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1. 10 way sumi way sumi way sumi way sumi way sumni way suni orna way sumi onna 5 2 0 INIS 9 0 ONES 9 0 ILIS t O Sse1d ONEIS 0 5 Z O NEIS V O ONEIS 0 0 UO 5791 10 ejeq 6 580 10 GENERAL PERFORMANCE DATA Table 21 1 Power Code Description Blower Model Power Code Voltage 115 230 575 208 230 460 115 230 575 208 230 460 115 230 575 208 230 460 115 230 575 208 230 460 115 230 575 208 230 460 115 230 575 208 230 460 115 230 575 208 230 460 115 230 575 208 230 460 115 230 575 208 230 460 115 230 575 208 230 460 115 230 575 208 230 460 115 230 575 208 230 460
2. 1 1 3 3 1 1 3 3 1 1 3 3 1 1 3 3 1 1 3 3 1 1 3 3 1 1 3 3 1 1 3 3 1 1 3 3 1 1 3 3 1 1 3 3 1 1 3 3 D For selection of correct Power Code refer to the tables on page 20 6 580 10 21 PERFORMANCE DATA HOODS Table 22 1 Performance Data 30 60 and 90 Downward Deflector Hoods Mounting 30 Downward Hood For Propeller Units eig to Bottom Heater 16 36 49 18 38 15 34 47 17 37 14 33 45 15 35 12 30 42 14 33 10 27 38 12 31 6 20 29 9 26 Mounting Height t Bottom PDP of PDP 250 BDP 175 BDP 250 BDP 400 Heater 2 X Y Z X Z 9 0 0 0 0 0 0 0 0 0 0 0 Data based on units fired at full rated input with an entering air temperature of 60 80 F Maximum mounting heights higher versus units without outlet devices Data based on unit fired at full rated input 60 80 F entering air temperature and a 40 F temperature rise through unit Maximum mounting heights higher versus units without outlet devices THROW FLOOR COVERAGE 77 30 DOWNTURN HOOD eeeeeecece
3. 60 DOWNTURN HOOD io 30 ee MOUNTING ey 60 90 HEIGHT ey 9 an NOTE v ese b A n nid Nome Y Z x 30 NOZZLE Y gt 2 30 60 HOOD 22 6 580 10 90 PERFORMANCE DATA NOZZLES Figure 23 1 Mounting Height Heat Throw Heat Spread in feet 2 NOZZLE gt lt lt lt gt s 40 bw DOWNWARD E NOZZLE 5 WAY Q T H S 40 SPLITTER NOZZLE d S Eon md Table 23 1 Mounting Height Heat Throw Heat Spread in feet Model Number BDP 150 BDP 175 BDP 200 BDP 250 BDP 300 BDP 350 BDP 400 40 Max Mounting Ht ft H Downward Heat Throw ft T Nozzle Heat Spread ft S 90 Vertical Max Mounting Ht ft H Nozzle Heat Spread ft S Max Mounting Ht ft H 40 Splitter Heat Throw ft T Nozzle Heat Spread ft S 5 Way Max Mounting Ht ft H Nozzle Heat Spread ft S The above table is based on an inlet air temperature of 70 F and an air temperature rise of 55 F Air deflectors on 40 and 90 discharge nozzles set perpendicular to the face of the air discharge opening On 5 way nozzles all air deflectors set perpendicular to floor Static pressure measured at 0 1 W C for 90 nozzle 0 2 W C for 40 downward and 5 way nozzle and 0 3 W C for 40
4. Gas Connections Blower Wheel Diameter Approx Weight 152 Vent connection is 5 connected to a factory supplied vent transition For model sizes 150 and 175 the factory supplied transition is 4 to the power exhauster outlet to 5 to the vent system For model size 200 the factory supplied transition is 6 to the power exhauster outlet to 5 to the vent system BDP 150 thru BDP 300 4 holes 2 on blower and 2 on unit BDP 350 and BDP 400 6 holes 2 on blower and 4 on unit Listed is the hole diameter and threads per inch to accept threaded rod G This is an approximate dimension for standard motors allow for sheave and optional motors amp Distance between mounting hole in unit casing and mounting hole on blower On the BDP 350 and BDP 400 the distance is from rear mounting hole in casing to the mounting hole on blower For natural gas may vary depending on control availability 6 580 10 25 WARNING When servicing or repairing this equipment use only factory approved service replacement parts A complete replacement parts list may be obtained by contacting the factory 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 1 Service or repair of
5. 6 MODINE 6 580 10 5H0782130000 November 2014 INSTALLATION AND SERVICE MANUAL A WARNING 1 Improper installation adjustment alteration service or maintenance can cause property damage injury or death and could cause exposure to substances which have been determined by various state agencies to cause cancer birth defects or other reproductive harm Read the installation operating and maintenance instructions thoroughly before installing or servicing this equipment Do not locate ANY gas fired units in areas where chlorinated halogenated or acidic vapors are present in the atmosphere These substances can cause premature heat exchanger failure due to corrosion which can cause property damage serious injury or death FOR YOUR SAFETY WHAT TO DO IF YOU SMELL GAS Open windows Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Extinguish any open flame Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you can not reach your gas supplier call your fire department power vented gas fired unit heaters models PDP and BDP Listed Intertek All models approved for use in California by the CEC and in Massachusetts Unit heater is certified for non residential applications FOR YOUR SAFETY The use and storage of gasoline or other flamma
6. gt NEM gt c ume 1 m H er TO CONTROLS PLUGGED 3 E 1 8 NPT TEST GAGE CONNECTION SEDIMENT TRAP Manual shut off valve is in the OFF position when handle is perpendicular to pipe Table 10 1 Sea Level Manifold Pressure amp Gas Consumption i Propane Model Size y s vid zu bi Orifices CFH Gal Hr Propane Orifice Drill Size CFH Gal Hr Propane Orifice Drill Size CFH Gal Hr Propane Orifice Drill Size CFH Gal Hr Propane Orifice Drill Size CFH Gal Hr Propane Orifice Drill Size CFH Gal Hr Propane Orifice Drill Size CFH Gal Hr Propane Orifice Drill Size Table 10 2 Gas Pipe Capacities Natural Gas 2 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 of 1 1 4 pipe The natural gas capacity is 400 CFH Divide by 1 6 to get 250 CFH for propane gas 6 580 10 INSTALLATION HIGH ALTITUDE ACCESSORY KIT HIGH ALTITUDE ACCESSORY KIT Modine s gas fired equi
7. 17 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 18 Recheck the gas supply pressure at the field installed manual shut off valve The minimum inlet pressure should be 6 W C on natural gas and 11 W C on propane gas The maximum inlet pressure for either gas is 14 W C If inlet pressure exceeds 14 W C a gas pressure regulator must be added upstream of the combination gas valve 19 Open the field installed manual gas shut off valve 20 Open the manual main gas valve on the combination gas valve Call for heat with the thermostat and allow the pilot to light for intermittent pilot ignition If the pilot does not light purge the pilot line If air purging is required disconnect the pilot line at outlet of pilot valve In no case should line be purged into heat exchanger Check the pilot flame length See Pilot Flame Adjustment 21 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 Inspect the condition of the main flame and if necessary resolve flame appearance problems see Burner Flame Adjustment and Figures 28 1 through 28 4 22 Check to insure that gas controls sequence properly see Control Operating Sequence Verify if the un
8. NFPA 54 latest edition and other applicable local building codes In Canada the installation of these units must comply with local plumbing or waste water codes and other applicable codes and with the current code CSA B149 1 1 All installation and service of these units must be performed by a qualified installation and service agency only as defined in ANSI 2223 1 NFPA 54 latest edition or in Canada by a licensed gas fitter 2 This unit is certified with the controls furnished For replacements parts please order according to the replacement parts list on serial plate Always know your model and serial numbers Modine reserves the right to substitute other authorized controls as replacements 3 Unit is balanced for correct performance Do not alter fan or operate motors at speeds below what is shown in this manual 4 Information on controls is supplied separately 5 The same burner is used for natural and propane gas SI Metric Conversion Factors To Convert Multiply By To Obtain W C 0 249 kPa oF F 32 x 5 9 C BTU 1 06 kJ Btu ft3 37 3 kJ m3 Btu hr 0 000293 kW ftS hr 0 000472 m3 min ftS hr 0 00000787 m3 s CFM 0 0283 m3 min CFM 0 000472 m3 s feet 0 305 m Gal Hr 0 00379 m3 hr Gal Hr 3 79 gallons 3 79 Horsepower 746 inches 25 4 mm pound 0 454 kg psig 6 89 psig 27 7 6 580 10 3 SI METRIC C
9. Table 20 1 Models With or Without Blower Enclosure Blower Model BDP GENERAL PERFORMANCE DATA eis alo x 2 So SAUP ASZS 20 dH z I L 8 1 Pars 215 glg amp 28 8 eu Ajoeds Ag 8 10 dH 2 1 1 9 1 AO9v O 2 5 20 a9 olo o O O O O 2 RI 5 x o 2 o ES e SISSE S Buuepio ueuM Heys 8 2 n 22 z 55 ge Z BABAYS JOJOW teures 3y S 5 Ale i 92025 se siequnu e Zu 2259 Slolololo olo pue eures BSN UMOYS jou 9 55 ala 2 g gole a a Sis udi xoeuo 104 25 S T 2 gt 538 S s b 2985585 uedo suin 5 A HE g 3 28 s 3 S 2856 55 2g eBseessis ees epeue jdde seoa 8 25 O29o582z9 amp aalala eos 0001 Y SS oSot c22 Alala lA lalalo wj Cals aq 0 spaau 0002 104 S23 8 855592 m m m m m m 0002 0 dn suone eje ee lt 2 5912 02 5202255
10. be made for disposal of condensate 7 When locating units it is important to consider that the exhaust vent piping must be connected to the outside atmosphere 8 Maximum equivalent vent lengths are listed in Section A General Instruction All Units of the Venting Instructions 9 Do not install units in locations where gas ignition system is exposed to water spray rain or dripping water 10 Do not install units below 7 measured from the bottom of the unit to the floor unless properly guarded to provide protection from moving parts Figure 4 1 Combustible Material and Service Clearances Side 5 Table 41 Combustible Material Clearances Access Non Access Top of Power Model Side Side Bottom Exhauster Size A B C D Not shown 150 175 1 1 4 12 2 200 400 1 T 5 12 Provide sufficient room around the heater to allow for proper combustion and operation of fan Free area around the heater must not be less than 1 1 2 times the discharge area of the unit Table 4 2 Recommended Service Clearances Access Non Access Top of Power Model Side Side Top Bottom Exhauster Size A B C D Not shown 150 175 18 18 6 22 2 200 400 18 18 6 25 3 Combustion Air Requirements The National Fuel Gas Code defines an unconfined space as a space whose volume is gr
11. splitter nozzle Outlet velocities are approximately 1 750 FPM for the 40 nozzles 1 000 FPM for the 90 nozzle and 1 300 FPM for 5 way For motor size drive and blower rpm refer to page 20 Mounting height measured from bottom of unit 6 580 10 23 DIMENSIONAL DATA Figure 24 1 Dimensional Drawings Propeller Units Model PDP i m aie W U cx EE E D OPENING MIN DISTANCE TO WALL Table 24 1 Dimensions inches PDP Dimension Model Number Symbol PDP 150 PDP 175 PDP 200 PDP 250 PDP 300 PDP 350 PDP 400 23 1 2 25 5 8 25 5 8 28 5 8 33 5 8 40 35 1 4 40 1 4 40 1 4 40 1 4 40 1 4 22 25 25 25 25 25 21 1 16 23 316 23 316 26 3 16 31 3 16 20 24 24 24 24 24 12 13 1 2 13 1 2 14 6 9 16 7 1 2 7 1 2 7 1 2 7 1 2 19 7 8 22 25 30 36 3 8 509 50 6 6 6 K 38 16 3 8 16 38 16 3 8 16 L 35 9 16 40 3 4 40 3 4 44 3 16 29 96 34 11 16 38 3 16 5 5 16 16 9 9 7 1 4 7 1 4 3 3 8 6 13 16 32 7 8 32 7 8 35 1 2 40 1 2 as Connections 3 4 3 4 Fan Diameter 22 24 Approx Weight 338 418 Do not use propeller units with duct work Q Vent connection is 5 connected to a factory supplied vent transition For model sizes 150 and 175 the factory supplied transition is 4 to the power exhauster outlet to 5 to the vent system For model size 200 the fa
12. 250 000 Btu hr input etc Dev Digit Heat Exchanger Burner Fan Guard Digit A Aluminized Steel Aluminized Steel N None all blower models S Stainless Steel Aluminized Steel S Standard T Stainless Steel Stainless Steel F Fingerproof Ignition Type Control Code Type E Intermittent Pilot 30 Complete Control Code descriptions are shown Power Code on page 18 01 02 etc Complete Power Code descriptions are shown on pages 19 and 21 6 580 10 29 30 THIS PAGE INTENTIONALLY LEFT BLANK 6 580 10 THIS PAGE INTENTIONALLY LEFT BLANK 6 580 10 31 COMMERCIAL WARRANTY Seller warrants its products to be free from defects in material and workmanship EXCLUSIVE HOWEVER of failures attributable to the use of materials substituted under emergency conditions for materials normally employed This warranty covers replacement of any parts furnished from the factory of Seller but does not cover labor of any kind and materials not furnished by Seller or any charges for any such labor or materials whether such labor materials or charges thereon are due to replacement of parts adjustments repairs or any other work done This warranty does not apply to any equipment which shall have been repaired or altered outside the factory of Seller in any way so as in the judgment of Seller to affect its stability nor which has been subjected to misuse negligence or operating conditions in excess of those for whi
13. 86 0 84 1 10 1 28 Model Size 115V 1ph 175 2 35 230V 1ph 0 84 1 28 460V 3ph 0 42 0 72 575V 3ph 0 44 0 62 150 175 200 400 Ratings shown are for elevations up to 2 000 feet For elevations above 2 000 feet ratings should be reduced at the rate of 4 for each 1 000 feet above sea level In Canada see rating plate Reduction of ratings requires use of a high altitude kit Data taken at 55 F air temperature rise At 65 F ambient and unit fired at full rated input Mounting height as measured from bottom of unit and without deflector hoods G All motors used are produced rated and tested by reputable manufacturers in accordance with NEMA standards and carry the standard warranty of both the motor manufacturer and Modine Model BDP motors are totally enclosed and all single phase motors have built in thermal overload protection amp Amp draw data shown is operating amp draw at incoming power For units that use a field installed accessory step down transformer as noted the amp draw shown is the primary side operating amp draw For sizing of circuit protection for equipment with transformers please refer to the National Electric Code For BDP models add the Motor Amp Draw and Control Circuit Amp Draw to get the Total Unit Amp Draw Transformers for blower models are typically smaller than those used for propeller models as the transformer is not needed for the blower motor 6 580 10 19
14. a stiff non wire brush 5 The heat exchanger should be checked annually for cracks and discoloration of the tubes If a crack is detected the heat exchanger should be replaced before the unit is put back into service If the tubes are dark gray airflow across the heat exchanger should be checked to insure that a blockage has not occurred or the blower is operating properly Electrical Wiring The electrical wiring should be checked annually for loose connections or deteriorated insulation Gas Piping amp Controls The gas valves and piping should be checked annually for general cleanliness and tightness The gas controls should be checked to ensure that the unit is operating properly Propeller Assembly Check the motor for lubrication if the motor is not permanently lubricated Inspect the fan for damage and fit on motor shaft Clean any dust dirt or foreign matter from the fan blades 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 stret
15. amp Gas heating values are derated 4 per 1 000 of elevation in the USA and 10 between 2 000 and 4 500 elevation in Canada in accordance with ANSI 2223 1 and CSA B149 respectively ET 11 3 High Altitude Kits for PDP BDP U S A and Canada Model Model size 2 001 4 500 ft 4 501 5 500 ft 5 501 6 500 ft 6 501 7 500 ft Label onl 150 400 LEUR Code Label only Label only Label only For Label Only kits Modine part number 5H0807146005 is required to be filled out and attached to the unit by the installer Please contact the local Modine representative at 1 866 828 4328 HEAT 6 580 10 11 INSTALLATION HIGH ALTITUDE ACCESSORY KIT If the heating value of the gas being supplied is different than the values shown in Tables 11 1 and 11 2 use the following equation to determine the appropriate manifold pressure for the altitude and gas heating value being supplied Equation 12 1 Manifold Pressure for Derated Gas _ BTU ra args 2 x MPs WHERE Manifold Pressure in W C at Altitude Manifold pressure setting for the heater being installed BTU BTU ft Content of Gas Obtained from Tables 11 1 or 11 2 whichever is applicable BTU BTU ft Content of Gas Obtained from the local utility company MP Manifold Pressure in W C at Sea Level Use 3 5 W C for natural gas and 10 0 W C for propane gas NOTE Only the primary manif
16. applied midway between the sheaves see Figure 14 3 Since the belt tension will decrease dramatically after an initial run in period it is necessary to periodically re check the tension Excessive tension will cause bearing wear and noise 4 The blower bearings are lubricated for life however before initial unit operation the blower shaft should be lubricated at the bearings with SAE 20 oil This will reduce initial friction and start the plastic lubricant flowing 5 Make electrical connections as outlined in the section Electrical Connections on page 13 Blower Adjustments Following electrical connections check blower rotation to assure blow through heating If necessary interchange wiring to reverse blower rotation Start fan motor and check blower sheave RPM with a hand held or strobe type tachometer RPM should check out with the speeds listed in Performance Data shown on page 20 A single speed motor with an adjustable motor sheave is supplied with these units If blower fan speed changes are required adjust motor sheave as follows NOTE Do not fire unit until blower adjustment has been made or unit may cycle on limit overheat control 1 Shut off power before making blower speed adjustments Refer to Determining Blower Speed on page 13 and to Performance Data on page 20 to determine proper blower RPM 2 Loosen belt and remove from motor sheave 3 Loosen set screw on outer side of adjustable motor sheave see F
17. at the front of the burner are located properly on their shoulder rivets and that the burner retaining pins are put back into their proper locations Reconnect the ignition cable and pilot gas supply line 8 Turn on the electric and gas supply N 26 6 580 10 SERVICE amp TROUBLESHOOTING Table 27 1 Troubleshooting Trouble Pilot does not light Main burners do not light Pilot is lit Lifting Flames See Figure 28 2 Yellow Tipping With propane gas some yellow tipping is always present Wavering Flames See Figure 28 1 Flashback Floating Flames see Figure 28 3 Flame Rollout see Figure 28 4 SNA A PONS Possible Cause Main gas is off Power supply is off Air in gas line Dirt in pilot orifice Gas pressure out of proper range Pilot valve does not open a Defective ignition controller b Blown fuse on control board c Defective gas valve No spark at ignitor a Loose wire connections b Pilot sensor is grounded c Blown fuse on control board d Defective ignition controller Safety device has cut power Pilot valve is off Dirty thermocouple contact Excessive drafts Pilot orifice Fitting leak Defective valve Loose wiring Defective pilot sensor Defective ignition controller Improper thermostat wiring Too much primary air Main pressure set too high Orifice too large Insufficient primary air Dirty orifice Misaligned orifice Dr
18. factory installed on the left side air blowing at you of the unit heater If the limit temperature is exceeded the gas controls are de energized until the switch is cooled Pressure Switch STD An automatic reset vent pressure switch is designed to prevent operation of the main burner if there is restricted venting of flue products This restriction may occur due to an improper vent diameter long vent runs unapproved vent terminal high winds high negative pressure within space etc After the cause of the restriction has been corrected the pressure switch will reset automatically See the troubleshooting section for more information Power Exhauster STD All power vented unit heaters are supplied with a round vent pipe connection Some models may require the use of a vent transition from the power exhauster outlet to the vent pipe see Table 6 1 The power exhauster may be rotated 180 to allow for various venting directions Blower Motor STD on BDP models only The blower motor can be provided in a variety of supply voltages and motor horsepowers Refer to the model nomenclature to determine the 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 Table 18 1 Control Descriptions Models PDP amp BDP Control Code Thermostat Voltage Service Voltage Co
19. failure etc and freight prepaid OPTIONAL SUPPLEMENTAL WARRANTY Provided a supplemental warranty has been purchased Seller extends the warranty herein for an additional four 4 years on certain compressors Provided a supplemental warranty has been purchased Seller extends the warranty herein for an additional four 4 years or nine 9 years on certain heat exchangers EXCLUSION OF CONSUMABLES amp CONDITIONS BEYOND SELLER S CONTROL This warranty shall not be applicable to any of the following items refrigerant gas belts filters fuses and other items consumed or worn out by normal wear and tear or conditions beyond Seller s control including without limitation as to generality polluted or contaminated or foreign matter contained in the air or water utilized for heat exchanger condenser cooling or if the failure of the part is caused by improper air or water supply or improper or incorrect sizing of power supply APPLICABLE WARRANTY PERIOD TEN YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER WITHIN Heat Exchangers Gas Fired Units OCCURS FIRST TEN YEARS FROM DATE OF RESALE BY BUYER OR ANY OTHER USER WITHIN TEN YEARS FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION OR WITHIN ONE HUNDRED TWENTY SIX MONTHS FROM DATE OF SHIPMENT FROM SELLER WHICHEVER Heat Exchangers Low Intensity Infrared Units Compressors Condensing Units for Cassettes FIVE YEARS FROM DATE OF FIRS
20. of a 90 elbow is 6 for 5 diameter and 7 for 6 diameter C5 All horizontal Category III vents must be terminated with a listed vent cap The cap must terminate a minimum distance beyond the exterior wall surface as shown in Figure 9 2 and Table 9 1 The vent must be supported as shown in Figure 9 1 Precautions must be taken to prevent degradation of building materials by flue products Table 9 1 Dimension Between Vent Cap and Exterior Wall Vent Terminal A Min Selkirk Starkap or Constant Air Flo 2433 Gary Metals 1092 or Modine 5H072285 Tjernlund VH1 Figure 9 1 Exhaust Vent Construction Through Combustible Walls and Support Bracket FIBER GLASS INSULATION MIN 2 VENT PIPE DIAMETER d METAL FACE PLATE 4 34 VENT TERMINATION SUPPORT BRACKET where required Make from 1 x 1 steel angle Figure 9 2 Horizontal Venting PITCH VENT PIPE DOWNWARD FROM UNIT 1 4 PER FOOT LI Min POWER EXHAUSTER OUTLET LISTED TERMINAL 7 1 k y k aA V TEEWITHDRIP LEG AND CLEANOUT AT LOW POINT OF F VENT SYSTEM C6 When condensation may be a problem the vent system shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators relief openings or othe
21. 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 884 latest edition and in repair garages the standard for repair garages 30A latest edition formerly 888 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 CSA B149 codes In aircraft hangars keep the bottom of the unit at least 10 from the highest surface of the wings or engine enclosure of the highest aircraft housed in the hangars and in accordance with the requirements of the enforcing authority and or NFPA 409 latest edition Installation of units in high humidity or salt water atmospheres will cause accelerated corrosion resulting in a reduction of the normal life of the units Do not install units below 7 measured from the bottom of the unit to the floor in commercial applications unless unit is properly guarded to provide user protection from moving parts Be sure no obstructions block air intake and discharge of unit heaters The minimum distance from combustible material is based on the combustib
22. properly according to direction of air flow if applicable 9 Perform a visual inspection of the unit to make sure no damage has occurred during installation Lower bottom pan and visually inspect all components in the burner compartment Check to ensure all fasteners are in place and the burner openings are properly aligned with the heat exchanger tubes and that the gas orifices are centered in the burner inspirator tube opening opening as shown in Figure 16 2 10 Check that all horizontal deflector blades are open a minimum of 30 as measured from vertical 11 Turn on power to the unit at the disconnect switch Check to insure that the voltage between electrical junction box terminals T1 and G is 24V 12 Check the thermostat ignition control gas valve and supply fan blower motor for electrical operation If these do not function recheck the wiring diagram Check to insure that none of the Control Options have tripped 13 Check the blower wheel for proper direction of rotation when compared to the air flow direction arrow on the blower housing if applicable Blower wheel rotation not air movement must be checked as some air will be delivered through the unit with the blower wheel running backwards 14 For blower units check the blower speed rpm Refer to Blower Adjustments for modification 15 Check the motor speed rpm 16 Check the motor voltage On three phase systems check to make sure all legs are in balance
23. sizes 350 and 400 and all BDP units except size 350 and 400 and 3 kits for BDP unit sizes 350 and 400 6 580 10 Figure 5 1 Adjustable Mounting Brackets To Adjust PE L L J 2 1 Remove outer side panels 2 Set screws loosen and position bracket where needed then tighten set screws 3 Re attach outer side panels Figure 5 2 Suspension Methods LATA Threaded Rod Suspension 3 s L Suspension with Pipe Adapter Kit INSTALLATION VENTING A WARNING Gas fired heating equipment must be vented do not operate unvented A built in power exhauster is provided additional external power exhausters are not required or permitted existing heater is being replaced 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 54 or CSA B149 1 latest edition Failure to follow these instructions can result in serious injury or death 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 A CAUTION Installation 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 edit
24. unit continues to operate until the thermostat is satisfied at which time both the main and pilot valves close 100 8 The air mover stops after 30 to 90 seconds to remove residual heat from the heat exchanger 6 580 10 17 UNIT AND CONTROL OPTIONS Figure 18 1 Factory Mounted Option Location t All units include the standard STD features The unit must reviewed to determine the optional OPT features that may have been supplied with the unit Gas Valve a Single Stage Gas Valve STD 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 b Two Stage Gas Valve OPT The two stage gas valve provides the pilot regulator main gas 100 and 50 fire and manual shutoff functions For additional information see the supplier literature included with the unit Ignition controller STD The ignition controller is factory installed on the back of the unit heater with the spark igniter and sensor located on the burner For additional information refer to Control Operating Sequence on page 16 and the supplier literature included with the unit G Time Delay Relay STD The time delay relay is factory in
25. 20 Check the gas inlet pressure at the unit upstream of the combination gas control The inlet pressure should be 6 7 W C on natural gas or 12 14 W C on propane If inlet pressure is too high install an additional pressure regulator upstream of the combination gas control Service or repair of this equipment must be performed by a qualified service agency Do not attempt to reuse any mechanical or electronic ignition controller which has been wet Replace defective controller IMPORTANT prevent premature heat exchanger failure do not locate ANY gas fired appliances in areas where corrosive vapors i e chlorinated halogenated or acidic are present in the atmosphere 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 Start up and adjustment procedures must be performed by a qualified service agency BEFORE YOU BEGIN A CAUTION 1 All literature shipped with this unit should be kept for future use for servicing or service diagnostics Leave manual with the owner Do not discard any literature shipped with this unit 2 Consult piping electrical and venting instructions in this manual before final installation 3 Do not attach ductwork air filters or polytubes to any propeller unit heater In the U S the installation of these units must comply with the National Fuel Gas Code ANSI 2223 1
26. 403 Phone 1 800 828 4328 HEAT www modinehvac com
27. FROM BREACH OF WARRANTY NONCONFORMITY TO ORDERED SPECIFICATIONS DELAY IN DELIVERY OR ANY LOSS SUSTAINED BY THE BUYER 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 BUYER AS A COMPONENT PART OF EQUIPMENT MANUFACTURED BY BUYER BUYER S REMEDY FOR BREACH AS LIMITED HEREIN SHALL BE LIMITED TO ONE YEAR FROM DATE OF SHIPMENT FROM SELLER FOR GAS FIRED PRODUCTS INSTALLED IN HIGH HUMIDITY APPLICATIONS AND UTILIZING STAINLESS STEEL HEAT EXCHANGERS BUYER S REMEDY FOR BREACH AS LIMITED HEREIN SHALL BE LIMITED TO TEN YEARS FROM DATE OF SHIPMENT FROM SELLER These warranties are issued only to the original owner user and cannot be transferred or assigned No provision is made in these warranties for any labor allowance or field labor participation Seller will not honor any expenses incurred in its behalf with regard to repairs to any of Seller s products No credit shall be issued for any defective part returned without proper written authorization including but not limited to model number serial number date of
28. ONVERSION FACTORS UNIT LOCATION UNIT LOCATION A DANGER Appliances must not be installed where they may be exposed to a potentially explosive or flammable atmosphere A CAUTION Clearances to combustible materials are critical Be sure to follow all listed requirements Heaters are designed for use in heating applications with ambient startup temperatures between 40 F and 90 F and ambient operating temperatures between 40 F and 90 F Do not install unit outdoors 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 In parking garages the unit must be installed in accordance with the standard for parking structures ANSI NFPA 88A latest edition and in repair garages the standard for repair garages NFPA latest edition formerly 888 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 CSA B149 codes In aircraft hangars keep the bottom of the unit at least 10 from the highest surface of the wings or engine enclosure of the highest aircraft housed in the hangars and in accordance with the requirements of the enforcing authority and or 409 latest edition Installation of units in high h
29. PCO1 230 60 1 PCO2 208 60 1 Table 19 2 Propeller Unit Model PDP Operating Electrical Data Model PDP Sizes 200 250 300 1 6 1 6 1 6 HP For motor size details refer to pages 20 and 21 Supply Voltage Power Code Motor Amps Total Amps Transformer kVA Transformer kVA 208V Total Amps Motor Amps Total Amps Transformer kVA 230V Total Amps Motor Amps Total Amps 115V 1 Phase x 01 115V with Transformer 208V 1 Phase 03 208V 01 115V with Transformer 230V 1 Phase 02 230V 208V 3 Phase 01 115V with Transformer kVA Transformer 208V Total Amps 230V 3 Phase 01 115V with Transformer kVA Transformer 230V Total Amps 460V 3 Phase 01 115V with Transformer kVA Transformer 460V Total Amps 575V 3 Phase 01 115V with Transformer kVA Transformer 575V Total Amps Table 19 5 Blower Model BDP Accessory Transformer Size kVA Table 19 3 Blower Model Motor Amp Draw Supply Voltage 115V 1ph 230V 1ph 208V 3ph 230V 3ph 460V 3ph 575V 3ph Supply Voltage 230V 460V n a 0 25 0 50 Model Size 150 175 200 400 n a Table 19 4 Blower Model BDP Control Circuit Amp Draw 2 Supply Voltage 208V 3ph 230V 3ph 0
30. T 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 TWO YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER WITHIN Other TWO YEARS FROM OF RESALE BY BUYER IN ANY UNCHANGED CONDITION OR WITHIN S THIRTY MONTHS FROM DATE OF SHIPMENT FROM SELLER WHICHEVER OCCURS FIRST Components excluding Heat Exchangers Coils Condensers Burners Sheet Metal Heat Exchangers Coils Indoor and Outdoor Duct Furnaces and System Units Steam Hot Water Units Oil Fired Units Electric Units Cassettes Vertical Unit Ventilators Geothermal Units Compressors Vertical Unit Ventilators Geothermal Units Burners High Intensity Infrared Units Sheet Metal Parts All Products ONE YEAR FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER WITHIN ONE YEAR FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION OR WITHIN EIGHTEEN MONTHS FROM DATE OF SHIPMENT FROM SELLER WHICHEVER OCCURS FIRST As Modine Manufacturing Company has a continuous product improvement program it reserves the right to change design and specifications without notice MODINE Modine Manufacturing Company 2014 Modine Manufacturing Company 1500 DeKoven Avenue Racine WI 53
31. TU content heating value before operating any heater Tables 11 1 and 11 2 show the standard derated heating values 496 per 1 000 of elevation in the USA and 1096 between 2 001 and 4 500 elevation in Canada of natural and propane gases at various altitudes If the utility is supplying gas with heating values as shown in Tables 11 1 and 11 2 the manifold pressure should be set to 3 5 W C for natural gas and 10 0 W C for propane gas NOTE Only the high fire gas pressure need be adjusted low fire gas pressure should remain the same Table 11 2 Propane Gas Heating Values at Altitude 2 Altitude ft 0 2 000 Gas Heating Values at Altitude BTU ft3 USA Canada 2 001 3 000 3 001 4 000 4 001 4 500 2 001 3 000 3 001 4 000 4 001 4 500 4 501 5 000 4 501 5 000 5 001 6 000 5 001 6 000 6 001 7 000 6 001 7 000 7 001 8 000 7 001 8 000 8 001 9 000 8 001 9 000 9 001 10 000 9 001 10 000 Values shown are for 3 5 W C manifold pressure for other BTU content values available from local utility use Equation 12 1 to calculate manifold pressure Values shown are for 10 0 W C manifold pressure for other BTU content values available from local utility use Equation 12 1 to calculate manifold pressure When installed at altitudes above 2 000 a pressure switch may need to be changed Refer to Table 11 3 to determine if a switch change is required
32. afts across burner Misalignment of burner Cracked heat exchanger 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 6 580 10 YONA PON Sa Possible Remedy Open manual gas valve 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 Fuse c Replace gas valve a Check all ignition controller wiring b Replace sensor if cracked or worn c Replace fuse d Replace ignition controller Check all safety devices High limit pressure switch blocked vent safety Switch etc Determine and correct problem Reset if necessary Turn gas control knob or lever on combination gas control to pilot position Be sure thermocouple contact is clean If problem persists replace thermocouple Find source and re direct airflow away from unit Tighten pilot orifice Flame impingement on thermocouple may cause thermocouple to become inoperative Replace valve Check wiring to gas valve Replace pilot sensor Replace ignition controller Verify wiring compared to wiring dia
33. 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 Install a ground joint union with brass seat and a manual shut off valve 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 10 1 4 Use 2 wrenches when connecting field piping to units 5 Provide a sediment trap before each unit and in the line where low spots cannot be avoided see Figure 10 1 6 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 10 Figure 10 1 Recommended Sediment Trap Manual Shut off Valve Installation for Gas Connection GAS SUPPLY LINE GROUND ls JOINT eA NION rit W BRASS MANUALGAS SEAT SHUT OFF VALVE GAS por od SUPPLY LINE o poses as ad
34. as material distortion or discoloration A9 Avoid venting through unheated space when possible When venting does pass through an unheated space or if the unit is installed in an environment that promotes condensation insulate runs greater than 5 to minimize condensation Inspect for leakage prior to insulating and use insulation that is noncombustible with a rating of not less than 400 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 8 1 Table 6 1 Vent Pipe Diameters Transitions and Total Equivalent Vent Pipe Lengths for Horizontal Vent Systems Model Vent Transition Vent Pipe Minimum Maximum Size Included Diameter Eqv Length Eqv Length eo 175 405 2 j e 200 ses s 2 s 7 7 Figure 6 1 Venting Through Combustible Roof or Wall Double Wall Vent Pipe Specified 4 amp 4 Terminal Single Wall Vent Pipe Specified a Terminal Flashing Listed Clearance Specified Thimble by Type B Vent Mfg Flashing Single Wall Double Wall Specified Single Wall Vent Pipe Terminating SS Terminal with Double wall vent pipe Clearance by Vent Mfg Specified la Terminal Single Wall Vent Pipe Listed Thimble See Instruction A12 for attaching single wall pipe
35. aust end of the double wall vent pipe 3 Drill 3 holes through the pipe and the vent terminal Using 3 4 long sheet metal screws attach the cap to the pipe Do not over tighten How to connect a single wall vent system to a double wall Type B vent pipe 1 Slide the single wall pipe inside the inner wall of the double wall pipe 2 Drill 3 holes through both walls of the single and double wall vent pipes Using 3 4 sheet metal screws attach the 2 pieces of pipe Do not over tighten 3 The gap between the single and double wall pipe must be sealed but it is not necessary to fill the full volume of the annular area To seal run a large bead of 400 F silastic around the gap A13 Vent termination clearances must be maintained Table 7 1 Vent Termination Clearances A16 The venting system must be exclusive to a single appliance and no other appliance is allowed to be vented into it A17 Precautions must be taken to prevent degradation of building materials by flue products A18 Single wall vent pipe must not pass through any unoccupied attic inside wall concealed space or floor A19 Uninsulated single wall vent pipe must not be used outdoors for venting appliances in regions where the 99 winter design temperature is below 32 F A20 The vent terminal must be Table 7 2 Vent Terminals Model Size Modine PN Other Listed Terminals 150 200 Gary Steel 1092 Tjernlund VH1 Starkap Selkirk or Constant Air F
36. ble 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 All installation and service of these units must be performed by a qualified installation and service agency Inspection on Arrival 1 Inspect unit upon arrival In case of damage report it immediately to transportation company and your local Modine 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 Table of Contents Inspection on Arrival nope melee RR 1 Special Precautions 2 SI Metric Conversion Factors 3 Before You eos pee ed edd Oe bots 3 Unit LOCaliOn ids m ciere ieee eee 4 Combustible Material and Service Clearances 4 Unit Mounting ace Rte tme mens 5 Installation een hed ete pe ede ee een ded dns 6 REN CE 6 Gas Connections 2 2 10 High Altitude Accessory Kit 11 Electrical oser ssp lp eee ev eke 13 Start Up Procedure Operation 15 Unit Components e saree sank arnat raa 18 Perfo
37. ch such equipment was designed This warranty does not cover the effects of physical or chemical properties of water or steam or other liquids or gases used in the equipment BUYER AGREES THAT SELLER S WARRANTY OF ITS PRODUCTS TO BE FREE FROM DEFECT IN MATERIAL AND WORKMANSHIP AS LIMITED HEREIN SHALL BE IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES EITHER EXPRESS OR IMPLIED WHETHER ARISING FROM LAW COURSE OF DEALING USAGE OF TRADE OR OTHERWISE THERE ARE NO OTHER WARRANTIES INCLUDING WARRANTY OF MERCHANTABILITY OR FITNESS FOR PURPOSE WHICH EXTEND BEYOND THE PRODUCT DESCRIPTION CONFIRMED BY BUYER AND SELLER AS OF THE DATE OF FINAL AGREEMENT This warranty is void if the input to the product exceeds the rated input as indicated on the product serial plate by more than 5 on gas fired and oil fired units or if the product in the judgment of SELLER has been installed in a corrosive atmosphere or subjected to corrosive fluids or gases been subjected to misuse negligence accident excessive thermal shock excessive humidity physical damage impact abrasion unauthorized alterations or operation contrary to SELLER S printed instructions or if the serial number has been altered defaced or removed BUYER AGREES THAT IN NO EVENT WILL SELLER BE LIABLE FOR COSTS OF PROCESSING LOST PROFITS INJURY TO GOODWILL OR ANY OTHER CONSEQUENTIAL OR INCIDENTAL DAMAGES OF ANY KIND RESULTING FROM THE ORDER OR USE OF ITS PRODUCT WHETHER ARISING
38. ching After the initial start up monthly checks are recommended Manifold Assembly Removal To remove the manifold 1 Shut off gas and electric supply 2 Lower bottom pan to expose burner and manifold see Figure 16 2 3 Disconnect pilot tubing and thermocouple lead or ignition cable at the combination gas control and ignition control 4 Disconnect control wires for the combination gas control Disconnect gas manifold at ground union joint 6 Remove the 2 screws holding the manifold to the heat exchanger support 7 Clean the orifices and adjust the air shutters as necessary 8 Follow steps 2 6 in reverse order to install the manifold assembly 9 Turn on the electric and gas supply 10 Check the ground union joint for leaks with a soap solution Tighten if necessary a Burner and Pilot Assembly Removal To remove the burner 1 Shut off gas and electric supply 2 Lower bottom pan to expose burner and manifold see Figure 16 2 3 Disconnect pilot tubing and thermocouple lead or ignition cable at the combination gas control and ignition control 4 Remove the 2 burner retaining pins holding the burner in place The burner can then be easily lowered from the unit 5 Examine the burner and pilot assembly for cleanliness and or obstructions as necessary see General Unit for cleaning instructions 6 Replace the burner assembly in reverse order In replacing the burner be certain that the slots
39. ctory supplied transition is 6 to the power exhauster outlet to 5 to the vent system PDP 150 through PDP 300 2 holes and the level hanging adjustment feature PDP 350 through PDP 400 4 holes Listed is the hole diameter and threads per inch to accept threaded amp Dimension equals overall plus 6 For natural gas may vary depending on control availability 24 6 580 10 DIMENSIONAL DATA Figure 25 1 Dimensional Drawings Blower Units Model BDP DD 9 p gt 5 916 w a BLOWER FILTER RACK 0 OPENING gt APPROX 7 encrosune lt _ L MIN DISTANCE WALL J OPTIONAL 2 A 1 1 MIN DISTANCE TO WALL Table 25 1 Dimensions inches BDP Dimension Model Number Symbol BDP 150 BDP 175 BDP 200 BDP 250 BDP 300 BDP 350 BDP 400 21 116 28 346 23 316 26 3 16 31 3 16 20 24 24 24 24 12 13 1 2 13 1 2 14 6 9 16 7 1 2 7 1 2 7 1 2 7 1 2 19 7 8 22 22 25 30 50 50 6 6 6 K Mounting Holes L w Blwr Encl amp Filt Rk L w o Blwr Encl amp Filt Rk 61 61 61 61 MG 55 55 55 55 N 25 716 25 716 24 15 16 17 15 16 8 1 2 8 1 2 8 1 2 8 1 2 Q Blower Encl Ht R Inlet Duct Height S Center to Center Blower Mtg Holes T Inlet Duct Width V Blower Encl Width
40. e 11 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 After adjustment move the field installed manual shut off valve to the OFF position and replace the 1 8 pipe plug 7 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 Burner Flame 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 flame may be adjusted by sliding the manifold Also for propane gas the air shutters can be adjusted to control the burner flame height The air shutters can be accessed by lowering the bottom pan of the unit heater Natural Gas Flame Control Control of burner flames on unit heaters utilizing natural gas is achieved by resetting the manifold position to either increase or decrease primary combustion air Prior to flame adjustment operate unit heater for about fifteen minutes The main burner flame can be viewed after loosening and pushing aside the gas designation disc on the back of the unit To increase primary air loosen the manifold mounting screws and move the manifold away from the burne
41. e wiring diagram could result in a hazard to persons and property Any original factory wiring that requires replacement must be replaced with wiring material having a temperature rating of at least 105 C Ensure that the supply voltage to the appliance as indicated on the serial plate is not 5 greater than the rated voltage 2 6 580 10 A WARNING 12 When servicing or repairing this equipment use only factory approved service replacement parts A complete replacements parts list may be obtained by contacting the factory 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 All literature shipped with this unit should be kept for future use for servicing or service diagnostics Do not discard any literature shipped with this unit Consult piping electrical and venting instructions in this manual before final installation Do not attach ductwork air filters or polytubes to any propeller unit heater Clearances to combustible materials are critical Be sure to follow all listed requirements Heaters are designed for use in heating applications with ambient startup temperatures between 40 F and 90 F and ambient operating temperatures between 40 F and 90 F Do not install unit outdoors In garages or other sections
42. eater than 50 cubic feet per 1 000 Btu Hr input of the installed appliance s A confined space is 50 cubic feet or less per 1 000 Btu Hr input of the installed appliance s 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 2223 1 54 or CSA B149 1 Installation Code latest edition Sound and Vibration Levels All standard 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 of a primary support beam Smaller deflections typically result in reduced vibration and noise transmission 4 6 580 10 INSTALLATION UNIT MOUNTING 1 Be sure the means of suspension is adequate to support the w
43. eight of the unit see pages 24 and 25 for unit weights 2 For proper operation and to assure that flames are directed into the center of the heat exchanger tubes the unit must be installed in a level horizontal position Use a spirit level to ensure that the unit is suspended correctly 3 Clearances to combustibles as specified in Figure 4 1 and Tables 4 1 and 4 2 must be strictly maintained 4 All standard units are shipped fully boxed Larger units are also supplied with skid supports on the bottom of the box The larger units 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 and the forks support the whole depth of the unit If the unit must be lifted from the bottom for final installation without the carton in place be sure to properly support the unit over its entire length and width to prevent damage When lifting units make sure the load is balanced 5 Propeller models up to size 350 have 2 mounting holes size 350 and above have 4 mounting holes and blower models up to size 350 have 4 mounting holes size 350 and above have 6 mounting holes Units with two point suspension incorporate a level hanging feature Depending on what options and accessories are being used the heater may not hang level as recieved from the factory Do not hang heaters with deflector hoods until referring to the Installation Manual for Deflector Hoods and making the
44. even distribution of the air across the heat exchanger Recommended layouts are shown in Figure 13 1 When installing blower units with ductwork the following must be done 1 Provide uniform air distribution over the heat exchanger Use turning vanes where required see Figure 13 1 2 Provide removable access panels in the ductwork on the downstream side of the unit heater These openings should be large enough to view smoke or reflect light inside the casing to indicate leaks in the heat exchanger and to check for hot spots on exchanger due to poor air distribution or lack of sufficient air 3 If ductwork is connected to the rear of the unit use a Modine blower enclosure kit or if using a field designed enclosure maintain dimensions of the blower enclosure as shown on page 25 Figure 13 1 Recommended Ductwork Installations TURNING VANES C TURNING VANES BAFFLE SIDE VIEW BAFFLE SIDE VIEW TOP VIEW Dimension B Should Never Be Less than 1 2 of A Additional Requirements for Blower Model BDP Determining Blower Speed The drive assembly and motor on all blower units are factory assembled and adjusted for operation under average conditions of air flow and without any external static pressure The motor sheave should be adjusted as required when the unit is to be operated at other than average air flows and or with external static pressures Adjustment must always be within the performa
45. gram 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 Eliminate drafts Align burner on locator pins Replace heat exchanger Reduce primary air Adjust to maximum of 14 W C Check orifice size with those listed on the serial plate Increase primary air Adjust to a maximum of 14 W C Check orifice size with those listed on the serial plate Clean correct venting system Adjust to a maximum of 14 W C Check orifice size with those listed on the serial plate Clean correct venting system 27 SERVICE amp TROUBLESHOOTING Trouble Not Enough Heat d Loose belt Unit undersized Too Much Heat b Short circuit Defective gas valve Automatic Reset High Limit The unit heater comes standard with an automatic reset high limit switch that will shut off the gas should the discharge air temperature become excessive See Figure 18 1 indicator 7 for the location of either the standard automatic 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 En
46. h single wall can be used if the requirements of the National Fuel Gas Code are followed B9 Vertical vents must terminate a minimum horizontal and vertical distance from roof lines and adjacent walls or obstructions These minimum distances are outlined as follows based on National Fuel Gas Code requirements for vents with diameters less than 12 For double wall vent pipe and 8 or greater horizontal distance to any vertical wall or similar obstruction the vent must terminate above the roof in accordance with Figure 8 1 and Table 8 1 For double wall vent pipe and less than 8 horizontal distance to any vertical wall or similar obstruction the vent must terminate at least 2 above the highest point where it passes through a roof of a building and at least 2 higher than any portion of a building within a horizontal distance of 10 see Figure 8 1 12 MIN RECOMMENDED Table 8 1 Minimum Height from Roof to Lowest Discharge Opening Min Height H ft 0 6 Flat to 6 12 6 7 6 12 to 7 12 7 8 7 12 to 8 12 8 12 to 9 12 9 12 to 10 12 10 12 to 11 12 11 12 to 12 12 12 12 to 14 12 14 12 to 16 12 16 12 to 18 12 18 12 to 20 12 20 12 to 21 12 Size according to expected snow depth For single wall vent pipe and 10 or greater horizontal distance to any portion of a building the vent must terminate at least 2 above the highest point where it pa
47. heat source must be added Check replace thermostat a Check unit wiring against the wiring diagram b Check for loose or worn wires Adjust to a maximum of 14 W C Replace gas valve Figure 28 3 Floating Flame Condition Figure 28 4 Flame Rollout Appearance 28 6 580 10 MODEL NUMBER RATING PLATE IDENTIFICATION Figure 29 1 Serial Number Designations 5 01 10 09 17 09 23 09 1234 10000 Serial Number Prefix SPO Number lt blank gt if standard S if Special Product Order Number varies from 0000 to 9999 Motor Supplier Each unit within same week of 01 Century manufacture is to have unique number 03 General Electric 05 Universal Year of Manufacture 30 Fasco 15 Marathon 18 Franklin Week of Manufacture 29 Emerson 35 Baldor 38 Regal Beloit EPC Gas Valve Supplier 39 McMillan 01 RobertShaw 43 Nidec 05 Honeywell 09 White Rogers Fan Blower Vendor Code 20 Morrison i Control Supplier 01 1 01 RobertShaw 0 au 09 White Rogers 08 Brookside 2 JOKSI 05 Honeywell 19 Air Drive 30 United Tech 09 Fenwal Series Identity Number Figure 29 2 Model Number Designations PDP 150 A E 01 30 S B A N PDP Propeller Unit Factory Installed Option Digit BDP Blower Unit N None MBH Input Future 150 150 000 Btu hr input A Al 175 175 000 Btu hr input 250
48. igure 14 2 4 To reduce the speed of the blower turn outer side of motor sheave counterclockwise 5 To increase the speed of the blower turn outer side of motor sheave clockwise 6 Retighten motor sheave set screw replace belt and retighten motor base Adjust motor adjusting screw such that there is 3 4 belt deflection when pressed with 5 pounds of force midway between the blower and motor sheaves see Figure 14 3 Since the belt tension will decrease dramatically after an initial run in period it is necessary to periodically re check the tension to assure proper belt adjustment 7 Check to make certain motor sheave and blower sheave are aligned Re align if necessary 8 Re check blower speed after adjustment 9 Check motor amps Do not exceed amps shown on motor nameplate Slow blower if necessary 10 Check air temperature rise across unit Check temperature rise against values shown in Performance Tables on page 20 to assure actual desired air flow is being achieved 11 If adjustments are required recheck motor amps after final blower speed adjustment Figure 14 2 Motor Sheave Adjustment Figure 14 3 Belt Tension Adjustment SET SCREW TOWARD MOTOR 3 4 DEFLECTION WITH 5 FORCE ADJUSTABLE HALF OF SHEAVE 14 6 580 10 START UP PROCEDURE IMPORTANT 1 To prevent premature heat exchanger failure observe heat exchanger tubes If the botto
49. ion In Canada installation must be in accordance with CSA B149 1 Model PDP and BDP unit heaters must be vented with the proper passageway as described in these instructions to convey flue gases from the unit or the vent connector to the outside atmosphere The venting instructions are organized in sections based on installation type The sections are identified as follows Applicable Installation Instructions by Vent System Type General Instructions for ALL Installations VERTICAL CATEGORY vent systems HORIZONTAL CATEGORY III vent systems The differences between vertical and horizontal vent systems will be identified in Section A General Instructions All Units Section A General Instructions All Units A1 If the unit heater being installed is replacing existing equipment and using the existing vent system from that equipment inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code ANSI Z223 1 NFPA 54 or CSA B149 1 Installation Code latest edition and these instructions Determine that there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition A2 The vent pipe should be galvanized steel or other suitable corrosion resistant material Follow the National Fuel Gas Code for minimum thickness of vent material The minimum thickness for connectors varies depending on the pipe diameter Do not ven
50. ions 3 Make sure all multi voltage components motors transformers etc are wired in accordance with the power supply voltage 4 The power supply to the unit must be protected with a fused or circuit breaker switch 5 The power supply must be within 10 percent of the voltage rating and each phase must be balanced within 2 percent of each other If not advise the utility company 6 External electrical service connections that must be installed include a Supply power connection 120 208 240 480 or 575 volts b Thermostats summer winter switches or other accessory control devices that may be supplied 24 volts NOTE Certain units will require the use of a field step down transformer Refer to the serial plate to determine the unit supply voltage required Additional information may be found in Tables 19 2 and 19 3 and in the step down transformer installation instructions 7 Refer to Figure 18 1 for the electrical junction box locations 8 supply power electrical connections are made in the electrical junction box of the unit The low voltage thermostat and accessory control devices can be wired to the terminals on the electrical junction box Refer to the wiring diagram for the terminal location of all low voltage wiring DUCT INSTALLATION IMPORTANT Do not attempt to attach ductwork of any kind to propeller models When installing the heater always follow good duct design practices for
51. it has any additional control devices and set according to the instructions in the Control Options 23 Once proper operation of the unit has been verified remove any jumper wires that were required for testing 24 Replace the electrical junction box cover 25 If installed at altitudes above 2 000 affix label included with high altitude kit and fill in all fields with a permanent marker Pilot Burner Adjustment The pilot burner is orificed to burn properly with an inlet pressure of 6 7 W C on natural gas and 11 14 W C on propane gas but final adjustment must be made after installation If the pilot flame is too long or large it is possible that it may cause soot and or impinge on the heat exchanger causing failure If the pilot flame is shorter than shown it may cause poor ignition and result in the controls not opening the combination gas control A short flame can be caused by a dirty pilot orifice Pilot flame condition should be observed periodically to assure trouble free operation To Adjust the Pilot Flame 1 Create a call for heat from the thermostat 2 Remove the cap from the pilot adjustment screw For location see the combination gas control literature supplied with unit 3 Adjust the pilot length by turning the screw in or out to achieve a soft steady flame 3 4 to 1 long and encompassing 3 8 1 2 of the tip of the thermocouple or flame sensing rod see Figure 15 1 4 Replace the cap from the pilot adj
52. izontal Category IIl Vent System Installation 6 580 10 7 INSTALLATION VENTING Section B Vertical Vent System Installation Figure 8 1 Vertical Category Vent System B1 This section applies to vertically vented Category vent systems and is in addition to Section A General Instructions All Units B2 Vertical vent systems terminate vertically and must be sized in accordance with the National Fuel Gas Code ANSI Z223 1 NFPA 54 latest edition B3 The horizontal portion of the vent run cannot exceed 75 of the vertical rise Example If the vent height is 10 the ROOF PITCH IS X 12 12 horizontal portion of the vent system cannot exceed 7 5 USE LISTED THIMBLE B4 It is recommended to install a tee with drip leg and clean out THROUGH ROOF AND cap as shown in Figure 8 1 B5 The vent terminates a minimum of 5 above the vent LISTED TERMINAL ROOF FLASHING connector on the unit ds B6 All vertically vented heaters that are Category must be connected to a vent complying with a recognized standard with a material acceptable to the authority having jurisdiction Venting into a masonry chimney is not permitted Refer to the National Fuel Gas Code ANSI Z223 1 NFPA 54 latest edition for instructions on common venting 1 B7 Use a listed vent terminal to reduce down drafts and moisture in the vent B8 Double wall vent pipe is recommended althoug
53. le material surface not exceeding 160 F Clearance from the top of the unit may be required to be greater then the minimum specified if heat damage other than fire may occur to materials above the unit heater at the temperature described Allow 18 of clearance at rear or 12 beyond end of motor at rear of unit whichever is greater and access side to provide ample air for proper operation of fan Installation 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 CSA B149 1 SPECIAL PRECAUTIONS SI METRIC CONVERSION FACTORS A CAUTION 15 Purging of air from gas supply line should be performed as described in the National Fuel Gas Code ANSI 2223 1 NFPA 54 latest edition In Canada installation must be in accordance with CSA B149 1 16 When leak testing the gas supply piping system the appliance and its combination gas control must be isolated during any pressure testing in excess of 14 W C 1 2 psi 17 The unit should be isolated from the gas supply piping system by closing its field installed manual shut off valve This manual shut off valve should be located within 6 of the heater 18 Turn off all gas before installing appliance 19 Ensure that the supply voltage to the appliance as indicated on the serial plate is less than 5 below the rated voltage
54. lo 2433 style 5H0722850001 5H0722850002 A21 If left hand facing front of heater with air blowing in face power exhauster discharge is desired the power exhauster may be rotated 1809 To do this remove the screws in the vent collar rotate the power exhauster then replace the screws A22 In addition to following these general instructions specific instructions for Vertical Category or Horizontal Category vent systems must also be followed The following outlines the differences 250 400 Table 7 3 ANSI Unit Heater Venting Requirements Category Description Venting Requirements Negative vent pressure Non condensing Follow standard venting requirements Negative vent pressure Condensing Positive vent pressure Condensate must be drained Vent must be gas tight Minimum Clearances for Structure Vent Terminal Location Forced air inlet within 10 3 above Combustion air inlet of another appliance 6 all directions 4 horizontal and below 1 above Door window gravity air inlet or any building opening 4 horizontal U S 6 horizontal Canada Electric meter gas meter gas regulator and relief equipment 3 horizontal U S Gas regulator 6 horizontal Canada Adjoining building or parapet wall 6 all directions Adjacent public walkways 7 all directions Grade ground level 3 above Do not terminate the vent direct
55. ly above a gas meter or regulator A14 Do NOT vent this appliance into a masonry chimney A15 Do NOT use dampers or other devices in the vent or combustion air pipes Non condensing Vent must be liquid and gas tight Condensate must be drained Positive vent pressure Condensing Note Vent connectors serving Category appliances shall not be connected into any portion of mechanical draft systems operating under positive pressure Vertical Category Vent Vertical vent systems terminate vertically up an example is shown in Figure 8 1 The horizontal portion of the vent run cannot exceed 75 of the vertical rise Example If the vent height is 10 the horizontal portion of the vent system cannot exceed 7 5 The vent terminates a minimum of 5 above the vent connector on the unit If the vent system to be installed meets ALL these criteria an example is shown in Figure 8 1 proceed to Section B Vertical Vent System Installation For all other cases proceed to the next section for Horizontal Category III Vent System Determination Horizontal Category Ill Vent Horizontal vent systems terminate horizontally sideways an example is shown in Figure 9 2 A vent system that terminates vertically but has a horizontal run that exceeds 7596 of the vertical rise is considered horizontal Horizontal vent configurations are Category Ill Additional requirements are covered in Section C Hor
56. m of the tubes become red while blower and furnace are in operation check to be sure the blower has been set to the proper rpm for the application Refer to page 14 for blower adjustments 2 Start up and adjustment procedures must be performed by a qualified service agency 1 Turn off power to the unit at the disconnect switch Check that fuses or circuit breakers are in place and sized correctly Turn all hand gas valves to the OFF position 2 Remove electrical junction box cover 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 If installed at altitudes above 2 000 and the high altitude kit includes a combustion air proving switch replace the switch in the unit with the switch provided in the kit Take care to ensure that the tubing and electrical connections are securely fastened 4 Check to insure that the venting system is installed correctly and free from obstructions 5 Check to see that there are no obstructions to the intake and discharge of the unit 6 For blower units check the belt tension and sheave alignment Refer to Blower Adjustments for proper belt tension 7 Check bearings for proper lubrication if applicable 8 Check to make sure that all filters are in place and that they are installed
57. med as described in the National Fuel Gas Code ANSI 2223 1 NFPA 54 latest edition or in Canada CSA B149 codes When leak testing the gas supply piping system the appliance and its combination gas control must be isolated during any pressure testing in excess of 14 W C 1 2 psi The unit should be isolated from the gas supply piping system by closing its field installed manual shut off valve This manual shut off valve should be located within 6 of the heater Turn off all gas before installing appliance 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 2223 1 54 Latest Edition In Canada installation must be in accordance with CSA B149 1 2 Piping to units should conform with local and national requirements for type and volume of gas handled and pressure drop allowed in the line Refer to Table 10 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 10 2 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 10 1
58. nce range shown on page 20 and the temperature rise range shown on the unit s rating plate To determine the proper blower speed and motor sheave turns open the operating conditions must be known For example a model BDP350 unit operating with no external static pressure e g no ductwork nozzles etc is to deliver an air volume of 6481 cfm cfm cubic feet per minute This requires the unit be supplied with a 5 hp motor a 207 drive and the drive sheave set at 2 5 turns open to achieve a blower speed of 960 6 580 10 13 INSTALLATION rpm see performance table for units with or without blower enclosure page 20 See Blower Adjustments for setting of drive pulley turns open If a blower unit is to be used with ductwork or nozzles etc the total external static pressure under which the unit is to operate and the required air flow must be known before the unit can be properly adjusted Any device added externally to the unit and which the air must pass through causes a resistance to air flow called pressure loss If Modine filters are used the pressure loss through the filters is included in the performance data on page 20 If Modine supplied discharge nozzles are used the pressure drop of the nozzles can be found footnoted at the bottom of page 23 If filters nozzles or ductwork are to be used with the unit and they are not supplied by Modine the design engineer or installing contractor must determine the pre
59. ntrol System Description Natural Propane 115V 208 230V 460V 575V Single Stage 115V Two Stage 208 230V All controls are intermittent pilot ignition 100 shut off with continuous retry Factory wired 460 575 available on blower models Field installed step down transformer may be used for 460 575 propeller applications 18 6 580 10 GENERAL PERFORMANCE DATA Table 19 1 Performance Propeller PDP and Blower Models Model Number PDP 400 BDP 150 400 000 150 000 320 000 120 000 5440 2020 1587 2778 40 70 BDP 350 350 000 280 000 4714 3704 6481 40 70 BDP 400 400 000 320 000 5387 4233 6584 40 70 BDP 175 175 000 140 000 2357 1852 3241 40 70 BDP 200 200 000 160 000 2694 2116 3704 40 70 BDP 250 250 000 200 000 240 000 3367 4040 2646 4630 3175 5556 40 70 40 70 BDP 300 300 000 PDP 150 150 000 120 000 2180 PDP 175 175 000 140 000 2550 PDP 200 200 000 160 000 2870 PDP 250 250 000 200 000 3700 PDP 300 300 000 240 000 4460 PDP 350 350 000 280 000 4870 Btu Hr Input Btu Hr Output Entering Airflow CFM CFM Range 53 Air Temp Rise F 51 52 50 Max Mounting Hgt Ft Heat Throw Ft Max Mtg Hgt 50 17 15 19 21 20 15 13 16 18 19 19 59 51 67 74 70 52 47 58 64 67 68 Motor 115 60 1
60. old pressure should be adjusted on units equipped with 2 stage or modulating gas controls No adjustments to the low fire manifold pressure are necessary on these units 12 6 580 10 INSTALLATION ELECTRICAL CONNECTIONS A WARNING Disconnect power supply before making wiring connections to prevent electrical shock and equipment damage 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 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 less than the rated voltage 1 Installation of wiring must conform with local building codes or in the absence of local codes with the National Electric Code ANSI NFPA 70 Latest Edition Unit must be electrically grounded in conformance to this code In Canada wiring must comply with CSA C22 1 Part 1 Electrical Code 2 Two copies of the unit wiring diagram are provided with each unit One is located in the electrical junction box and the other is suppled in the literature packet Refer to this diagram for all wiring connect
61. on charts are differentiated by product type altitude and fuel type If converting from natural gas to propane gas and operation at high altitude both a propane conversion kit and a pressure switch kit must be used if applicable Selection charts include the proper kit suffix when required Table 11 1 Natural Gas Heating Values at Altitude z Gas Heating Values at Altitude BTU ft3 Altitude ft USA Canada 0 2 000 Manifold Pressure Adjustment The inlet pressure to the unit must be confirmed to be within acceptable limits 6 7 W C for natural gas and 11 14 W C for propane gas before opening the shutoff valve or the combination gas valve may be damaged Heaters for use with natural gas have gas valves factory set at 3 5 W C manifold pressure at 7 0 W C inlet pressure Units for use with propane gas are set for 10 0 W C manifold pressure at 14 0 W C inlet pressure Installation above 2 000 elevation requires adjustment of the manifold pressure as described Derated BTU Content Gas and Manifold Pressure Calculation Some utility companies may derate the BTU content heating value of the gas provided at altitude to a value other than 1 050 BTU ft for natural gas or 2 500 BTU ft for propane gas 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 B
62. ough Heat section of Service amp Troubleshooting Figure 28 1 Wavering Flame or Misalignment GOOD BAD ay e Figure 28 2 Lifting Flame Condition Possible Cause 1 Unit cycling on high limit a Obstructions leaks in duct system b Main pressure set too high c Blower motor not energized e Blower speed too low Blocked damaged venting system f Air distribution baffle removed high g f g temperature rise units only h Defective high limit switch h Main pressure set too low Too much outside air Thermostat malfunction Gas controls wired incorrectly Thermostat malfunction Gas controls do not shut off a Gas controls wired incorrectly Main gas pressure set too high 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 Replace air distribution baffle 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
63. pment standard input ratings are certified by ETL For elevations above 2 000 ANSI 2223 1 requires ratings be reduced 4 percent for each 1000 above sea level For units in Canada CSA requires that ratings be reduced 10 percent at elevations above 2 000 The high altitude adjustment instructions and pressure switch kits listed in this manual are for use with units that will be installed over 2 000 These methods and kits comply with both ANSI 2223 1 and CSA requirements 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 pressure adjustment methods and pressure switch kits listed herein For the Selection and Installation Instructions for propane conversion kits please see the latest revision of Modine Manual 75 511 Selection of the Proper Pressure and Kit To determine the proper manifold pressure at altitude and if required the proper combustion air pressure switch kit the full model number of the heater the fuel to be used and the altitude the unit will be installed at must be known Refer to the unit serial plate or carton label to obtain the necessary information about the unit After obtaining this information refer to the gas pressure and selection charts shown in Tables 11 1 through 11 3 The pressure charts are differentiated by elevation fuel type and country the product is being installed in The selecti
64. r equipment C7 The venting system must be exclusive to a single unit and no other unit is allowed to be vented into it C8 When vented horizontally maintain a 1 4 per foot rise away from the heater and place a drip leg with clean out near the unit as shown in Figure 9 2 Where local authorities have jurisdiction a 1 4 per foot downward slope is acceptable with a drip leg and clean out near the exit of the vent as shown in Figure 9 2 or allow the condensate to drip out the end 6 580 10 C9 For a vent termination located under an eave the distance of the overhang must not exceed 24 The clearance to combustibles above the exterior vent must be maintained at a minimum of 12 Consult the National Fuel Gas Code for additional requirements for eaves that have ventilation openings C10 Once venting is complete proceed to the section titled Installation Gas Connections INSTALLATION GAS CONNECTIONS A WARNING 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 Gas pressure to appliance controls must never exceed 14 W C 1 2 psi To reduce the opportunity for condensation the minimum sea level input to the appliance as indicated on the serial plate must not be less than 5 below the rated input or 5 below the minimum rated input of dual rated units A CAUTION Purging of air from gas lines should be perfor
65. r until the yellow tipped flames disappear see Figure 16 2 To decrease primary air move manifold closer to the burner until flames no longer lift from burner ports but being careful not to cause yellow tipping Retighten manifold mounting screws after adjustment Propane Gas Flame Control An optimum flame will show a slight yellow tip Prior to flame adjustment operate heater for at least 15 minutes Loosen air shutter set screws and move the air shutters away from the manifold to reduce the primary air until the yellow flame tips appear see Figure 16 3 Then increase the primary air until yellow tips diminish and a clean blue flame with a well defined inner cone appears It may also be necessary to adjust the manifold position in addition to adjusting air shutters to obtain proper flame Follow the instructions under Natural Gas Flame Control for adjusting the manifold Figure 16 1 Typical Combination Gas Control GAS CONTROL KNOB PRESSURE REGULATOR ADJUSTMENT SCREW UNDER CAP SCREW OUTLET PRESSURE TAP TAP INLET PILOT TUBING CONNECTION PILOT ADJUSTMENT RESET BUTTON SCREW Figure 16 2 Manifold Adjustment Natural Gas MANIFOLD MAIN BURNER ORIFICES MANIFOLD MOUNTING SCREW AND PIN MANIFOLD BURNER ORIFICES SHUTTER 16 6 580 10 START UP PROCEDURE Control Operating Sequence All units are supplied with intermittent pilot systems with continuous
66. recommended preliminary adjustments on the heater while the heater is resting on the floor The units can be mounted with 3 8 16 threaded rod as follows On each piece of threaded rod used screw a nut a distance of about 1 onto the end of the threaded rods that will be screwed into the unit heater Place a washer over the end of the threaded rod and screw the threaded rod into the unit heater weld nuts on the top of the heater at least 5 turns and no more than 10 turns Tighten the nut first installed onto the threaded rod to prevent the rod from turning Drill holes into a steel channel or angle iron at the same center line dimensions as the heater that is being installed The steel channels or angle iron pieces need to span and be fastened to appropriate structural members Cut the threaded rods to the preferred length place them through the holes in the steel channel or angle iron and secure with washers and lock nuts or lock washers and nuts A double nut arrangement can be used here instead of at the unit heater a double nut can be used both places but is not necessary Do not install standard unit heaters above the maximum mounting height shown in Table 19 1 NOTE A pipe hanger adapter kit shown in Figure 5 2 is available as an accessory One kit consists of two drilled 3 4 IPS pipe caps and two 3 8 16 x 1 3 4 capscrews to facilitate threaded pipe suspension Two kits would be required for PDP unit
67. retry control as standard For intermittent pilot systems both the main burner and pilot are turned off 100 when the thermostat is satisfied For all units the system will attempt to light the pilot for 70 seconds If the pilot is not sensed the ignition control will wait approximately 6 minutes with the combination gas control closed and no spark After 6 minutes the cycle will begin again After 3 cycles some ignition controllers lockout for approximately 1 hour before the cycle begins again This will continue indefinitely until the pilot flame is sensed or power is interrupted to the system Refer to Table 18 1 for control code descriptions Specific descriptions of the control sequence for different control codes are listed below 1 The thermostat calls for heat 2 The power exhauster relay is energized starting the power exhauster motor Once the motor has reached full speed the differential pressure switch closes 3 The pilot valve opens and the ignitor sparks for 70 seconds in an attempt to light the pilot 4 Once the pilot is lit the flame sensor proves the pilot and stops the ignitor from sparking 5 On single stage units the main gas valve is opened and the main burner is lit to 100 full fire On two stage units the gas valve may open at either 50 or 100 depending on what the two stage thermostat is calling for 6 The air mover starts after 30 to 90 seconds to allow the heat exchanger to warm up 7 The
68. rmance Data General 19 Performance Data Downturn Hoods 22 Dimensions ede 24 Service Troubleshooting 26 Serial Model Number Designations 29 Commercial Warranty THIS MANUAL IS THE PROPERTY OF THE OWNER PLEASE BE SURE TO LEAVE IT WITH THE OWNER WHEN YOU LEAVE THE JOB SPECIAL PRECAUTIONS SPECIAL PRECAUTIONS THE INSTALLATION AND MAINTENANCE INSTRUCTIONS IN THIS MANUAL MUST BE FOLLOWED TO PROVIDE SAFE EFFICIENT AND TROUBLE FREE OPERATION IN ADDITION PARTICULAR CARE MUST BE EXERCISED REGARDING THE SPECIAL PRECAUTIONS LISTED BELOW FAILURE TO PROPERLY ADDRESS THESE CRITICAL AREAS COULD RESULT IN PROPERTY DAMAGE OR LOSS PERSONAL INJURY OR DEATH THESE INSTRUCTIONS ARE SUBJECT TO ANY MORE RESTRICTIVE LOCAL OR NATIONAL CODES HAZARD INTENSITY LEVELS 1 DANGER Indicates an imminently hazardous situation which if not avoided WILL result in death or serious injury 2 WARNING Indicates a potentially hazardous situation which if not avoided COULD result in death or serious injury 3 CAUTION Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury 4 IMPORTANT Indicates a situation which if not avoided MAY result in a potential safety concern A DANGER Appliances must not be installed where they may be exposed to a potentiall
69. sses through a roof of a building and at least 2 higher than any portion of a building within a horizontal distance of 10 For single wall vent pipe and less than 10 horizontal distance to any portion of a building the vent must terminate at least 2 higher than any portion of that building 8 6 580 10 TEE WITH DRIP LEG AND CLEANOUT CAP SLOPE 1 4 PER FOOT DOWNWARD TOWARD DRIP LEG INSTALLATION VENTING Section Horizontal Category Ill Vent System Installation C1 This section applies to horizontally vented Category Ill vent systems and is in addition to Section A General Instructions All Units C2 Horizontal vent systems terminate horizontally sideways C3 All seams and joints must be sealed with metallic tape or silastic suitable for temperatures up to 400 F Wrap the tape 2 full turns around the vent pipe For single wall vent systems 1 continuous section of double wall vent pipe may be used within the vent system to pass through the wall to the listed vent cap Under no circumstances should 2 sections of double wall vent pipe be joined together within 1 vent system due to the inability to verify complete seal of inner pipes Refer to instruction A10 in Section A General Instructions All Units for attaching double wall pipe to single wall pipe C4 Refer to Table 9 1 for total minimum and maximum vent lengths making the system as straight as possible The equivalent length
70. ssure loss for the externally added devices or ductwork to arrive at the total external static pressure under which the unit is to operate Once the total static pressure and the required air flow are known the operating speed of the blower can be determined and the correct motor sheave adjustments made As an example a model BDP350 is to be used with a Modine supplied blower enclosure and filters attached to ductwork by others The unit is to move 6481 cfm of air flow against an external static pressure of 0 2 W C which must be added for the filter pressure drop for a total of 0 4 W C total pressure drop The performance table on page 20 for a BDP350 at 6481 cfm and 0 4 W C static pressure shows that the unit will require a 5 hp motor using a 207 drive and the motor sheave should be set at 5 turns open to achieve a blower speed of 1050 rpm To Install 1 Remove and discard the motor tie down strap and the shipping block beneath the belt tension adjusting screw Not used on all models 2 For 3 and 5 HP motors affix sheave to the motor shaft and install motor on the motor mounting bracket Install belt on blower and motor sheaves Figure 14 1 Blower Model THREADED MOUNTING BRACKETS ON BLOWER ASSEMBLY MOTOR MOUNTING BRACKET MOTOR SHEAVE MOVEABLE FACE TO OUTSIDE BLOWER HOUSING ADJUSTMENT SCREW 3 Adjust motor adjusting screw for a belt deflection of approximately 3 4 with five pounds of force
71. stalled in electrical junction box and controls propeller blower motor function For single phase units below 2 Hp the time delay relay controls the motor directly For single phase units 2 Hp and greater and all three phase units the time delay relay controls the motor starter For additional information refer to Control Operating Sequence on page 17 Low Voltage Terminal Board STD The low voltage terminal board is located in the electrical junction box The terminal board is labeled to match the electrical wiring diagram provided with the unit All low voltage field wiring connections should be made to the exposed side of the terminal board exterior of electrical junction box to prevent miswiring by modifying the factory wiring which is inside the electrical junction box Control Step Down Transformer STD The control step down transformer is located in the electrical junction box The transformer is used to step down the supply power 115V 208V 230V 460V 575V to 24V This transformer is used to control the gas controls fan delay relay field supplied motor starter etc All unit heaters are supplied with a 40VA control step down transformer To determine the control transformer supplied as well as any accessory field supplied transformers required reference the supply voltage listed on the serial plate and reference Tables 19 2 and 19 3 High Limit Switch STD The automatic reset high limit switch is
72. t unit with PVC or other forms of plastic venting material All heaters come with a vent adapter for attaching the vent pipe to the heater see Table 6 1 Attach the vent pipe to the adapter with 3 corrosion resistant screws Drill pilot holes through the vent pipe and adapter prior to screwing in place Vent pipe must not be smaller than the connector size A4 Limit the total equivalent vent pipe length to fall between the minimum and maximum equivalent vent lengths given in Table 6 1 making the vent system as straight as possible The equivalent length of a 5 elbow is 6 and for a 6 elbow is 7 5 A minimum of 12 straight pipe is recommended from the flue outlet before turns in the vent pipe A6 Horizontal sections of vent pipe are to be installed with a minimum downward slope from the appliance of 1 4 per foot and suspended securely from overhead structures at points not greater than 3 apart 7 Fasten individual lengths of vent together with at least 3 corrosion resistant sheet metal screws 8 Keep single wall vent pipe at least 6 from combustible materials For double wall vent pipe follow the vent pipe manufacturer s clearances to combustibles The minimum distance from combustible materials is based on the combustible material surface not exceeding 160 F Clearance from the vent pipe or the top of the unit may be required to be greater than 6 if heat damage other than fire could result such
73. this equipment must be performed by a qualified service agency 2 Do not attempt to reuse any mechanical or electrical controllers which have been wet Replace defective controller NOTE To check most of the possible remedies in the troubleshooting guide listed in Table 27 1 refer to the applicable sections of the manual General Maintenance The unit and venting system must be checked once a year by a qualified service technician All installation and service of these units must be performed by a qualified installation and service agency Before any service BE SURE TO TURN OFF GAS AT THE MANUAL SHUT OFF VALVE AHEAD OF THE COMBINATION GAS CONTROL AND TURN OFF ALL ELECTRIC POWER TO THE HEATER General Unit When providing annual maintenance for the unit heater keep the unit free from dust dirt grease and foreign matter Pay particular attention to 1 The combustion air and exhaust vent piping 2 The burner ports and pilot burner orifices avoid the use of hard sharp instruments capable of damaging surfaces for cleaning these ports To check the burner port and pilot burner orifice see Burner and Pilot Assembly Removal 3 The air shutters and main burner orifices avoid the use of hard sharp instruments capable of damaging surfaces for cleaning these orifices To check the air shutters and main burner orifices see for Manifold Assembly Removal 4 The heat exchanger Clean tubes from the bottom with
74. to double wall pipe 6 6 580 10 INSTALLATION VENTING A10 When the vent passes through a combustible INTERIOR wall or floor a metal thimble 4 greater than the vent diameter is necessary If there is 6 or more of vent pipe in the open space between the appliance and where the vent pipe passes through the wall or floor the thimble need only be 2 greater than the diameter of the vent pipe If a thimble is not used all combustible material must be cut away to provide 6 of clearance Where authorities have jurisdiction Type B vent may be used for the last section of vent pipe to maintain clearance to combustibles while passing through wall or floor See Figure 6 1 Any material used to close the opening must be noncombustible A11 All seams and joints of the single wall pipe must be sealed with metallic tape or silastic suitable for temperatures up to 400 F Wrap the tape 2 full turns around the vent pipe One continuous section of double wall vent pipe may be used within the vent system to pass through the wall to the listed vent cap Refer to instruction A12 in Section A General Instructions All Units for attaching double wall pipe to single wall pipe A12 The following are general instructions for double wall Type B terminal pipe installation How to attach a single wall vent terminal to double wall Type B vent pipe 1 Look for the flow arrow on the vent pipe 2 Slide the vent terminal inside the exh
75. umidity or salt water atmospheres will cause accelerated corrosion resulting in a reduction of the normal life of the units IMPORTANT To prevent premature heat exchanger failure do not locate ANY gas fired appliances in areas where corrosive vapors i e chlorinated halogenated or acidic are present in the atmosphere Location Recommendations 1 When locating the heater consider general space and heating requirements availability of gas and electrical supply and proximity to vent locations 2 Avoid installing units in extremely drafty locations Drafts can cause burner flames to impinge on heat exchangers which shortens life Maintain separation between units so discharge from one unit will not be directed into the inlet of another 3 Be sure the structural support at the unit location site is adequate to support the unit s weight For proper operation the unit must be installed in a level horizontal position 4 Do not install units in locations where the flue products can be drawn into the adjacent building openings such as windows fresh air intakes etc 5 Be sure that the minimum clearances to combustible materials and recommended service clearances are maintained Units are designed for installation on non combustible surfaces with the minimum clearances shown in Figure 4 1 and Tables 4 1 and 4 2 6 Units exposed to inlet air temperatures of 40 F or less may experience condensation therefore provisions should
76. ustment screw Figure 15 1 Correct Pilot Flame 3 4 to 1 6 580 10 15 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 unit heater in accordance with the input rating on the serial plate Actual input should be checked and necessary adjustments made after the unit heater 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 outlet pressure tap of the gas valve see Figure 16 1 To Adjust the Manifold Pressure 1 Move the field installed manual shut off valve to the OFF position 2 Remove the 1 8 pipe plug in the pipe tee or gas valve and attach a water manometer of U tube type which is at least 12 high 3 Move the field installed manual gas shut off valve to the ON position 4 Create a high fire call for heat from the thermostat 5 Determine the correct high fire manifold pressure 3 5 W C for natural gas 10 W C for propane gas Pressures at 0 2 000 elevation are 3 5 W C for natural gas 10 W C for propane gas for elevations above 2 000 refer to the instructions in Gas Connections High Altitude Accessory Kit on pag
77. y explosive or flammable atmosphere WARNING Gas fired heating equipment must be vented do not operate unvented A built in power exhauster is provided additional external power exhausters are not required or permitted If an existing heater is being replaced 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 NFPA 54 or CSA B149 1 latest edition Failure to follow these instructions can result in injury or death 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 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 Gas pressure to appliance controls must never exceed 14 W C 1 2 psi To reduce the opportunity for condensation the minimum sea level input to the appliance as indicated on the serial plate must not be less than 5 below the rated input or 5 below the minimum rated input of dual rated units Disconnect power supply before making wiring connections to prevent electrical shock and equipment damage All appliances must be wired strictly in accordance with wiring diagram furnished with the appliance Any wiring different from th

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