 2 19 1248 2 71 1384
50. 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 38 AIR 5 565 2 BLOWER SHEAVE ASSEMBLY DATA Table 39 1 Blower Sheave Assembly Components Sheave Assembly Motor Sheave Blower Sheave Sheave Assembly Motor Sheave Blower Sheave Browning Browning i i Belt in Prefix Suffix in Pitch Dia Pitch Dia Pitch Dia Pitch Dia Prefix Suffix Belt Bore in in 3H35125 cjoj jojo 2ljo m cioj J ojo in o m ak o o 3H35129 alfa Er _ 3H35126 N E o Qty 2 B74 Qty 2 B74 Qty 2 B78 Qty 2 B78 Qty 2 B77 Qty 2 B77 Qty 2 B82 Qty 2 B82 Qty 2 B79 Qty 2 B79 Qty 2 B77 Qty 2 B77 Qty 2 B75 Qty 2 B75 3H35130 RE RE RE RE REI REL o N 3H35127 k o
51. 49 1444 1 66 1529 1 84 1610 2 20 1762 2 57 1906 2 96 2041 43 50 2600 1 58 1344 1 76 1429 1 95 1510 2 14 1589 2 34 1664 2 54 1737 2 95 1877 372 43 3000 2 35 1526 2 57 1600 2 78 1673 3 00 1743 150 175 86 F 100 F 1296 0 25 609 0 37 734 79 F 93 F 1400 0 17 474 0 28 615 0 40 737 62 F 72 F 1800 0 28 526 0 41 650 0 55 760 0 70 859 0 85 952 51 F 59 F 2200 0 44 588 0 59 697 0 75 796 0 91 887 1 09 972 1 27 1052 1 67 1201 43 F 50 F 2600 0 67 657 0 83 753 1 01 842 1 19 925 1 39 1004 1 59 1078 2 02 1218 2 47 1348 2 96 1469 37 F 43 F 3000 0 96 729 1 15 815 1 35 895 1 55 972 1 76 1044 1 98 1114 2 45 1245 2 94 1368 3 45 1483 33 F 38 F 3400 1 35 804 1 55 881 1 77 955 2 00 1025 223 1092 2 47 1157 2 96 1280 3 49 1396 4 03 1505 29 F 34 F 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 26 31 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 24 28 4700 3 80 1058 3 58 1116 3 87 1172 4 16 1227 4 46 1281 4 76 1333 21 F 25 F 5200 4 40 1158 4 71 1212 200 225 c p 100 FM13 F
52. 6 primary line side of required step down transformer Table 40 2 Motor Data Table 40 3 Motor Data Supply Motor Size Motor Type Full Load Frame Efficiency Supply Motor Size Motor Type Full Load NEMA Efficiency Voltage pigit 17 Digit 18 6 Amp Draw Size Voltage Digit 17 Digit 18 Amp Draw Frame Size Digit 14 Digit 14 115V 60Hz 1ph A 208V 60Hz 1ph B 230V 60Hz 1ph C Single phase motors are not rated for use with a variable frequency drive Motors rated below 1hp have integral thermal overload protection Motors rated 1hp and larger require the use of a motor starter for overload protection Motor Sizes Digit 17 A through H do not include a motor starter D through H require a motor starter by others All others include a motor starter ODP Open Drip Proof TE Totally Enclosed Motor manufacturers typically do not list efficiency for single phase motors 40 AIR 5 565 2 MOTOR DATA Table 41 1 Motor Data 2 Table 41 2 Motor Data Ve Motor Size Motor Type Full Load NEMA Efficiency ie Motor Size Motor Type Full Load NEMA Frame Efficiency Digit 14 Digit 17 OG Digit 18 6 Amp Draw Frame Size Digit 14 Digit 17 Digit 18 Amp Draw Size ODP 1
53. 6000 0 11 0 16 0 22 0 25 0 60 128 0 26 0 38 0 14 6500 0 13 0 18 0 25 0 28 5200 Max CFM for Evap 0 30 0 45 0 16 1852 0 03 0 02 0 05 0 05 0 05 0 15 0 02 0 07 0 02 2000 0 03 0 03 0 05 0 06 0 06 0 17 0 02 0 08 0 02 2500 0 04 0 04 0 07 0 09 0 09 0 24 0 03 0 09 0 03 3000 0 05 0 06 0 10 0 11 0 18 0 32 0 04 0 12 0 04 3500 0 07 0 08 0 12 0 15 0 17 0 41 0 06 0 14 0 06 4000 0 08 0 10 0 15 0 18 0 23 0 52 0 08 0 16 0 07 4500 0 10 0 13 0 18 0 22 0 29 0 64 0 10 0 19 0 09 5500 0 14 0 19 0 25 0 81 0 43 0 91 0 15 0 25 0 13 6500 0 19 0 26 0 34 0 42 0 60 1 28 0 21 0 81 0 18 7250 0 23 0 32 0 41 0 51 6000 Max CFM for Eva 0 27 0 37 0 23 1925 0 02 0 01 0 03 0 03 0 02 0 08 0 02 0 07 0 02 3000 0 03 0 03 0 05 0 05 0 05 0 15 0 04 0 12 0 04 4000 0 05 0 05 0 08 0 09 0 09 0 23 0 08 0 16 0 07 5000 0 08 0 08 0 1 0 12 0 14 0 34 0 12 0 22 0 1 6000 0 1 0 1 0 15 0 16 0 20 0 46 0 18 0 28 0 16 7000 0 15 0 15 0 19 0 21 0 27 0 61 0 25 0 35 0 21 8000 0 19 0 20 0 24 0 27 0 35 0 77 0 33 0 42 0 28 9000 0 24 0 25 0 30 0 33 0 45 0 95 0 42 0 51 0 35 10400 0 32 0 33 0 38 0 42 0 60 1 23 0 57 0 64 0 47 1111 0 36 0 38 0 43 0 47 10400 Max CFM for 0 66 0 71 0 53 2593 0 02 0 02 0 04 0 04 0 05 0 16 0 02 0 03 0 01 3000 0 02 0 02 0 05 0 05 0 07 0 20 0 03 0 04 0 01 3500 0 03 0 03 0 06 0 06 0 10 0 25 0 04 0 05 0 01 4000 0 03 0 04 0 07 0 08 0 13 0 32 0 05 0 07 0 01 4500 0 04 0 05 0 09 0 10 0 16 0 39 0 06 0 09 0 02 5000 0 05 0 06 0 10 0 12 0 20 0 47 0 07 0 1 0 02 5500 0 06 0 07 0 12 0 14 0 24 0 55 0 0
54. 777 1 94 1931 28 F 2000 0 65 987 0 77 1095 0 90 1197 1 03 1295 1 16 1388 1 30 1477 1 59 1645 1 89 1802 2 20 1950 24 F 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 20 F 2778 1 59 1296 1 75 1377 1 92 1456 2 09 1532 2 26 1606 2 44 1679 2 80 1818 100 125 100 741 0 15 0 23 962 0 30 1093 0 38 1212 0 47 1320 0 60 1514 0 86 1686 1 07 1840 Start 125 80 F 100 F 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 62 F 77 F 1200 0 22 758 0 31 916 0 41 1052 0 52 1173 0 62 1282 0 74 1384 0 97 1568 1 22 1733 1 48 1884 53 F 66 F 1400 0 30 828 0 41 975 0 53 1103 0 64 1218 0 76 1323 0 89 1422 1 15 1600 1 42 1762 1 70 1910 41 F 51 F 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 34 F 42 F 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 28 F 36 F 2600 1 45 1315 1 65 1410 1 85 1500 2 05 1585 2 25 1666 2 46 1744 1 35 1638 25 F 31 F 3000 2 16 1489 2 39 1573 2 61 1654 2 84 1731 100 125 E F 41 51 1800 0 28 497 0 41
55. 7867 for 5 vent pipe 5H072285 0002 Item Code 27868 for 6 vent pipe A Gary Steel 1092 cap is an acceptable alternate 4 The vent must extend a minimum of 12 beyond the exterior wall surface and must be supported as shown in Figure 7 1 Precautions must be taken to prevent degradation of building materials by flue products 5 The vent system shall terminate at least 3 feet above any forced air inlet except direct vent units located within 10 feet and at least 4 feet below 4 feet horizontally from or 1 foot above any door window or gravity air inlet into any building The bottom of the vent terminal shall be located above the snow line or at least 1 foot above grade whichever is greater When located adjacent to public walkways the vent system shall terminate not less than 7 feet above grade 6 The venting system must be exclusive to a single unit and no other unit is allowed to be vented into it AIR 5 565 2 7 Horizontally vented units must use single wall vent pipe although one continuous section of double wall vent pipe may be used with the vent system Under no circumstances should two sections of double wall vent pipe be joined together within one vent system due to the inability to verify complete seal of inner pipes Figure 7 1 IBP ICP Horizontal Venting USE LISTED THIMBLE THROUGH WALL SPECIFIED SLOPE PIPE DOWN 1 4 PER FOOT TERMINAL TOWARD DRIP LEG
56. 9 0 14 0 03 6000 0 06 0 08 0 14 0 17 0 29 0 64 0 10 0 17 0 04 6500 0 07 0 10 0 16 0 19 0 34 0 74 0 12 0 20 0 04 7000 0 08 0 11 0 18 0 22 0 39 0 85 0 14 0 23 0 05 2503 0 02 0 01 0 02 0 02 0 08 0 11 0 02 0 03 0 01 3000 0 02 0 02 0 02 0 03 0 04 0 14 0 08 0 04 0 01 4000 0 03 0 03 0 04 0 04 0 08 0 22 0 05 0 07 0 01 5000 0 04 0 04 0 05 0 06 0 12 0 31 0 07 0 1 0 02 6000 0 06 0 05 0 07 0 08 0 18 0 42 0 10 0 17 0 04 7000 0 07 0 07 0 10 0 11 0 24 0 55 0 14 0 23 0 05 8000 0 09 0 09 0 12 0 13 0 32 0 70 0 19 0 30 0 08 9000 0 1 0 12 0 15 0 16 0 40 0 86 0 24 0 38 0 10 10000 0 13 0 14 0 18 0 19 0 50 1 04 0 30 0 48 0 14 11050 0 15 0 17 0 22 0 23 0 61 1 24 0 36 0 58 0 17 12000 0 18 0 20 0 26 0 27 0 43 0 69 0 21 13000 0 20 0 24 0 30 0 31 VIOSD MaX GEM Tor Evap 0 51 0 81 0 26 Accesssory Option static pressure losses are approximate values only Please consult the Accuspec selection software for static pressure losses at other than listed CFM 32 AIR 5 565 2 BLOWER PERFORMANCE DATA Table 33 1 Unit Performance Tables Total Static Pressure W C Digit dns 0 25 0 50 0 75 1 00 1 25 1 50 2 00 2 50 3 00 Unit Size 16 Rise Bup npM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM 75 A B 10
57. A two position damper actuator is provided with Air Control options DA EA and EQ Digits 20 amp 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 outside air percentages lower than 100 refer to the following section Setting the Damper Limiter 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 Setting the Damper Limiter The two position damper limiter is factory set to prevent the outside air damper from opening 100 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 22 1 which is shown at 50 rotation limit 3 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 4 Fasten the limiter to the actuator using the screw provided 5 Test the dam
58. B8 3H35127B10 3H35127B13 3H35127B15 213 or 215 Motor Frame Size 48 RPM Range 3H35127B11 3H35127B14 568 771 767 958 934 1136 1136 1380 3H35128B1 Digit 19 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 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 3H35129B7 3H35129B10 3H35129B12 3H35129B16 3H35129B19 254 3H35129B13 3H35129B17 3H35129B20 256 3H35129B14 Table 37 4 Digit 16 2 K 18 18 Blower Units with 15 Hp motor amp up RPM Range Motor Frame Size 3H35129B18 826 1009 995 1161 1101 1285 1232 1438 Digit 19 Sheave Assembly 3H35130B1 Digit 19
59. Both the main and pilot valves close 100 b Two Stage Units Once the high stage of the thermostat is satisfied the main valve closes to 50 fire The unit continues to operate until the low stage thermostat is satisfied at which time both the main and pilot valves close 100 c Electronic Modulation Units The unit continues to operate in this manner until the thermostat is satisfied or the BMS heat enable contact opens Power is then cut to both the main and pilot valves closing them 100 and stopping gas flow to the main and pilot burners If the unit was not provided with a time delay relay the blower stops immediately If the unit was provided with a time delay relay the blower stops after 30 to 45 seconds AIR 5 565 2 17 START UP PROCEDURE Multiple Furnace Controls Staged Control Digit 12 1 For control of multiple staged units each furnace would be individually controlled Refer to the section for Single Furnace Controls Staged Control Digit 12 1 or 2 Electronic Modulating Control Digit 12 4 These units are the same as Electronic Modulating Gas Controls Single Furnace Digit 12 4 except the Master unit features a modulating amplifier capable of driving multiple modulating gas valves for systems with a Master and up to two Slave units Slave units do not have a modulating amplifier The units would be controlled by one of the following Modulating room thermostat Modulating duct thermost
60. 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 lt MODINE Modine Manufacturing Company 2015 Modine Manufacturing Company 1500 DeKoven Avenue Racine WI 53403 Phone 1 866 823 1631 toll free www modinehvac com schoolsystems
61. E D TO H FEET MINMUM ABOVE WALL OR ADJOINING BUILDING PER TABLE 6 2 3 FEET MINIMUM SIZE ACCORNING TO EXPECTED SNOW DEPTH USE LISTED THIMBLE THROUGH CEILING Js WITH DRIP LEG AND CLEANOUT CAP LISTED WALL OR ADJOINING PUDING m e ROOF FLASHING OOS AS MAINTAIN MINIMUM CLEARANCE TO COMBUSTIBLES 5 SLOPE PIPE UP 1 4 PER FOOT TOWARD DRIP LEG USE LISTED THIMBLE THROUGH CEILING TEE WITH DRIP LEG AND CLEANOUT CAP Table 6 1 Minimum Height from Roof to Lowest Discharge Opening Roof Rise X in Equivalent Roof Pitch Flat to 10 12 Minimum Height H ft 10 12 to 12 12 12 12 to 14 12 14 12 to 16 12 16 12 to 18 12 18 12 to 21 12 Increase as required to accommodate snow depth Table 6 2 Minimum Height Above Adjacent Wall Less than 10 Feet Away 10 Feet or Less 2 Feet Minimum Greater than 10 Feet AIR 5 565 2 No Additional Height Required INSTALLATION 18 When condensation may be a problem the venting system shall not terminate over public walkways or over an area where condensation or vapor could create a nuisance or hazard or could be detrimental to the operation of regulator relief openings or other equipment 19 In cold ambient conditions such as Canada the following items are recommended for proper operation and equipment
62. ER USER WITHIN TEN YEARS FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION OR WITHIN ONE HUNDRED TWENTY SIX MONTHS FROM DATE OF SHIPMENT FROM SELLER WHICHEVER OCCURS FIRST Heat Exchangers Low Intensity Infrared Units Gas Heat option on MPR models 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 Compressors MPR Models Other Components excluding Heat Exchangers Coils Condensers Burners Sheet Metal TWO YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER WITHIN TWO YEARS FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION OR WITHIN THIRTY MONTHS FROM DATE OF SHIPMENT FROM SELLER WHICHEVER OCCURS FIRST Heat Exchangers Coils Indoor and Outdoor Duct Furnaces and System Units Steam Hot Water Units Oil Fired Units Electric Units Cassettes Vertical Unit Ventilators Compressors Vertical Unit Ventilators Burners High Intensity Infrared Units 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
63. FH for Propane gas 8 AIR 5 565 2 INSTALLATION Table 9 1 Burner Orifice Sizing and Gas Consumption au Type Orifice Natural Propane Qty Cfh Orifice Drill Size Cfh Orifice Drill Size Cfh Orifice Drill Size Cfh Orifice Drill Size Cfh Orifice Drill Size Cfh ifice Drill Size Cfh ifice Drill Size Cfh ifice Drill Size Cfh ifice Drill Size Cfh ifice Drill Size Cfh ifice Drill Size Cfh ice Drill Size Cfh ice Drill Size Cfh ice Drill Size Cfh ifice Drill Size Cfh ifice Drill Size Cfh ice Drill Size m 175 9 9 9 Q Q 500 es eS Q Q Based on natural gas properties of 1040 Btu Cu Ft and specific gravity of 0 60 Based on propane gas properties of 2500 Btu Cu Ft and specific gravity of 1 53 Model sizes 500 800 contain 2 furnaces Values shown are per furnace Model sizes 840 960 contain 3 furnaces Values shown are per furnace AIR 5 565 2 INSTALLATION Considerations for Elevation The standard ratings for Models IBG ICG and IBP ICP are certified for elevations up to 2000 feet above sea level Operation at elevations above 2 000 feet requires ratings be reduced 496 for each 1000 feet above sea level per ANSI Z223 1 The exception is for units in Canada CSA requires that ratings be reduced 1096 for elevations between 2 001 and 4500
64. Figure 8 1 5 When Pressure Leak testing pressures above 14 W C 1 2 psi close the field installed shut off valve disconnect the appliance and its combination gas control from the gas supply line and plug the supply line before testing When testing pressures 14 W C 1 2 psi or below close the manual shut off valve on the appliance before testing Figure 8 1 Recommended Sediment Trap Manual Shut off Valve Installation Side or Bottom Gas Connection GAS SUPPLY LINE GROUND a JOINT pA UNION EE W BRASS MANUAL GAS_q SEAT SHUT OFF VALVE GAS b N SUPPLY LINE ae as ee 14 iL k 7 TO Lf CONTROLS PLUGGED 3 1 8 NPT TEST MIN GAGE CONNECTION SEDIMENT TRAP Manual shut off valve is in the OFF position when handle is perpendicular to pipe Table 8 1 Gas Pipe Capacities Natural Gas Pipe Natural Gas Length ft 1 2 1 1 1 4 Capacities in Cubic Feet per Hour through Schedule 40 pipe with maximum 0 3 W C pressure drop with up to 14 W C gas pressure Specific gravity is 0 60 for Natural gas and 1 50 for Propane gas For Pipe Capacity with Propane Gas divide Natural gas capacity by 1 6 Example What is the Propane gas pipe capacity for 60 feet of 1 1 4 pipe The Natural gas capacity is 400 CFH Divide by 1 6 to get 250 C
65. IONS 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 DANGER Appliances must not be installed where they may be exposed to a potentially explosive or flammable atmosphere WARNING 1 Gas fired heating equipment must be vented do not operate unvented 2 a Model IBG ICG has a built in draft diverter additional external diverters are not required or permitted b Model IBP ICP has a built in power exhauster additional external power exhausters are not required or permitted 3 If you are replacing an existing heater it may be necessary to resize the venting systems Improperly sized venting systems can result in vent gas leakage or the formation of condensate Refer to the National Fuel Gas Code ANSI 2223 1 or CSA B149 1 latest edition Failure to follow these instructions can result in injury or death 4 For Model IBG ICG gas fired heating equipment which has been improperly vented or which experiences a blocked vent condition m
66. If the pilot does not light purge the pilot line If air purging is required disconnect the pilot line at outlet of pilot valve In no case should line be purged into heat exchanger Check the pilot flame length See Pilot Flame Adjustment 22 Once the pilot has been established check to make sure that the main gas valve opens Check the manifold gas pressure See Main Gas Adjustment and flame length See Air Shutter Adjustment while the supply fan blower is operating 23 Check to insure that gas controls sequence properly See Control Operating Sequence Verify if the unit has any additional control devices and set according to the instructions in the Control Options 24 Once proper operation of the unit has been verified remove any jumper wires that were required for testing 25 Close the electrical compartment door 26 Replace all exterior panels Refer to page 56 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
67. J or K L Max Temp Rise F 120 120 120 120 Min Temp Rise F 46 60 60 68 63 Max CFM 13000 13000 Min CFM 6481 6481 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 18 28 AIR 5 565 2 GENERAL PERFORMANCE DATA Table 29 1 Air Temperature Rise Air Temperature Rise through Unit F 40 45 50 55 60 65 70 CFM 75 000 60 000 100 000 80 000 125 000 100 000 150 000 120 000 175 000 140 000 200 000 160 000 225 000 180 000 250 000 200 000 300 000 240 000 350 000 280 000 400 000 320 000 ir Temperature Rise thro nit F 65 70 75 85 500 000 400 000 5291 600 000 480 000 6349 700 000 560 000 7407 800 000 640 000 8466 840 000 11111 960 000 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 must be derated to 9096 of the ra
68. L GAS 1 Open windows 2 Don t touch electrical switches 3 Extinguish any open flame 4 Immediately call your gas supplier FOR YOUR SAFETY The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous IMPORTANT The use of this manual is specifically intended for a qualified installation and service agency A qualified installation and service agency must perform all installation and service of these appliances Inspection on Arrival 1 Inspect unit upon arrival In case of damage report it immediately to transportation company and your local factory sales representative 2 Check rating plate on unit to verify that power supply meets available electric power at the point of installation 3 Inspect unit upon arrival for conformance with description of product ordered including specifications where applicable THIS MANUAL IS THE PROPERTY OF THE OWNER PLEASE BE SURE TO LEAVE IT WITH THE OWNER WHEN YOU LEAVE THE JOB SPECIAL PRECAUTIONS TABLE OF CONTENTS SPECIAL PRECAUTIONS THE INSTALLATION AND MAINTENANCE INSTRUCTIONS IN THIS MANUAL MUST BE FOLLOWED TO PROVIDE SAFE EFFICIENT AND TROUBLE FREE OPERATION IN ADDITION PARTICULAR CARE MUST BE EXERCISED REGARDING THE SPECIAL PRECAUTIONS LISTED BELOW FAILURE TO PROPERLY ADDRESS THESE CRITICAL AREAS COULD RESULT IN PROPERTY DAMAGE OR LOSS PERSONAL INJURY OR DEATH THESE INSTRUCT
69. NIMUM CLEARANCE TO COMBUSTIBLE MATERIAL MASSACHUSETTS MUN INPUT 2 00000 sx TE OF 585 or ni m rl D GAGEMENT MINIMUM POUR MATI RES COMSUSIELEI APPROVED FOR USE IN CALORIFIQUE Natural 400000 360000 iid en C BY THE CHC an ACCEPTED BY CITY MIN INLET PRESS FOR PURPOSE OF INPUT ADJ RECOMMENDED SERVICE CALORIEIQUE 117120 105408 24 a OF NEU YORK PRESSION D ALTMENTATIDN EN GAZ ADMISE CLEARANCES BTU HR NOV ACCESS DEGAGEMENT DE SERVICE RECOMMENDE ACCESS COTE SIDE 6 IN U C 49 kha MANIFOLD PRESSURE PRESSION A L TUBULURE D ALIMENTATION 3 5muc 0 87 TEMPERATURE RISE RANGE ELEVATION DE TEMPERATURE 20 100 _ INSTALL ON THE POSITIVE PRESSURE SIDE OF AIR CIRCULATING BLOWER INSTALLER DU COTE DE LA PRESSION POSITIVE DU VENTILATEUR ORIFICE 5179 DIM DE THIER ACC DEZ Alu 10416 VENT CATEGORY EXTERNAL STATIC PRESSURJVENT CONNECTOR IZR VENT CAT GORIE PRESSION STATIQUE EXTERIEUR CONNECTEUR DE VENTILATION III I 3 woe ror 6 m m G N RAL SEULEMENT POUR NSTALLATION INT RIEURE LA TEMPERATURE MINIMUM DE L AIR DEHORS GENERAL FOR INDOOR INSTALLATIONS ONLY MINIMUM AMBIENT TEMPERATURE 40 F FOR INSTALLATION DOWNSTREAM OF REFRIGERATION dinde SYSTEMS INSTALLER DU COT 08 L PRESSION POSITIVE DU VENTILATEUR FOR UNITS WITH MANUAL RESET HIGH LIMIT SWITCH RESET BUTTON IS LOCATED IN ELECTRICAL JUNCTION BOX USA FOR INSTALLATIONS AB
70. OVE 2000 FEET DERATE 4 PERCENT FOR EACH 1000 FEET OF ELEVATION ABOVE SBA LEVEL THIS APPLIANCE REQUIRES A SPECIAL VENTING SYSTEM REFER TO INSTALLATION INSTRUCTIONS HO 5 564 FOR PARTS LIST AND METHOD OF INSTALLATION POUR APPAREILS AVEC INTERRUPTEUR REMIS MANUEL HAUT LIMITE REMISE BST SITU E DANS LA BO TE JUNCTION SLECTRIQUE POUR REMBTTRE PRESSER LE BOUTON CET APPAREIL N CESSITE UN SYST ME D VACUATION SP CIAL LA M THODE D INSTALLATION ET LA LISTE DES PIRCES N CESSAIRES FIGURENT DANS LES INSTRUCTIONS 1 DUTPUT BTU HR 320009 268000 23 1 OPEN ALL GAS VALVES TURN ON POWER 2 SET THERMOSTAT TO DESIRED SETTING CINIBCIOR 5 CONNECTEUR D AERATIDN DESIGN COMPLIES WITH DUCT FURNACE STANDARD om CSA 2 6 2013 ca ANSI 283 8 2013 372 01 NON COT D ACCES AIR THROUGHPUT DEBIT D AIR MIN VARIABLE SPEED 5H80581B INSTRUCTIONS D ALLUMAGE 1 DUVRIR TOUTES LES ROBINETS A GAZ DONNER LE COURANT 2 REGLER LE THERMOSTAT SUR LA POSITION DESIREE REFERREZ AU MANUAL D INSTALLATION ET DE SERVICE POUR PLUS D INSTRUCTIONS POUR APPAREILS AVEC DEUX PHASES MODULATION MECHANIQUE QU APPAREILS DE CONTR LE DE GAZ LECTRIQUES MODULES UN AIR CONTR LEUR D CHARGE INSTALL LA MANUFACTURE BY THERMOSTAT DE CHAMBRE N EST PAS INCLUS INSTRUCTIONS DE FER METURE LIGHTING INSTRUCTIONS 18S08HS REFER TO INSTALLATION AND
71. SERVICE MANUAL FOR MORE INSTRUCTIONS FOR UNITS WITH TWO STAGE MECHANICAL MODULATION OR ELECTRONIC MODULATING GAS CONTROLS A FACTORY DISCHARGE AIR CONTROLLER AND NO ROOM THERMOSTAT INCLUDED SHUT DOWN INSTRUCTIONS TURN OFF POWER amp CLOSE ALL GAS VALVES 1 COUPER LE COURANT ET FERMER TOUTES LES ROBINETS GAZ COMMON REPLACEMENT PARTS 5H080687 FOR PARTS ORDERING contdct the parts wholesaler or the manufacture 5 080689 representative serving your area WHEN INQUIRING ABOUT PARTS 1 5 71675 provide model number serial number description and part number ibH79441 ordering parts provide part number listed FOR SERVICE contact yd5H73598 local qualified installation and service contractor or appropriate 118 80563 Comb Gas Valve 5H71956 1 Ctrl Transformer Ignition Control 3H37454 1 Pilot Replace Kit TD1 Relay 3H37398 11 Heat Exch Kit 3 Pressure Switch 3 35628 6 Burner Kit 1 Power Exhauster 5 71790 Optional TDR 4 Wiring Diagram 54 AIR 5 5 65 2 MODEL DESIGNATIONS Figure 55 1 Model Identification Plate MODEL IDENTIFICATION PLATE Model Number Serial Number IBP75AFRHN10A1AA1AAA1A MOTOR DATA Voltage Hertz Phase Amps SYSTEM DATA Supply Voltage Hertz Phase Max System Amps Fuse Size Time Delay Time Delay Relay COMMON REPLACEMENT PARTS For parts ordering contact the parts wholesaler or the manufacturer s representative serving your area A complete
72. ances should two sections of double wall vent pipe be joined together within one horizontal vent system due to the inability to verify complete seal of inner pipes General Venting Instructions 1 Installation of venting must conform with local building codes or in the absence of local codes with the National Fuel Gas Code ANSI 2223 1 NFPA 54 Latest Edition In Canada installation must be in accordance with CAN CGA B149 1 for natural gas units and CAN CGA B149 2 for propane units 2 To determine the Venting Category of the unit being installed refer to Table 5 1 Table 5 1 Venting Category Determination Venting Vent Configuration Category IBG ICG Vertically vented units only lo Vertically vented units only IBP ICP Horizontally vented units only Vent is negative pressure non condensing Follow standard venting requirements Vent is positive pressure non condensing Vent must be gastight 3 For units vented as Category I refer to Table 5 2 for vent sizing Vent sizing for units vented as Category Ill are covered in a later section on page 7 Do not use a vent pipe smaller than the size of the outlet or vent transition of 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 Table 5 2 Category Minimum Vent Pipe S
73. arly inspect and clean the cooling coil cabinet condensate drain pan and trap drain System to ensure proper function Depending on climate freeze protection of the trap may be required during non cooling days Cooling Coil Maintenance 1 2 C Periodically inspect the coil for signs of corrosion and leaks Repair and replacement of the coil and the connecting piping valves etc must be performed as needed by a qualified technician Should the coil surface need cleaning caution should be exercised in selecting the cleaning solution as well as the cleaning equipment Improper selection can result in damage to the coil and or health hazards Cleaning solutions must not be corrosive or cause damage to copper tube aluminum fin coils Clean the coil from the leaving air side so that foreign material will be washed out of the coil rather than pushed further in Be sure to carefully read and follow the cleaning fluid manufacturer s recommendations before using any cleaning fluid For DX coils replace the filter dryer s as needed For chilled fluid coils a Maintain the circulated fluid free of sediment corrosive products and biological contaminants b Freeze Protection During the winter chilled water coils need to be protected against freezing Two common methods are 1 blowing out the coils with air or 2 flushing coils with inhibited glycol designed for corrosion protection in HVAC applications Select an i
74. at with remote temperature set point adjuster The sequence of operation for Electronic Modulating Gas Controls Master Slave is the same as Electronic Modulating Gas Controls Single Furnace The modulating amplifier sends an equal voltage signal to all of the modulating gas valves so that they modulate at the same percentage between 40 and 100 full fire Electronic Modulating Control Digit 12 7 or 8 For control of multiple electronic modulation units for BMS control each furnace would be individually controlled Refer to the section for Single Furnace Controls Electronic Modulation Control Digit 12 7 or 8 Variable Air Movement Applications Units may be supplied with variable frequency drives for applications where variable air volume is required The minimum air flow may be varied between 30 and 100 of the full speed air flow depending on the controls selection of the unit Due to the extra restrictions of the controller all selections must be performed with the AccuSpec configuration software Within AccuSpec three variable frequency drive speed control changeover options are available 1 Two speed which may be controlled by a manual high low Switch which may be factory mounted on the control panel or shipped loose for field installation or by exhaust fan interlocks 2 Floating building pressure sensing which utilizes a photohelic pressure controller to adjust the building pressure by varying the amount of makeup air
75. ay have flue gases accidentally spilled into the heated space See page 53 for specific information about the blocked vent safety switch supplied on the unit 5 For Model IBP ICP under no circumstances should two sections of double wall vent pipe be joined together within one horizontal vent system due to the inability to verify complete seal of inner pipes 6 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 7 Gas pressure to appliance controls must never exceed 14 W C 1 2 psi 8 Disconnect power supply before making wiring connections to prevent electrical shock and equipment damage 9 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 10 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 11 Ensure that the supply voltage to the appliance as indicated on the serial plate is not 5 greater than the rated voltage 12 Any original factory wiring that requires replacement must be replaced with wiring material having a temperature rating of at least 105 C 13 When servicing or repairing this equipment use only factory
76. ay require the removal of the manifold see Manifold Assembly Removal Adjusting the primary combustion air is achieved by resetting the primary air shutters See Figure 50 2 Prior to flame adjustment operate duct furnace for about fifteen minutes The main burner flame can be viewed after loosening and pushing aside the gas designation disc on the side of the burner box 1 To increase primary air loosen the air shutter set screws and move the air shutters closer to the manifold until the yellow tipped flames disappear and a clean blue flame with a well defined inner cone appears 2 To decrease primary air move the air shutters away from the manifolds until flames no longer lift from burner ports but being careful not to cause yellow tipping 3 Re tighten set screws after adjustment AIR 5 565 2 15 START UP PROCEDURE Blower Adjustments If blower fan speed changes are required adjust motor sheave as follows 1 Refer to page 33 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 16 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 counter
77. bination 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 19 could change the listed sequence of operation based on their function The descriptions given are for the basic duct furnace Single Furnace Controls Staged Control Digit 1221 or 2 These units utilize a single or two stage combination gas valve an ignition control and a low voltage thermostat Electronic Modulating Control Digit 12 4 7 or 8 These units utilize a single stage combination gas valve an electronic modulating gas valve a modulating amplifier an ignition control and one of the following Modulating room thermostat Modulating duct thermostat with remote temperature set point adjuster Building Management System BMS signal by others an inverted signal where 0 VDC or 4 mA is high fire and 10 VDC or 20 mA is low fire The control operating sequence for all units is as follows 1 The thermostat calls for heat For BMS controlled units the BMS closes a heat enable contact at the unit 2 Model IBP ICP only The power exhauster relay is energized starting the power exhauster motor Once the motor has reached full speed the differential pressure switch closes
78. ccuSpec for line size diameters Q Dual Circuit DX coils have 2 each Suction Line and Liquid Lines Refer to AccuSpec for line size diameters Figure 47 2 Chilled Water Coil Drawing All dimensions in inches 350 400 DX Dual Circuit 23 Airflow Direction V Rows 4 6 W 75 TOP VIEW gt W lt L lt Eb lt 1 5 15 Y 18 gt eo Return Water Line o s 29 Connection turned 90 in direction of airflow 2d EE Coil for Right Hand Units 225 Digit 9 FE Airflow sipe VIEW Headers on opposite side for Direction Left Hand Units FRONT VIEW 2 25 Supply Water Line Connection turned 90 in 4 direction of airflow v 1 k I gt 1 8 Table 47 2 Chilled Water Coil Dimensions Model Size 75 Supply Line 1 50 MPT Return Line 1 50 MPT 100 125 1 50 MPT 1 50 MPT 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 AIR 5 565 2 1 50 MPT 1 50 MPT 47 DIMENSIONS WEIGHTS Figure 48 1 Remote Panel Dimensions Table 48 3 Remote Panel Dimensions All dimensions in inches Remote Panel Type Light and Switch Panels Only Light and Switch Panels with Single Stage Thermostat or Electronic Set Point Adjustor Light and Switch Panels with Two Stage The
79. ce or field labor participation Seller will not honor any expenses incurred in its behalf with regard to repairs to any of Seller s products No credit shall be issued for any defective part returned without proper written authorization including but not limited to model number serial number date of failure etc and freight prepaid OPTIONAL SUPPLEMENTAL WARRANTY Provided a supplemental warranty has been purchased Seller extends the warranty herein for an additional four 4 years on certain compressors Provided a supplemental warranty has been purchased Seller extends the warranty herein for an additional four 4 years or nine 9 years on certain heat exchangers EXCLUSION OF CONSUMABLES amp CONDITIONS BEYOND SELLER S CONTROL This warranty shall not be applicable to any of the following items refrigerant gas belts filters fuses and other items consumed or worn out by normal wear and tear or conditions beyond Seller s control including without limitation as to generality polluted or contaminated or foreign matter contained in the air or water utilized for heat exchanger condenser cooling or if the failure of the part is caused by improper air or water supply or improper or incorrect sizing of power supply APPLICABLE WARRANTY PERIOD Heat Exchangers Gas Fired Units except MPR Models TEN YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER WITHIN TEN YEARS FROM DATE OF RESALE BY BUYER OR ANY OTH
80. ch For instructions on common venting refer to the National Fuel Gas Code The vent must terminate no less than 5 above the vent connector for Category vent systems A unit 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 concealed space or floor Do NOT vent Model IBP ICP units into a masonry chimney Model IBG ICG units can be vented into a masonry chimney if the following requirements are met a Do not vent a Category unit into a common vent with mechanical draft systems operating under positive pressure Category Ill or IV units b When connecting a vent to an existing chimney do not push the vent pipe beyond internal surface of chimney c 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 d When venting into a common vent the individual vents should enter at different levels Figure 6 1 Vertical Category Vent System 10 FEET OR LESS TO ROOF PEAK NAE 2 FEET MINIMUM ROOF PITCH IS L x112 USE LISTED THIMBLE THROUGH ROOF H FEET MINIMUM PER TABLE 6 1 ROOF FLASHING MAINTAIN MINIMUM CLEARANCE TO COMBUSTIBLES 12 MINIMUM H SLOPE PIPE UP 1 4 PER FOOT TOWARD DRIP LEG DISTANC
81. changer 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 Z2 in Selection Example Conditions the Air Temperature Rise is 60 F 70 F 10 F However using the output capacity of the IBP400 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 AIR 5 565 2 UNIT SELECTION 10 11 12 Determine the Supply Voltage From item 9 listed above the 460V 60Hz SPh results in the Supply Voltage F Determine the Transformer For IBP ICP models a 75VA Transformer is required Thus the Transformer 2 Determine the Blower Size and Bearing Type Using Table 29 1 the Model Size 400 has three available blowers for w
82. clockwise 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 16 2 Belt Tension Adjustment 3 4 deflection with 5 Ibs of force 7 Recheck blower rpm after adjustment NOTE Do not fire unit until blower adjustment has been made or unit may cycle on high limit control 8 Check motor amps Do not exceed nameplate amps shown on motor nameplate Lubrication Recommendations The blower can be provided with either spider or pillow block bearings Spider bearings are permanently lubricated and do not require lubrication Pillow block bearings are shipped greased from the factory but will require lubrication The bearings should be checked and lubricated before each heating season but a more frequent lubrication schedule may be required based on the environment in which the unit is installed and the frequency of the equipment operation Shell Alvania Z2 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 da
83. crated with Skid supports below the unit The unit may be lifted from the bottom by means of a fork lift or other lifting device only if the shipping support skids are left in place DO NOT attempt to lift the unit from the bottom unless the shipping skid supports are still in place When lifting units make sure the load is balanced All extended cabinet systems are shipped without a crate and cannot be lifted with a fork truck Use a crane or other overhead lifting device in conjunction with the lifting holes refer to page 46 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 t
84. ct furnace are in operation check to be sure the blower has been set to the proper rpm for the application Refer to page 16 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 51 1 on pages 51 52 refer to the applicable sections of the manual Table of Contents Inspection on 1 Special Precautions no ates eese mero ck wh E 2 SI Metric Conversion Factors 3 Unit Location 2 my m mde RR 3 Combustible Material and Service Clearances 3 Unit Lifting and Unit Mounting 4 Unit Installation onm ro edet e RUE 5 Duct lnstallatiori garda dra mend Rr DRE SK achkan 5 mE mm 5 Gas Connections 8 Connections for 10 Electtical Connections 555529 weg RE IRR RS 11 Cooling Coil Specifications and Installation 12 Start Up Procedure cites ek y TR Eck RUP hte oen 14 Pilot Burner Adjustment 14 Main Burner 15 Blower 16 Lubrication 16 Con
85. d servicing 55 Differential Pressure Switch A differential pressure switch is supplied on all power vented duct furnaces and is designed to prevent operation of the main burner in the event there is improper venting through the vent System This 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 See Troubleshooting 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 26 1 Circuit Analyzer Circuit analyzer tagging will vary based on the unit ordered Circuit analyzer shown is for reference only V2 26 AIR 5 565 2 THIS PAGE INTENTIONALLY LEFT BLANK AIR 5 565 2 27 GENERAL PERFORMANCE DATA Table 28 1 General Performance Data Models With Blower Model Size Digits 4 6 Btu Hr Input 125 000 150 000 175 000 Btu Hr Output D 100 000 120 000 140 000 Blower Style Digit 16 Letter Cor D Eor F Cor D Eor F Cor D Eor F
86. del has been determined the additional options and accessories outlined on pages 19 26 can be added to the unit AIR 5 565 2 31 OPTION amp ACCESSORY PRESSURE DROP DATA Table 32 1 Option amp Accessory Pressure Drop Tables in W C Unit Size 75 100 125 150 175 200 225 250 300 500 600 350 400 700 800 840 960 Digit 16 A B C D C D E F C D E F C D E F G H E F G H LJ K L E F G H IJ K L All Units Weatherproof Unit Only gt 8 8 8 s 5 c 5 5 o m 2 Es 89 832 Pg 5 iS 86 88 pz s gt E crm NE GE AE as HER a5 556 0 01 0 01 0 02 0 03 0 02 0 07 0 00 0 01 0 00 600 0 01 0 01 0 02 0 03 0 02 0 07 0 00 0 01 0 01 800 0 02 0 01 0 03 0 04 0 04 0 12 0 01 0 02 0 01 1000 0 02 0 02 0 04 0 05 0 06 0 17 0 01 0 03 0 01 1200 0 03 0 02 0 05 0 06 0 08 0 22 0 02 0 03 0 01 1400 0 03 0 03 0 06 0 07 0 11 0 29 0 03 0 04 0 02 1600 0 04 0 04 0 07 0 09 0 15 0 36 0 04 0 06 0 02 1800 0 04 0 04 0 08 0 10 0 19 0 44 0 05 0 07 0 03 2000 0 05 0 05 0 10 0 11 0 23 0 53 0 06 0 08 0 03 2300 0 06 0 07 0 11 0 13 0 31 0 68 0 08 0 11 0 04 2778 0 08 0 09 0 15 0 16 0 45 0 96 0 12 0 15 0 06 741 0 01 0 02 0 02 0 02 0 02 0 08
87. dun MODINE AIR 5 565 2 5H0806450000 August 2015 AIREDALE INSTALLATION AND SERVICE MANUAL gas fired indoor gravity and power vented duct furnace make up air units Model ICP A WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or death and could cause exposure to substances which have been determined by various state agencies to cause cancer birth defects or other reproductive harm Read the installation Operating and maintenance instructions thoroughly before installing or servicing this equipment Installing starting up and servicing heating ventilation and air conditioning equipment poses significant hazards and requires specialized knowledge of Modine products and training in performing those services Failure to have any service properly performed by or making any modification to Modine equipment without the use of qualified service personnel could result in serious injury to person and property including death Therefore only qualified service personnel should work on any Modine products models IBG ICG IBP ICP LISTED Intertek IBP ICP models approved for use in California by the CEC CAUTION To prevent premature heat exchanger failure do not locate ANY gas fired units in areas where chlorinated halogenated or acid vapors are present in the atmosphere FOR YOUR SAFETY IF YOU SMEL
88. e 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 condensation Inspect for leakage prior to insulating and use insulation that is noncombustible with a rating of not less than 350 F Install a tee fitting at the low point of the vent system and provide a drip leg with a clean out cap as shown in Figure 6 1 When the vent passes through a combustible 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 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 pipes Precautions must be taken to prevent degradation of building materials by flue products For category vent systems the outlet of the vent should extend as shown in Figure 6 1 and Tables 6 1 and 6 2 Use a listed vent terminal to reduce downdrafts and moisture in vent For model IBG ICG a vent terminal that is very open will avoid spillage at unit s diverter relief opening and tripping of the blocked vent safety swit
89. e field installed manual shut off valve to the OFF position 2 Remove the 1 8 pipe plug in the pipe tee or gas valve and attach a water manometer of U tube type which is at least 12 high 3 Move the field installed manual gas shut off valve to the ON position 4 Create a high fire call for heat from the thermostat 5 Determine the correct high fire manifold pressure For natural gas 3 5 W C for propane gas 10 W C Adjust the main gas pressure regulator spring to achieve the proper manifold pressure for location see the combination gas control literature supplied with unit 6 Iftheunit has Electronic Modulation gas controls determine from the Model Identification Digit 12 the low fire gas pressure needs to be adjusted Using Figure 15 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 b 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
90. e trip condition is indicated by a red color in the trip indicator window The motor starter can be placed in the automatic or manual reset positions Automatic reset is accomplished by depressing the RESET button and turning the button 1 4 turn When in the automatic reset position if the overload module trips the module will reset itself once the overload relay has cooled In the manual reset position if the overload module trips the RESET button must be depressed before the blower can operate The contractor module includes one 1 normally open auxiliary contact The contact rating is 10 amps If the factory installed motor starter option was not ordered with a unit that has a three phase motor or single phase motor 1 1 2 Hp or greater a motor starter must be field supplied and installed Figure 25 2 Motor Starter bord CONTACTOR MODULE TRIP INDICATOR CURRENT J WINDOW SETPOINT pa amp g mo RESET ees LI LULA 1 OVERLOAD Fe MODULE GG 6 9 8 8 8 42 Proportional Temperature Controller OPT A proportional temperature controller is provided with Air Control options GG GH GK or GM Digits 20 amp 21 and factory installed in the electrical section The controller compares the mixed air temperature set point and the mixed air temperature from
91. ement Tables 36 1 through 37 5 2 Locate the unit Model Identification Plate and note Digit 16 give the Sheave Assembly numbers used on units that include a and Digit 19 of the model number Digit 16 is the Blower blower The Sheave Arrangement is Digit 19 and is found on the Size and Type and Digit 19 is the Sheave Arrangement unit Model Identification Plate The Sheave Assembly describes 3 Once the Blower Size and Type Digit 16 is known enter the motor and blower sheave size and bore as well as the belt the proper Sheave Arrangement table provided 4 Use the Sheave Arrangement Digit 19 to determine the Sheave Assembly provided To determine how many turns open the motor sheave should be set for y P 5 Use Table 38 1 and the Sheave Assembly number to determine the required turns open to achieve the 1 Follow the Selection Procedure found on pages 30 31 desired blower rpm to determine what blower rpm is required to meet the job 6 Set the motor sheave as described in Blower Adjustments specifications Figure 36 1 Blower Section EXTENDED ADJUSTABLE FILTER GREASE MOTOR RACK LINES SHEAVE EXTENDED T GREASE LINE ZERK FITTINGS 1 4 PERIMETER GASKETED BLOWER CONNECTION CONVENIENCE OUTLET BLOWER DOOR BOTTOM SAFETY SWITCH SUPPORTED BLOWER AND MOTOR DIRECT DRIVE DAMPER ACTUATOR Blower Sheave Assembly Numbers Table 36 1 Digit 16 2 A or B 9 7 Blower Units RPM Range Motor Frame 656
92. emove the residual heat from the heat exchanger For single phase units below 1 1 2 Hp the time delay relay controls the motor directly For single phase units 1 1 2 Hp and greater and all three phase units the time delay relay controls the motor starter 10 Furnace Low Voltage Terminal Strip STD The furnace low voltage terminal strip is located in the duct furnace electrical junction box The terminal strip is labeled to match the electrical wiring diagram provided with the unit Low voltage labeling ranges from terminal numbers 1 to 79 All field wiring connections should be made to the top side of the terminals to prevent miswiring by modifying the factory wiring which is made to the bottom of the terminal strip 12 Furnace Supply Power Terminal Strip STD The furnace supply power terminal strip is located in the duct furnace electrical junction box The terminal strip is labeled to match the electrical wiring diagram provided with the unit Supply power labeling ranges from terminal numbers 80 to 99 All field wiring connections should be made to the bottom side of the terminals to prevent miswiring by modifying the factory wiring which is made to the top of the terminal strip 13 Control Step Down Transformer STD The control step down transformer is located in the duct furnace electrical junction box The transformer is used to step down the supply power 115V 208V 230V 460V 575V to 24V This transformer is
93. en Figure 49 1 Filter Replacement Arrangement for Blower Size Digit 16 A B C D E F G and H FILTER SPACER Sy 75 100 125 150 175 FILTER SPACER 200 225 250 300 er 500 600 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 49 2 Filter Replacement Arrangement for Blower Size Digit 16 J K and L NON ACCESS NON ACCESS SIDE FILTER SPACER FILTER SPACER 20 25 16 25 C 20 x 16 700800 500 600 D 15 X 25 840 960 Cooling Coil Drain Pan and Drain System The drain pan trap and drain pipe must be cleaned regularly to avoid blockage that can reduce or stop water flow as follows 1 At the beginning of the cooling season inspect and clean the entire cooling coil cabinet and condensate drain pan to remove contaminants Inspect and clean the condensate drain trap and piping The use of a cleanout opening at the top of the trap can help facilitate this maintenance Fill the trap with water to ensure proper operation and replace the cap on the cleanout opening to close the system During the end of cooling season shutdown of the system disconnect and remove all water from the trap and drain to prevent freeze damage If local building codes permit the trap may be filled with an antifreeze solution If the unit is used year round regul
94. entage 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 10096 outside air Figure 21 2 Minimum Positioner AIR 5 565 2 21 OPTIONS 20 21 Extended Grease Lines OPT The extended grease lines 21 are factory installed in the blower section and include Zerk grease fittings 20 factory installed on the exterior corner post between the electrical and blower sections This option allows the pillow block bearings to be lubricated with a grease gun without requiring the service personnel to remove both blower doors to access the bearings Refer to Lubrication Recommendations for lubricant recommendations 22 Return Air Fire Stat OPT The return air fire stat is factory installed in the electrical section with the sensor in the return air stream In case of elevated temperatures in the return air stream the manual reset switch shuts down the entire unit If the limit temperature is exceeded a service person must inspect the unit for the cause of the high discharge temperature take corrective action and then reset the switch 23 Blower Housing STD The blower housing is factory installed in the blower
95. er and pilot assembly for cleanliness and or obstructions as necessary see Duct Furnace for cleaning instructions Replace the burner assembly in reverse order In replacing the burner be certain that the rear burner slots are located properly on the burner retaining pins Do not force the burner side access panel it will not fit if the burner is not properly aligned Reconnect the ignition cable and pilot gas supply line Turn on the electric and gas supply Figure 50 2 Burner and Pilot Assembly Removal AIR SHUTTERS NOT SHOWN ARE LOCATED ON THE MANIFOLD PILOT ASSEMBLY IGNITION CABLE 50 AIR 5 565 2 SERVICE amp TROUBLESHOOTING Table 51 1 Troubleshooting Trouble Power Exhauster Motor will not start Models IBP ICP only Possible Cause 1 Power supply is off 2 No 24V power to thermostat 3 Thermostat malfunction 4 Defective power exhauster relay 5 Defective power exhauster motor Possible Remedy 1 Turn on main power 2 Check control transformer 3 Check replace thermostat 4 Replace power exhauster relay 5 Replace power exhauster motor Pilot does not light stay lit Main burners do not light Pilot is lit Lifting Flames See Figure 52 1 Yellow Tipping With propane gas some yellow tipping is always present Flashback Floating Flames See Figure 52 2 Flame Rollout See Figure 52 3 Bom 10 omn ON _
96. er is disconnected to all unit wiring electrically following the switch See Warning For servicing the unit the disconnect switch can be manually overridden by using a wrench and turning the disconnect switch shaft 90 clockwise See Figure 21 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 Figure 21 1 Dead Front Disconnect Switch Assembly BLOWER SECTIO ELECTRICAL COMPARTMENT ACCESS DOOR DISCONNECT SWITCH HANDLE OPERATION INSTRUCTION LABEL BLOWER SECTION ELECTRICAL COMPARTMENT STAND OFF PANEL DISCONNECT SWITCH HANDLE SHOWN IN THE ON POSITION SUPPLY POWER NG TERMINALS SEE WARNING z DISCONNECT SWITCH HANDLE SHOWN IN THE OFF POSITION 17 Step Down Transformer Fuses OPT The transformer fuses are factory installed in the electrical section The fuses are included to protect the transformer Fuses included 18 Step Down Transformer OPT The step down transformer is factory installed in the 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 perc
97. er 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 unit When the main disconnect switch is de energized the convenience outlet power supply remains energized The convenience outlet is factory installed in the blower section for providing power for 115V service equipment trouble light power tools etc The 115V ground fault circuit interrupter GFCI is rated for 15 amps and includes test and reset Switches A separate field supplied 115V 1Ph power supply must be routed through the electrical section wall into the back of the convenience outlet junction box 38 Blower Door Switch OPT The blower door switch is factory installed inside the blower section door on the access side of the unit When the blower section door is removed the momentary switch is released and interrupts power to the low voltage circuit For single phase units 1 1 2 Hp and less the door switch de energizes a relay that controls blower motor operation For three phase units and single phase units 1 1 2 Hp and greater the door switch de energizes the motor starter that controls blower motor operation For servicing the swi
98. he burner modulates to full fire operation until the room override is satisfied The unit then reverts back to duct sensing control When equipped with both either the duct sensor or the room override thermostat can call for heat d BMS Signal The main gas valve is opened 10096 and the burner firing rate is modulated between 40 and 10096 full fire ABMS 0 10VDC or 4 20mA signal inverted such that 0 VDC or 4 is high fire and 10 VDC or 20 mA is low fire is converted by the signal conditioner modulating amplifier into an inverted DC voltage OVDC for high fire to 12 VDC for low fire The output voltage is applied to the modulating gas valve to control the gas flow to the main burner The signal conditioner can accept a 0 10 VDC signal when all the dip switches are in the OFF position and 4 20 mA signal when all the dip switches are in the ON position The modulating valve is modulated open or closed based on the voltage from the amplifier less gas flow required higher voltage more gas flow required lower voltage which correlates to the control signal from the BMS Note For further information regarding the operation of any of the electronic modulating system options above consult the literature provided with the unit If the unit was provided with a time delay relay the blower starts after 30 to 45 seconds The unit continues to operate until the thermostat is satisfied Once satisfied a Single Stage Units
99. he unit Refer to Figure 46 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 Figure 4 1 Unit Suspension Method 3 4 SUSPENSION RODS BY OTHERS P 1 3 4 LOCKWASHER N 1 es j x 2 4 NUTS M LOCKWASHER Model IBP standard blower cabinet shown Mounting is the same for Model IBG Floor Mounted Units For floor installations the floor structure must be adequately designed to support the live weight load of the unit and any other required support structure Additional reinforcement should be provided if necessary The floor should include threaded 5 8 inch anchor bolts spaced according to Figure 4 2 for securing the unit in place Anchor bolts should extend at least 1 1 2 above the surface of the floor to allow clearance for mounting washers nuts and bolts mounting washers nuts and bolts by others Figure 4 2 Floor Mounted Unit Anchor Bolt Locations 5 8 Dia 4 pod Digit 16 75 100 25 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 or K 700 800 G or H 700 800 l J K or L 840 960 l J K or L 4 AIR 5 565
100. hich the performance tables are shown on pages 33 35 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 32 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 32 for the Model Size 400 with Digit 16 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 B Using the total static pressure T S P calculated in step 12a use blower performance tables for the Model Size 400 Table 34 1 Using Table 34 1 enter the table at the required 5000 cfm for E F blowers and follow the
101. il 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 24 AIR 5 565 2 OPTIONS Figure 25 1 Dirty Filter Pressure Switch and Air Flow Proving Switch Negative pressure Positive pressure connector connector z Pressure adjustment set screw 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 1 1 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 th
102. ir damper will remain open The damper can be manually closed through the use of the manual override switch on the floating damper actuator 31 Enthalpy Controller OPT An enthalpy controller is provided with Air Control option GJ Digits 20 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 The components used for the Enthalpy Economizer are Enthalpy Economizer Controller The Enthalpy Controller is used in conjunction with the Enthalpy Sensor and a Mixed Air Temperature sensor The controller is factory mounted in the blower control cabinet Outside Air Enthalpy Sensor The sensor provides a signal in relation to enthalpy temperature and humidity of the outside air The sensor is installed in the outside air stream Mixed Air Temperature Sensor The sensor is factory installed in the blower section to sense the mixed air temperature of the fresh and return air streams Typical Sequence of Operation Heating or Ventilation Mode When the space thermostat calls for heat or the fan is on without a call for cooling ventilation mode the economizer is automatically locked out and holds the outdoor air damper at the minimum position setting The mini
103. isting of both can be found in your Installation and Service Manual When inquiring about parts always provide model number serial number description and part number _ When ordering parts provide part number listed For service contact your local qualified installation and service contractor or appropriate utility company Blower Motor 2 Sheave Motor Sheave Design conforms to UL Std 1995 Certified to CAN CSA C22 2 No 236 tiste 9900100 Blower Belt c 15 9 6 9900100 5H764718 Rev B Figure 55 2 Serial Number Designation Furnace 09 17 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 10 0123 10000 SPO NUMBER lt blank gt if standard THHHHE if Special Product Order SEQUENTIAL NUMBER Varies 0000 TO 9999 Each unit in a week has a unique number YEAR PRODUCED WEEK PRODUCED Figure 55 3 Serial Number Designations System Serial Number Designations 01 10 201 01 02 1000 MOTOR SEQUENCE VENDOR CODE NUMBER 01 Century 15 Marathon etc mE YEAR OF FAN OR BLOWER MANUFACTURE VENDOR CODE 01 2001 10 Lau 02 2002 20
104. izing 75 100 125 Minimum Vent Pipe Diameter 2 IBG ICG IBP ICP 150 175 200 225 250 500 300 400 600 960 Requires a 4 to 5 adapter for the larger 5 vent pipe diameter Per furnace AIR 5 565 2 5 4 9 10 11 12 13 14 15 16 17 For Category vent systems 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 vertical vent as close to the unit as possible For Model IBP ICP units a minimum of 12 straight pipe is recommended from the power exhauster outlet before turns in the vent system Fasten individual lengths of vent together with at least three corrosion resistant sheet metal Screws Itis recommended that vent pipes be fitted with a tee with a drip leg and a clean out cap to prevent 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 a minimum clearance of 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 fir
105. l Strip 12 Furnace Supply Power Terminal Strip 20 21 22 23 24 25 26 2f 30 45 44 42 41 89 Extended Grease Line Zerk Fittings Extended Grease Lines Return Air Fire Stat Blower Housing Pillow Block Bearings Blower Motor Filters Fresh Air Damper Direct Drive Damper Actuator 36 35 33 31 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 Blower Door Switch Dirty Filter Switch Motor Starter VFD Control Mild Temperature Thermostat Proportional Temp Controller Warm Up Stat Blower Supply Power Terminal Strip Service Switches Electronic Modulating Amplifier Electronic Modulating Gas Valve Air Flow Proving Switch High Limit Switch Supply Air Fire Stat Main Gas Valve Burner Box 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 Not Shown The discharge thermostat is field 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 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 and capilary to be field installed in duct work The
106. l and propane gas units the ignition controller is 100 shut off with continuous retry On a call for heat the system will attempt to light the pilot for 70 seconds If the pilot is not sensed for any reason the ignition control will wait for approximately six minutes with the combination gas control closed and no spark After six minutes the cycle will begin again After three cycles some ignition controllers lockout for approximately one hour before the cycle begins again This will continue indefinitely until the pilot flame is sensed or power is interrupted to the system 8 Control Relay OPT The control relay 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 20 AIR 5 565 2 OPTIONS 9 Time Delay Relay STD The time delay relay is factory installed in the duct furnace electrical junction box The time delay relay allows the gas controls to operate for approximately 30 seconds before the blower starts This allows the heat exchanger a warm up period so that the initial delivered air coming out of the ductwork is not cool The time delay relay also keeps the motor running for approximately 30 seconds after the call for heat has been satisfied to r
107. led 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 0 s Steel drain pan Right or left hand coil 1 stubbed drain header access to match connection gas controls Condensate Drain Pan Trap The condensate drain line needs to include a P trap immediately downstream of the connection to the unit This trap should extend at least 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 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 12 2 General DX Piping Expansion Valve By Others Suction Line Remote Sensing Bulb Sauco 1 Inspect the refrigerant distributor and verify that the
108. lters 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 ft 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 provided Two position Modulating and Floating Two position Damper Actuator
109. mation refer to Control Operating Sequence 48 Air Flow Proving Switch OPT The air flow proving switch is factory installed in the duct furnace electrical junction box The air flow proving switch monitors the pressure differential between the duct furnace and the atmosphere The purpose of the air flow proving switch is to cut power to the gas controls if a positive pressure is not measured by the switch This could be caused by a lack of air movement through the heat exchanger NOTE The air flow proving switch will prevent any heat exchanger warm up because the gas controls can not be energized until air flow is proven Setting the Air Flow Proving Switch The range of the air flow proving switch is adjustable between O 17 to 5 0 W C 1 Set the thermostat so that there is a call for heat This should start the blower and then the 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 Tum 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 s
110. mper 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 16 3 4 Tighten the 5 16 hex head screw on the ball joint Figure 16 3 Damper Linkage Adjustment BALL CONNECTING ROD BLADE ARM DAMPER L Cooling Coil Operation 1 Proper air distribution is vital to coil performance Air flow anywhere on the coil face should not vary by more than 20 2 Air velocities should be maintained between 200 and 550 feet per minute 3 For chilled fluid coils fluid velocities should be maintained within the recommended values of 1 to 8 feet per second fps for Water and 1 to 6 fps for Glycol solutions 16 AIR 5 565 2 START UP PROCEDURE Control Operating Sequence IMPORTANT To prevent premature heat exchanger failure with all control Systems a blower starting mechanism must be provided so that the blower is running or energized within 45 seconds of the gas control operation Indoor duct furnaces are supplied with intermittent pilot systems with continuous retry which both the main burner and pilot burner are turned off 10096 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 com
111. mum position adjustment keeps the outdoor air damper from closing completely during System operation to provide ventilation in both the heating and cooling modes 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 a temperature of 53 F default adjustable at the mixed temperature air sensor 2 During economizer operation mechanical cooling is operated by the second stage of the cooling on the space thermostat Outdoor Air Enthalpy is Above Changeover Set Point 1 The outdoor air damper is closed to its minimum position 2 A call for cooling from the space thermostat brings on mechanical cooling For complete details on the Enthalpy Economizer controller setup and operation please refer to the latest revision of Modine publication 5 598 Setup Instructions Enthalpy Economizer Controller Figure 23 2 Enthalpy Controller AIR 5 565 2 23 OPTIONS 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
112. n the system The lines between the unit and the structure should be insulated to prevent freezing of the water 1 Once installed the coil should be pressurized to 100 psig with dry nitrogen or other suitable gas The coil should be left pressurized for a minimum of 10 minutes If the coil holds the pressure the hook up can be considered leak free If the pressure drops by 5 psig or less re pressurize the coil and wait another 10 minutes If the pressure drops again there is more than likely one or more small leaks which should be located and repaired Pressure losses greater than 5 psig would indicate a larger leak that should be isolated and repaired 2 All field brazing and welding should be performed using high quality materials and an inert gas purge such as nitrogen to reduce oxidation of the internal surface of the coil 3 All field piping must be self supporting System piping should be flexible enough to allow for thermal expansion and contraction of the coil 4 Fill the coil with water with all air vents open so that air is eliminated from within the coil circuitry and headers Verify that all vents and drains are not obstructed and do discharge a stream of water 5 Close all vents and perform a hydrostatic leak test of all brazed threaded or flanged joints valves and interconnecting piping Recheck the coil level and correct if necessary When the setup is found to be leak free discharge and discard initial water charge
113. nections The blower section back and bottom and cooling cabinet section discharge are designed to accept 90 flanged ductwork see Figure 5 2 Provide an airtight seal between the ductwork and the unit to prevent leakage Seams with cracks in the ductwork should be caulked and or taped and be of permanent type Figure 5 2 Blower Section and Cooling Cabinet Duct Connections BLOWER OR COOLING COIL SECTION DUCTWORK WITH 90 1 2 FLANGE VENTING AWARNING 1 Gas fired heating equipment must be vented do not operate unvented 2 a Model IBG ICG has a built in draft diverter additional external diverters are not required or permitted b Model IBP ICP has a built in power exhauster additional external power exhausters are not required or permitted If you are replacing an existing heater it may be necessary to resize the venting systems Improperly sized venting systems can result in vent gas leakage or the formation of condensate Refer to the National Fuel Gas Code ANSI 2223 1 or CSA B149 1 latest edition Failure to follow these instructions can result in injury or death For Model IBG ICG 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 53 for specific information about the blocked vent safety switch supplied on the unit For Model IBP ICP under no circumst
114. nhibited glycol solution that will protect the coil from the lowest possible temperatures that can occur at that locality AIR 5 565 2 49 MAINTENANCE Manifold Assembly Removal To remove the manifold Refer to Figure 50 1 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 4 Slide the manifold through the manifold bracket 5 Clean the orifices and adjust the air shutters as necessary 6 Follow steps 3 6 in reverse order to install the manifold assembly 7 Turn on the electric and gas supply 8 Check the ground union joint for leaks with a soap solution Tighten if necessary Figure 50 1 Manifold Assembly Removal ELECTRICAL JUNCTION BOX MANIFOLD SERIAL PLATE BURNER SIDE ACCESS PANEL Burner and Pilot Assembly Removal To remove the burner Refer to Figure 50 2 1 Shut off gas and electric supply 2 3 Disconnect the pilot supply line from the gas valve Disconnect the ignition cable from the ignition controller located in the electrical junction box Feed the cable through the bushing in the bottom of the electrical junction box Remove the screws holding the burner side access panel Attached to the panel are the burner retaining pins that align the burner Slide the burner assembly out The pilot is attached to the burner assembly Examine the burn
115. nit that is ETL ETL Canada certified For this reason two identification plates are used on these models The Serial Plate is used to identify the duct furnace and its components The Model Identification Plate is used to identify the complete model including blower and cooling sections Figure 54 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 54 1 and the model identification plate See Figure 55 1 For a complete description of the model number see Model Identification Modine Manufacturing Company Made in U S A 1500 Dekoven Avenue Racine WI 53403 2552 9 Phone 1 866 823 1631 GAS FIRED DUCT FURNACE FOR INDUSTRIAL COMMERCIAL USE usce us GENERATEUR D AIR CHAUD A GAINE POUR USAGE INDUSTRIEL COMMERCIAL MODEL NUMBER IN USA EOR INSTALLATIONS ABOVE 2000 FEET DERATE VOLTS masi mel F 40 OAMRNN2 4A154321 4 FOR EACH 1000 FEET OF ELEVATION ABOVE SEA ms Ai APPROVALS sm 60917094908 0034 APPROVED FOR USE IN NUMERO DE SERIE e Lu MI
116. nnect switch Check that fuses or circuit breakers are in place and sized correctly Turn all hand gas valves to the OFF position 2 Remove the blower exterior panels and open the electrical compartment door 3 Check that the supply voltage matches the unit supply voltage listed on the Model Identification plate Verify that all wiring is secure and properly protected Trace circuits to insure that the unit has been wired according to the wiring diagram 4 Checkto insure that the venting system is installed and free from obstructions 5 Check to see that there are no obstructions to the intake and discharge of the unit 6 Check the belt tension and sheave alignment Refer to Blower Adjustments for proper belt tension 7 Check bearings for proper lubrication For units provided with pillow block bearings See Model Nomenclature refer to Lubrication Recommendations for lubrication requirements 8 Check to make sure that all filters are in place and that they are installed properly according to direction of air flow 9 Perform a visual inspection of the unit to make sure no damage has occurred during installation 10 Turn on power to the unit at the disconnect switch Check to insure that the voltage between duct furnace electrical box terminals 1 and 2 is 24V 11 Check the thermostat ignition control gas valve and supply fan blower motor for electrical operation If these do not function recheck the wiring diagram Check t
117. nozzle is in place 2 All field brazing and welding should be performed using high quality materials and an inert gas purge such as nitrogen to reduce oxidation of the internal surface of the coil 3 For DX coils the use of filter dryers in the system piping is recommended along with a sight glass that has a moisture indicator 4 Connect the suction line and suction connection 5 Install the expansion valve By Others Follow the expansion valve manufacturer s recommendations for installation to avoid damaging the valve 6 Connect the liquid line to the expansion valve Pressurize the coil expansion valve assembly and suction connection to 100 psig with dry nitrogen or other suitable gas The coil should be left pressurized for a minimum of 10 minutes 7 If the coil holds pressure the installation can be considered leak free If the pressure drops by 5 psi or less repressurize the coil and wait another 10 minutes If the pressure drops again there are more than likely one or more small leaks which should be located and repaired Pressure losses greater than 5 psi would indicate a larger leak which should be isolated and repaired Be sure to check valves and fittings as potential sites for leakage or bleed 8 Use a vacuum pump to evacuate the coil and any interconnecting piping that has been open to atmosphere Measure the vacuum in the piping using a micron gauge located as far from the pump as possible the vacuum at
118. o insure that none of the Control Options have tripped 12 For units with a return air damper the return air damper linkage needs to be adjusted Refer to Damper Linkage Adjustment 13 Check to make sure that the damper opens properly without binding 14 Check the blower wheel for proper direction of rotation when compared to the air flow direction arrow on the blower housing Blower wheel rotation not air movement must be checked as some air will be delivered through the duct furnace with the blower wheel running backwards 15 Check the blower speed rpm Refer to Blower Adjustments for modification 16 Check the motor speed rpm 17 Check the motor voltage On three phase systems check to make sure all legs are in balance 18 Check the motor amp draw to make sure it does not exceed the motor nameplate rating On three phase Systems check all legs to insure system is balanced 19 Recheck the gas supply pressure at the field installed manual shut off valve The 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
119. or 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 9 Supply Voltage 460V 60Hz 3Ph 10 Altitude 1000 feet ouo With the information listed above the basic model using the Model Nomenclature shown on page 57 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 power vented that are obtained from item 5 Using the Model Nomenclature on page 57 the Model Configuration and Venting IBP 2 Determine the Furnace Input Rating MBH Using the Heating output capacity the Furnace Input Rating is determined from Table 29 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 Z2 in Selection Example Conditions the Heat Exchanger and Burner required are 409 Stainless Steel Because the Drip Pan material is not specified the standard Aluminized Steel drip pan will be used Thus the Heat Ex
120. order g Using maximum adjustment screw 4 adjust high fire manifold pressure to 3 5 W C for natural gas and 10 W C for propane gas h Disconnect power i Replace cover plate 2 and re install all wires from Maxitrol amplifier terminal 3 or duct furnace terminal 43 7 After adjustment move the field installed manual shut off valve to the OFF position and replace the 1 8 pipe plug 8 After the plug is in place move the field installed manual shut off valve to the ON position and recheck pipe plugs for gas leaks with soap solution Figure 15 1 Manifold Pressure Test Points Manifold Pressure Test Point Standard Controls Figure 15 2 Maxitrol Modulating Valve Adjustments 1 TOP HOUSING 2 COVER PLATE 3 SEAL GASKET 4 MAXIMUM ADJUSTMENT SCREW 5 MAXIMUM ADJUSTMENT SPRING 6 SOLENOID 7 MINIMUM ADJUSTMENT SPRING 8 PLUNGER 9 MINIMUM ADJUSTMENT SCREW 10 MINIMUM ADJUSTMENT SCREW STOP Air Shutter Adjustment Proper operation provides a soft blue flame with a well defined inner core A lack of primary air will reveal soft yellow tipped flames Excess primary air produces short well defined flames with a tendency to lift off the burner ports For both natural and propane gas the air shutters can be adjusted to control the burner flame height The air shutters can be accessed by reaching behind the gas valve in Figure 15 1 The larger models m
121. per rotation either manually with the manual crank or apply power Re adjust if necessary 6 If the damper end switch is being used in the control circuit and needs to be adjusted for the new minimum position refer to the next section Adjusting the Damper End Switch Figure 22 1 Two position Damper Actuator and Limiter Philips screwdriver 22 AIR 5 565 2 OPTIONS Adjusting the Damper End Switch If the damper limiter was adjusted in the previous section it may be required to adjust the Damper End Switch as follows 1 The actuator must be in its fail safe position 2 Insert the crank handle into the torx shaped hole located in the center of the adjustable switch pointer as shown in Figure 23 1 3 Gently rotate the crank until the switch pointer is at the desired switch point in degrees as shown Figure 23 1 Adjusting the Damper End Switch Rotate with crank handle Factory setting 90 60 set Modulating Damper Actuator A modulating damper actuator is provided with Air Control options GA GB GC GD GE GG GH GJ GK and GM 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 u
122. re 53 2 for additional troubleshooting information a lt BLOCKED VENT SAFETY SWITCH Figure 53 2 Blocked Vent Safety Switch Troubleshooting Flow Chart Model IBG ICG only S NO NO YES Is there a negative pressure in space see note 2 Replace blocked vent switch Does switch still trip YES YES NO Can negative pressure Is vent in compliance be corrected with NFGC YES NO Correct Install negative power vent pressure accessory Is unit overfired Reduce input Can one or more of the following be done Lengthen vertical vent run Insulate vent Use larger diameter vent Use less restrictive weather cap 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 Install power vent smoke comes back at you there is accessory spillage The flame or smoke should be pulled in Note 2 One indication of negative pressure is Install power that outside doors tend to be pulled toward inside of space exhauster accessory AIR 5 565 2 53 MODEL DESIGNATIONS Model Identification Duct furnace make up air units contain an 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 u
123. rinted instructions or if the serial number has been altered defaced or removed BUYER AGREES THAT IN NO EVENT WILL SELLER BE LIABLE FOR COSTS OF PROCESSING LOST PROFITS INJURY TO GOODWILL OR ANY OTHER CONSEQUENTIAL OR INCIDENTAL DAMAGES OF ANY KIND RESULTING FROM THE ORDER OR USE OF ITS PRODUCT WHETHER ARISING FROM BREACH OF WARRANTY NONCONFORMITY TO ORDERED SPECIFICATIONS DELAY IN DELIVERY OR ANY LOSS SUSTAINED BY THE BUYER Component Applicable Models BUYER S REMEDY FOR BREACH OF WARRANTY EXCLUSIVE OF ALL OTHER REMEDIES PROVIDED BY LAW IS LIMITED TO REPAIR OR REPLACEMENT AT THE FACTORY OF SELLER ANY COMPONENT WHICH SHALL WITHIN THE APPLICABLE WARRANTY PERIOD DEFINED HEREIN AND UPON PRIOR WRITTEN APPROVAL BE RETURNED TO SELLER WITH TRANSPORTATION CHARGES PREPAID AND WHICH THE EXAMINATION OF SELLER SHALL DISCLOSE TO HAVE BEEN DEFECTIVE EXCEPT THAT WHEN THE PRODUCT IS TO BE USED BY BUYERAS A COMPONENT PART OF EQUIPMENT MANUFACTURED BY BUYER BUYER S REMEDY FOR BREACH AS LIMITED HEREIN SHALL BE LIMITED TO ONE YEAR FROM DATE OF SHIPMENT FROM SELLER FOR GAS FIRED PRODUCTS INSTALLED IN HIGH HUMIDITY APPLICATIONS AND UTILIZING STAINLESS STEEL HEAT EXCHANGERS BUYER S REMEDY FOR BREACH AS LIMITED HEREIN SHALL BE LIMITED TO TEN YEARS FROM DATE OF SHIPMENT FROM SELLER These warranties are issued only to the original owner user and cannot be transferred or assigned No provision is made in these warranties for any labor allowan
124. rmostat 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 48 1 Blower Package Unit Operating Weights All weights in pounds Model Blower Type i Dampers Dampers i Double Wall Digit 16 Filters oh Alr F amp RA nsulation an Sections NIN Joyo E F G or H I J orK E F G or H I J orK GorH I J K or L I J K orL I J K or L _ A zx A See Motor Data Table 48 2 Cooling Package Unit Operating Weights All weights in pounds Blower Dampers Model Type Dampers Fresh amp Double Wall Size Digit 16 Filters Fresh Air Return Air Insulation All Sections 5 All 100 125 All All All EFG or H See Motor I J or K Data E F G or H l J or K 48 AIR 5 565 2 MAINTENANCE A WARNING When servicing or repairing this equipment use only factory approved service replacement parts A complete replacement parts list may be obtained by contacting Modine Manufacturing Company Refer to the rating plate on the appliance for complete appliance model number serial number and company address Any substitution of parts or controls not approved by the factory will be at the owner s risk A CAUTION Do not attempt to reuse any mechanical
125. ss Side Model Size 75 100 125 150 175 Non Access Side B 200 225 250 300 500 600 350 400 700 800 840 96 Combustion Air Requirements Units installed in tightly sealed buildings or confined spaces must be provided with two permanent openings one near the top of the confined space and one near the bottom Each opening should have a free area of not less than one square inch per 1 000 BTU per hour of the total input rating off all units in the enclosure freely communicating with interior areas having in turn adequate infiltration from the outside For further details on supplying combustion air to a confined tightly sealed space or unconfined space see the National Fuel Gas Code ANSI Z223 1 of CAN CGA B149 1 or 2 Installation Code latest edition Sound and Vibration Levels All standard blower mechanical equipment generates some sound and vibration that may require attenuation Libraries private offices and hospital facilities will require more attenuation and in such cases an acoustical consultant may be retained to assist in the application Locating the equipment away from the critical area is desirable within ducting limitations Generally a unit should be located within 15 feet of a primary support beam Smaller deflections mean lesser vibration and noise transmission UNIT LOCATION UNIT LIFTING UNIT MOUNTING UNIT LIFTING All standard blower system units are shipped fully
126. 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 The allowable minimum CFM of the system can be 66 of the minimum listed CFM in Table 29 1 if the unit is applied as follows 1 The unit is provided with 2 stage or electronic modulating gas controls 2 The unit is provided with a discharge air thermostat 3 The system does not include a room thermostat The discharge air thermostat will prevent the unit from firing above the allowable 100 F rise when the unit is at or above the minimum CFM by monitoring the discharge air and going to low fire A room thermostat because it is located remote from the unit could cause the unit to over fire 18 AIR 5 565 2 OPTIONS Options Factory Installed Figure 19 1 Factory Mounted Option Locations 46 19 21 23 DEAS 22 24 25 26 27 8 2 13 10 4 DA D ae s Q mam Og NE 27 50 90 ca OO 49 5 069 UNITS WITH PREMIUM CONTROL BOX 40 38 34 30 2 Low Gas Pressure Switch 3 High Gas Pressure Switch 4 Power Exhauster 5 Timed Freeze Protection 6 Ignition Controller 8 Control Relay 9 Differential Pressure Switch 10 Furnace Low Voltage Termina
127. tch is equipped with an override position that can be manually pulled out to override the switch See Figure 24 2 Figure 24 2 Blower Door Switch with Manual Override DOOROPEN OVERRIDE DOOR CLOSED POSITION POSITION POSITION COM NC NO 39 Dirty Filter Switch OPT The dirty filter pressure switch is factory installed in the electrical section The dirty filter pressure switch monitors the pressure differential between the two sides of the filters When the filters become dirty the differential pressure increases and trips the pressure switch which energizes a light on the remote monitoring panel The pressure differential switch must be field Set because setting the switch requires the blower to be in operation and the ductwork to be installed Setting the Dirty Filter Switch The range of the dirty filter pressure switch is adjustable between 0 17 to 5 0 W C 1 Ensure that the unit filters are clean Clean or replace if necessary 2 Connect the leads of a continuity tester to the NO and C terminals of the dirty filter pressure switch See Figure 25 1 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 unt
128. ted above For the Selection and Installation Instructions for propane conversion kits please see the latest revision of Modine Bulletin 75 511 10 AIR 5 565 2 UNIT INSTALLATION Electrical Connections WARNING 1 Disconnect power supply before making wiring connections to prevent electrical shock and equipment damage 2 All appliances must be wired strictly in accordance with wiring diagram furnished with the appliance Any wiring different from the wiring diagram could result in a hazard to persons and property 3 Any original factory wiring that requires replacement must be replaced with wiring material having a temperature rating of at least 105 C 4 Ensure that the supply voltage to the appliance as indicated on the serial plate is not 5 greater than rated voltage 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
129. the packing slip to determine the coil type provided The cooling section includes a full coverage 3 way sloping 409 stainless steel drain pan to remove condensate from coil headers thermal expansion valves and refrigerant piping Insulation is standard on outdoor units and optional on indoor units The cabinet includes two doors a removable upper door for service access to the coil once the plumbing has been installed and a lower door which includes a factory supplied 1 stubbed drain connection to the exterior of the cabinet Field connections for coil inlet and outlet piping can be made through the cabinet corner post or back of the unit The cooling section duct transition includes 1 1 2 flanges for fastening the sides of the coil The bottom duct transition is angled to remove any condensation that may be entrained in the supply air stream For field supplied coils do not exceed the maximum coil dimensions listed in Literature 82 135 The dimensions listed are for the maximum coil dimensions If the coil supplied is smaller than the listed dimensions field supplied blank off plates are required to prevent air bypass around the coil The coil is supported by two 14 gauge support rails which contain mounting provisions for fastening 4 5 6 7 5 8 5 and 10 deep coils Figure 12 1 Cooling Section Optional double wall construction DX single circuit shown and dual circuit coils available Installed DX or Chil
130. thermostat body contains the discharge air set point adjuster that must be field set AIR 5 565 2 13 Control Step Down Transformer 31 Enthalpy Controller 14 Control Relay 32 Damper to Damper Linkage 15 Blower Low Voltage Terminal Strip 33 Return Air Damper 16 Dead Front Disconnect Switch 34 Proportional Temp Controller Sensor 17 Step Down Transformer Fuses 35 Motor and Blower Vibration Isolation 18 Step Down Transformer 36 Blower Support 19 Factory Installed Minimum Positioner 37 Convenience Outlet 55 Time Delay Relay Figure 19 2 Two Stage Capillary Type Thermostat Downstream Ductwork by others Setpoint Adjuster Capillary Thermostat body Shown with cover removed 19 OPTIONS b Two stage Electronic Type Thermostat Includes a field 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 20 1 Two Stage Electronic Type Thermostat Sensor Note Second stage 5350 module not shown C Electronic Modulating Discharge Air Thermostat Includes a field installed mixing tube and discharge air sensor field installed in duct work The set point adjuster is field installed remotely and must be field set Refer to Literature 5 578 latest revision Figure 20 2 Electronic Modulating Discharge Air Thermostat
131. they may be exposed to a potentially explosive or flammable atmosphere IMPORTANT To prevent premature heat exchanger failure do not locate ANY gas fired appliances in areas where corrosive vapors i e chlorinated halogenated or acid are present in the atmosphere Location Recommendations 1 When locating the furnace consider general space and heating requirements availability of gas and electrical supply and proximity to vent locations 2 Unit must be installed on the positive pressure side of the circulating blower 3 Besure 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 notinstall units in locations where the flue products can be drawn into the adjacent building openings such as windows fresh air intakes etc 5 Besure 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
132. tilizes a resistor to convert from a 4 20 mA to 0 10 Vdc from a damper controller All modulating damper actuators are spring return so when the damper is de energized the fresh air damper will spring closed Floating Damper Actuator A floating damper actuator is provided with Air Control option HP Digits 20 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 a
133. ting listed above For Variable Air Movement Applications see page 18 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 AIR 5 565 2 29 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 10 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 10096 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 external static pressure E S
134. trol Operating Sequence 17 ODLUOFIS nha av RUE m e ERBEN dade 19 General Performance Data 28 Unit Selection oec De Il Pa ee 30 Option amp Accessory Pressure Drop Data 32 Blower Performance Data 33 Blower Sheave Assembly Data 36 Electrical Data 38 Motor Data i ua Caca WERE REM Sanu E LAE E Rue 40 DIMENSIONS es ins eek ea eee dead EP RU ena ede a 42 WEIGHS Rx X eee eb ken bete eR d 48 Maintenance c ucecienxken kr kh enden Re RE xe enden a 49 Service amp Troubleshooting 51 Model Designations 54 Start Up Checklist uy usss su pu sua ae mex Ens 56 Model Nomenclature 57 Commercial Warranty Back Page 2 AIR 5 565 2 SI METRIC CONVERSION FACTORS UNIT LOCATION SI METRIC CONVERSION FACTORS Table 3 1 To Convert Multiply By To Convert Multiply By W C 0 24 CFH 1 699 ms min psig 6 893 Btu ft 0 0374 mJ m F F 32 x 0 555 pound 0 453 kg inches 25 4 Btu hr 0 000293 kW hr feet 0 305 meters gallons 3 785 liters CFM 0 028 m min psig 27 7 W C UNIT LOCATION A DANGER Appliances must not be installed where
135. ty devices High limit air flow proving switch differential pressure switch gas pressure switches etc Determine and correct problem Reset if necessary Find source and re direct airflow away from unit Tighten pilot orifice Flame impingment on pilot sensor may cause pilot sensor to become inoperative Replace valve Check wiring to gas valve Replace pilot sensor Replace ignition controller Verify wiring compared to wiring diagram Refer to page 53 Reduce primary air Adjust to a maximum of 14 W C Check orifice size with those listed on the serial plate Increase primary air Check orifices and clean with compressed air if necessary Check manifold replace if necessary Reduce primary air Adjust to a maximim 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 2 Check orifice size with those listed on the serial plate Clean correct venting system 51 SERVICE amp TROUBLESHOOTING Trouble Not Enough Heat Too Much Heat 1 Possible Cause 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 venting system g Air distribution baffle remo
136. units should conform with local and national requirements for type and volume of gas handled and pressure drop allowed in the line Refer to Table 9 1 to determine the cubic feet per hour cfh for the type of gas and size of unit to be installed Using this cfh value and the length of pipe necessary determine the pipe diameter from Table 8 1 Where several units are served by the same main the total capacity cfh and length of main must be considered Avoid pipe sizes smaller than 1 2 Table 8 1 allows for a 0 3 W C pressure drop in the supply pressure from the building main to the unit The inlet pressure to the unit must be 6 7 W C for natural gas and 11 14 W C for propane gas When sizing the inlet gas pipe diameter make sure that the unit supply pressure can be met after the 0 3 W C has been subtracted If the 0 3 W C pressure drop is too high refer to the Gas Engineer s Handbook for other gas pipe capacities 3 The gas piping to the unit can enter the unit from the side of the unit or from below Install a ground joint union with brass seat and a manual shut off valve external of the unit casing and adjacent to the unit for emergency shut off and easy servicing of controls including a 1 8 NPT plugged tapping accessible for test gauge connection See Figure 8 1 Verify the manual shut off valve is gas tight on an annual basis 4 Provide a sediment trap before each unit in the line where low spots cannot be avoided See
137. urnace without using jumper wires The switches override the remote monitoring panel and or thermostats to energize each compo nent directly All switches need to be reset to the OFF position after testing otherwise the components will remain energized Figure 25 4 Service Switches SYSTEM OVERRIDE SWITCH POSITIONS DAMPERS ONLY ON OFF OFF qq DAMPERS amp BLOWER ONLY ON OFF ON DAMPERS BLOWER amp FURNACE ONLY ON ON ON RESET SWITCHES TO OFF POSITION AFTER TESTING ON ON on O OFF OFF OFF SHTS637A AIR 5 565 2 25 OPTIONS 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 The amplifier processes the thermostat temperature and set point signals to modulate the firing rate between 40 to 100 full fire For additional information refer to Control Operating Sequence 47 Electronic Modulating Gas Valve OPT An electronic modulating gas valve is provided factory installed in the duct furnace gas train when the unit is equipped with Electronic Modulating Gas Controls Digit 12 4 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 infor
138. used to control the gas controls damper actuator motor starter etc Refer to the unit model number to determine the volt amp VA capacity of the duct furnace The 15th digit indicates the VA See Model Nomenclature 14 Control Relay OPT The control relay is factory installed in the electrical section See description of Option 8 for additional details 15 Blower Low Voltage Terminal Strip STD The blower low voltage terminal strip is located in the electrical section The terminal strip is labeled to match the electrical wiring diagram provided with the unit Low voltage labeling ranges from terminal numbers 1 to 79 All field wiring connections should be made to the right side of the terminals to prevent miswiring by modifying the factory wiring which is made to the left side of the terminal strip 16 Dead Front Disconnect Switch OPT WARNING When the dead front disconnect switch is in the OFF position supply power remains energized at the blower supply power terminal strip and the top of the dead front disconnect switch When providing service on or near these terminals building supply power to the unit should be de energized The dead front disconnect switch is factory installed in the electrical section The disconnect switch is designed so that it must be turned OFF before entry to the electrical control cabinet can be obtained See Figure 21 1 When in the OFF position pow
139. ve thermal overload protection Overload protection is required through the use of a motor starter or variable frequency drive Motor Sizes Digit 17 A through K and V do not include a motor starter used with either a motor starter by others or variable frequency drive All others include a motor starter ODP Open Drip Proof TE Totally Enclosed the added suffix HE indicates NEMA Premium Efficiency Motor manufacturers typically do not list efficiency for three phase motors smaller than 1hp AIR 5 565 2 41 DIMENSIONS UNIT Figure 42 1 IBG Indoor Gravity Vented Blower Package Unit Dimensions 33 22 48 08 J Over Roof 3 86 L N Vent Dia gt x 2 20 I gt 3425 _ Wie Cw NN 2400 11 inside G INSIDE sun P C Width Outside U Cal m Se S 23 921 dios FAS 921 529 529 CD CD bi 5 l i l Pps s 119 s 65 Min i BOD 3 00 pprox Qty 4 Drill Locator Dimples for inside 4 85 Field Drilled Electrical Conduit Entry Holes spaced 2 0 apart Return Air Duct Connection 1 50 he 500 800 Model Shown Figure 42 2 ICG Indoor Gravity Vented Cooling Package Unit Dimensions
140. ved 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 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 Figure 52 1 Possible Remedy 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 conditions If unit is undersized an additional unit s or other heat source must be added Check replace thermostat amp 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 The duct furnace comes standard with an automatic reset high limit switch that will shut off the gas
141. wiring connections 3 The wire gauge must be sized according to the National Electric Code or CSA code based on the power supply voltage amp draw and length of run Refer to Table 11 1 for maximum wire lengths and the number of wires for which the low voltage terminal blocks in the unit are rated Table 11 1 Low Voltage 24V Maximum Wire Length ft 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 Size VA 18Ga 16Ga 14Ga 12Ga 10 Ga 162 315 360 495 86 43 26 5 1 40 216 2 75 168 192 264 3 150 4 250 Maximum of Wires per Terminal 4 Make sure all multi voltage components motors transform ers etc are wired in accordance with the power supply voltage 5 The power supply to the unit must be protected with a fused or circuit breaker disconnect switch Refer to the Factory Mounted Option Locations Figure 19 1 for the factory mounted disconnect switch location and then review the unit to determine if a factory installed dead front disconnect Switch was provided Accessory field installed disconnect Switches should be mounted where shown in Figure 11 1 For fusible disconnect switches refer to the Model Identification plate for the fuse size and type Figure 11 1 Recommended Accessory Field Installed Disconnect Switch Mounting Locations ELECTRICAL
142. witch is cooled Manual OPT The manual reset high limit switch is factory installed in place of the standard automatic reset high limit switch located in the duct furnace electrical junction box In case of a failure of the blower motor blockage of the inlet air etc the manual reset Switch prevents the unit from cycling on the high limit If the limit temperature is exceeded a service person must inspect the unit for the cause of the high discharge temperature take corrective action and then reset the switch 50 Supply Air Fire Stat OPT The supply air fire stat is factory installed in the duct furnace electrical junction box with the sensor in the discharge air stream In case of elevated temperatures in the supply air stream the manual reset switch shuts down the entire unit If the limit temperature is exceeded a service person must inspect the unit for the cause of the high discharge temperature take corrective action and then reset the switch 51 Main Gas Valve STD The main gas valve is factory installed in the duct furnace gas train The main gas valve provides the pilot regulator main gas and manual shutoff functions For additional information see the supplier literature included with the unit 52 Burner Box STD The burner box is located in the duct furnace section and contains the burner and pilot assembly The burner box includes an access panel for removal of the burner for inspection an

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