Modine - Harry Taylor Industrial and Commercial Heating
Contents
1. MODINE 6 592 August 1999 installation and service manual gas fired unit heaters CE models PDE G20 G31 0120 Contents Pages Inspection on arrival 1 Special precautions seen 2 General introduction esseeeeeenneenne 3 Technical d ta 2 1 eee e eeu 3 4 Installation ecrit e e tesi qid 4 6 Positioning heater sees 4 Ventilation 5 Unit suspension up Flue systerm one tene e tede 5 6 MIU pcc dah GAL eee ee eae neces 6 Gas SUpDly 2 2 0 Nec enestega ko ETEen 6 Electrical Supply kissie 2 ated aet ceres 6 Commissioning ooo ce rene e vete eee 7 SERVICING i edit EOS IER T UNES S 8 Wiring Diagram rre endete tenentis 9 Major Component Location eseeeeeeeene 9 Replacement of parts ccceecseeeseceeesereeeeeeeeeteeeeeeteeeeenes 10 Fault finding irc erede 11 Spare palts list keen 11 12 IMPORTANT The use of this manual is specifically intended for a qualified installation and service agency A WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or death and could cause exposure to substances which have been determined by various agencies to All installation and service of these units must be performed by a qualified installation and service agency cause cancer birth def2. 27 100mm for PDE unit 400 minimum clearance from the top is 100mm and from the flue collar is 125mm At least 150mm clearance at the sides and 300mm clearance at rear or 150mm beyond end of motor at rear of unit whichever is greater must be allowed to provide sufficient air for combustion and correct operation of the fan However see page 2 section 12 for clearances to combustible material The minimum distance required from combustible materials is based on the combustible material surface not exceeding 70 C Clearance from the top of the unit may be required to be greater than 150mm if heat damage other than fire may occur to materials above the unit heater at the temperature described PDE unit heaters are designed for use in heating applications with ambient temperatures between 0 C and 32 C If an application exists where ambient temperatures can be expected to fall outside of this range contact your local sales representative for recommendations Clearance must be provided for opening hinged bottom for servicing See Figure 1 Do not stand unit on its base To ensure that flames do not impinge on heat exchanger surfaces the unit must be suspended in a vertical and level position Failure to suspend a unit properly may shorten its life The unit heater must not be lifted by its gas controls or gas manifold Ensure there are no obstructions which block air intake and discharge of the unit heater Do not atta
3. 2 for heaters of heat input 60 kW or more the total mini mum free area shall not be less than 270 cm plus 2 25 cm per kilowatt in excess of 60 kW rated heat input Most traditional building constructions will provide air changes of at least 0 5 h without the need for ventilation openings In the case of a building having an air change rate less than 0 5 h low level ventilation will be necessary For indirect heaters installed in buildings with a design air change rate of 0 5 h or greater and where the volume of the heated space is greater than 4 7 mf per kilowatt of total rated heat input as appropriate additional high and low level ventilation will not be required 2 3 Unit Suspension The most common method of hanging PDE unit heaters is to utilize M10 threaded rod On each piece of threaded rod used screw a nut about 25mm onto the end of the rods that will be screwed into the unit heater Then put a washer over the end of the threaded rod and screw the rod at least 5 turns and no more than 10 turns into the weld nuts on the top of the heater Tighten the nut first installed onto the threaded rod to prevent it from turning Drill holes into a steel channel or angle iron at the same centreline 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 push them through the holes in the steel
4. 3 2 6 Check gas piping for leaks as described in IM 5 A CAUTION Important Supply pressure and setting pressure must be checked with heater in operation when making final adjustments 3 2 7 Check gas input rate by measuring burner pressure using the manometer fitted to test point at the outlet of the combination gas control Allow unit to operate for 15 minutes to stabilize Check the pressure and if necessary adjust to the figure shown in Table 2 on page 4 for the particular model The location of the pressure setting adjuster on the combination gas is shown in Figure 4 Remove the dust cover over the adjuster and using a small screwdriver turn the screw beneath clockwise to increase and anti clockwise to decrease the pressure Allow the unit to operate for 15 minutes then check the pressure again Replace the dust cover when finished Disconnect the manometer from the test point and replace the sealing screw in the pressure test nipple 3 3 Control Operating Sequence With pilot alight when the thermostat calls for heat power is supplied to the combination gas control and at the same time power is supplied to the fan timer The main burner should light immediately The fan motor will start in 15 to 45 seconds When the thermostat has been satisfied power is turned off to the combination gas control and fan timer The main burner will go out but the pilot will continue to burn The fan motor will continue to operate fo
5. Codes of Practice and Building Regulations See also BS 6891 Installation of Low Pressure Pipework BS 6230 Installation of Gas Fired Forced Convection Air Heaters for Commercial and Industrial Space Heating British Gas Publications IM 2 Purging Procedures of Non Domestic Gas Boilers IM 5 Soundness Testing Procedures for Non Domestic Gas Installations IM 11 Flues for Commercial and Industrial Gas Fired Boilers and Air Heaters IM 16 Guidance Notes for the Installation of Gas Pipework Model Number PDE Symbol 150 175 B Ziriommoom J Inches K Gas Conn Fan Diameter Approx Weight kg 1 PDE30 to PDE300 inclusive 2 holes and the level hanging adjustment feature PDE350 and PDE400 4 holes Dimension equals overall plus 150mm NOTE NOT ALL MODELS ARE AVAILABLE IN THE UK CHECK WITH YOUR SUPPLIER TABLE 2 Performance natural gas only See page 12 for propane details Model Number PDE Heat Input gross kW Heat Input net kW Output kW Burner set press mbar Injector No Diam mm Marking Gas rate m h Approx flue gas vol in secondary flue 3 7 CO amp 100 C 1 sec Air flow m sec Outlet velocity m sec Air Temp rise Mounting ht max m Heat throw at max mount ht m Power
6. 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 at both places but is not necessary The entire means of suspension must be adequate to support the weight of the unit see page 3 for unit weights For proper operation the unit must be installed in a level horizontal position Clearances to combustibles as specified below must be strictly maintained The heaters must not be installed above the maximum mounting height shown in Table 2 A CAUTION On all units except the PDE 350 and PDE 400 two M10 tapped holes are located in the top of the unit to receive threaded rods Units with two point suspension models PDE30 to PDE300 incorporate a level hanging feature PDESO to PDE300 units that do not hang level after being installed can be corrected in place Remove both outer side panels screws are on back flange of side panel exposing the adjustable mounting brackets Fig 2 Loosen the set screws holding the mounting brackets in place and using a rubber mallet or something similar tap the heater into a position where it does hang level Tighten set screws and replace the outer side panels The PDE 350 and PDE 400 have four mounting holes in the top of the unit To ensure that flames are directed into the centre of the heat exchanger tubes the unit must be supported in a vertical position with s
7. 18 2 08 Marking 54 49 44 49 45 43 47 45 42 43 44 45 Gas rate kg h 1 16 1 94 2 9 3 86 4 83 5 8 6 76 7 72 9 66 11 6 13 5 15 4 Approx flue 9 14 21 29 36 43 50 57 71 86 100 114 gas vol in secondary flue 4 496 CO amp 120 C 1 sec Air flow 0 21 0 35 0 51 0 69 0 87 1 03 1 20 1 36 1 75 2 10 2 34 2 66 m sec Outlet velocity 2 6 3 2 3 7 4 3 4 4 4 7 4 8 4 1 5 3 5 7 5 6 5 3 m sec Air temp rise 27 27 28 27 27 28 28 28 27 27 28 28 Mounting ht 2 1 2 7 3 7 4 3 4 3 4 9 5 2 4 6 5 8 6 4 6 1 6 7 max m Heat throw 7 6 10 1 12 5 14 9 15 5 16 8 18 15 5 20 4 22 6 21 9 23 2 at max mount ht m Power supply 230V 50Hz Power consupt 125 150 200 225 400 450 450 400 750 850 950 1 200 watts Based on propane gas typical calorific value 91 65 MJ M At 18 C ambient and unit fired at full rated input Mounting height as measured from bottom of unit Head Office Northern Sales Office Kitson s Works Units 1 3 Guide Bridge T E Aylesbury Road South Street H arr Ta l or Bromley Ashton under Lyne y y Kent BR2 0QZ Lancashire OL7 OHU Tel 020 8464 0915 0161 308 4550 Harry Taylor of Ashton Limited Sole Distributor in the British Isles Fax 020 8464 0916 0161 308 4551
8. 62 Delay timer 5H7381CB Thermocouple HTQ309A2754B Thermocouple interrupter HT0000021609 When servicing repairing or replacing parts on these units always give the complete Model Number and Serial Number from appliance data plate 11 TABLE 3 continued Description Number per unit Modine part Description Number per unit Modine part number number Capacitor Pilot assembly Not required 3H31982B1 HTFFE1049039 3H31982B1 HTFFE1049039 3H31982B2 HTFFE1049031 3H31982B2 HTFFE1049031 3H31982B2 HTFFE1049031 3H31982B5 HTFFE1049031 3H31982B5 HTFFE1049026 3H31982B5 HTFFE1049027 3H31982B5 HTFFE1049028 3H31982B5 HTFFE1049028 3H31982B6 HTFFE1049029 3H31982B6 3H33073B1 3H33073B2 3H33073B3 3H33073B4 3H33073B16 3H33073B5 3H33073B6 3H33073B7 3H33073B7 3H33073B9 3H33073B10 3H33073B11 TABLE 4 Performance Propane Units Only 36 29 18 29 23 18 24 24 OORWWWNNN HHH Model Number PDE 30 50 75 100 125 150 175 200 250 300 350 400 Heat Input gross kW 8 8 14 7 22 29 3 36 6 44 51 3 58 6 73 3 87 9 102 6 117 2 Heat Input net kW 8 13 5 20 2 27 33 7 40 5 47 2 53 4 67 4 80 9 94 4 107 8 Output kW 7 11 7 17 6 23 4 29 3 35 1 41 46 9 58 6 70 3 82 93 8 Inlet set 37 press mbar Injector No 1 1 1 2 2 2 3 3 3 4 5 6 Diam mm 1 40 1 85 2 18 1 85 2 08 2 26 1 99 2 08 2 37 2 26 2
9. ANIFOLD THERMOSTAT E zs BULB ORIFICES MANIFOLD MOUNTING y SCREW AND PIN MANUAL RESET FOR OVERHEAT THERMOSTAT BENEATH BLACK CAP COMBINATION GAS CONTROL an MOTOR CONDENSER VIEW FROM BELOW BOTTOM PAN OPEN 5 REPLACEMENT OF PARTS A CAUTION Always turn off the gas supply at the gas cock and disconnect the electricity supply to the appliance before servicing or replacing any components To replace 5 1 Burner pilot thermocouple Lower bottom pan by removing wing screws on the unit base Disconnect pilot pipe and thermocouple lead from multifunctional control Remove the two burner retaining pins holding the burner assembly in place IMPORTANT Do not attempt to remove the gas manifold to ease removal of the burner as this could seriously affect the correct operation of the appliance if it is not re positioned exactly as intended The assembly can now be lowered from the unit NOTE On refitting the burner assembly ensure that the slots at the front of the burner are correctly located on their shoulder rivets and that the retaining pins are refitted in the correct location 5 1 1 Burner It is not possible to replace single burner bars The complete burner assembly must be replaced Remove the pilot and thermocouple see 5 1 2 and refit to the new assembly 5 1 2 Pilot Remove the burner assembly as detailed above Unscrew the thermocouple Undo the pilot bracket retaining the nut
10. ORRECTLY EARTHED A 230V 50 Hz mains supply is required fused at 5 amps PDE 350 and 400 10 amps Wiring external to the appliance MUST be in accordance with E E BS 7671 Wiring Regulations and any local regulations which apply The mains wiring to the appliance must be fixed PVC insulated and the wires should be between 1 and 2 5 mm cross sectional area The mains wiring inlet to the junction box is in the base of the box and the installer MUST fit a suitable strain relief bush to this hole 3 COMMISSIONING A CAUTION Start up and adjustment procedures should be performed by a qualified engineer Before commencing commissioning Ensure that the electrical supply is off Extinguish all naked lights and open all doors and windows DO NOT SMOKE Check that the gas supply is turned on at the meter and that the main gas cock is open Loosen the union and allow air to be purged from the gas line until gas is smelled Tighten the union See BS 6891 and or IM 2 for further details Turn off the gas supply and connect a manometer to the test point at the outlet of the combination gas control Turn on the gas supply Check for gas soundness 3 1 Pre operational Checks Although this unit has been assembled and fired at the factory the following pre operational procedures should be performed to ensure correct on site operation Check burner for alignment Check fan clearance Fan should not contact casing when spu
11. The pilot gas pipe can now be unscrewed take care not to lose the pilot injector and the pilot assembly released by removing the two retaining screws Replace defective component and reassemble in reverse order 5 2 Thermocouple Lower bottom pan by removing wing screws on the unit base The thermocouple can be unscrewed 5 3 Main Burner Injector Lower bottom pan by removing wing screws on the unit base The main injector can be unscrewed from the manifold and replaced 5 4 Gas Valve Disconnect pilot gas pipe thermocouple and thermocouple interrupter from the gas valve Remove green cover from the solenoid actuator on the valve and detach flying leads from the terminal block noting their position Having ensured isolation of the gas supply uncouple the union gas cock and unscrew the gas valve from the appliance inlet gas pipe Replace gas valve and reassemble in reverse order 5 5 Thermocouple Interrupter Unscrew thermocouple from top of gas valve and extract thermocouple interrupter from the gas valve Release spade connections on interrupter cable from the overheat thermostat in the heater junction box and feed back through the cable grommet Replace component and reassemble in reverse order 10 5 6 Delay Timer The delay timer is located in the junction box Remove the junction box front cover by taking out the two retaining screws Remove the single retaining screw from beneath the junction box pull off the electr
12. actor or gas supplier 6 2 If pilot does not remain alight POSSIBLE CAUSES AND REMEDIES Check inlet pressure with all units operating making certain that there is correct pressure Check pipe size to unit Be sure all pilot connections are tight Check for excessive draughts Check for blocked pilot orifice or pilot line Check for leaks around pilot fittings If leaks cause flame impingement on thermocouple lead thermocouple may become inoperative Ensure thermocouple and interrupter connections are both clean and tight at the gas valve Ensure all connections between overheat thermostat and thermocouple are clean and secure i Check the overheat thermostat for correct operation See page 8 j If the above steps do not correct the condition consult your qualified installation and service contractor or gas supplier 6 3 Effect of pilot operation on safety controls POSSIBLE CAUSES AND REMEDIES a A short pilot flame may cause poor ignition or reduce heat on thermocouple to the point where the automatic controls become inoperative thereby shutting off gas supply to main burners This may result from a blocked injector b Check electrical connection from the thermocouple interrupter to the safety valve to ensure good electrical contact Also check location of pilot flame in relation to thermocouple element 6 4 If main burners do not light POSSIBLE CAUSES AND REMEDIES a Check power to appliance
13. an motor is mounted in the centre of the guard Remove the junction box front cover by taking out two retaining screws Disconnect the fan motor wires from the terminal block noting their position and feed back through the grommet Remove the four guard mounting bolts and lift assembly clear The fan and motor can be removed from the guard by undoing the four bolts IMPORTANT Care must be taken to note if the guard is mounted on the front or rear fixing points of the motor Incorrect re assembly will cause damage to the unit The fan can be removed from the motor by removing the retaining screw Reassemble in reverse order making sure the fan and guard are correctly mounted using the four sleeves to prevent overtightening and that the fan spins freely without catching on the casing If in doubt as to the correct electrical connection consult the wiring diagram on page 9 6 FAULT FINDING GUIDE 6 1 If pilot does not light POSSIBLE CAUSES AND REMEDIES a Check that manual gas control knob on combination gas control is in the pilot position b Bleed air from the pilot line take special care when bleeding propane units C If pilot splutters check pilot line for condensate or other obstruction d If pilot flame is feeble or short check orifice for cleanliness Replace if necessary See page 7 for pilot flame adjustment e If the above steps do not correct the condition consult your qualified installation and service contr
14. ch duct work or air filters to any PDE model unit heaters In aircraft hangars the bottom of the unit must be at least 3m from the highest surface of the wings or engine enclosures of the highest aircraft housed in the hangar and the installation must be in accordance with the requirements of the enforcing authority In garages or other sections of aircraft hangars such as offices and shops which communicate with areas used for servicing or storage the bottom of the unit must be at least 1 8m above the floor The piping electrical ventilation and flueing instructions in this manual should be carefully read before commencing installation All literature shipped with the unit should be kept for future use for servicing or service diagnosis None of the literature shipped with the unit should be discarded Only approved service replacement parts should be used when servicing or repairing these unit heaters A complete replacement parts list may be obtained by contacting your appliance supplier The data plate on the unit gives the unit model number serial number and company address Any substitution of non approved parts or controls is at the owners risk and may invalidate the EC Certification Always turn off the gas supply at the gas cock and disconnect the electricity supply to the appliance before servicing or replacing any components These unit heaters will normally be controlled by a room thermostat Harry Taylor have availab
15. east 2m and for this height no more than 0 6m horizontal run may be installed immediately after the appliance outlet For greater heights 0 3m horizontal run may be added for each extra metre of flue height The chimney must terminate in a downdraught free zone Compliance with the recommendations made in BS 6644 British Gas publication IMII Flues for Commercial and Industrial Gas fired boilers and gas heaters and the Third Edition of the 1956 Clean Air Memorandum should be strictly observed where applicable The flue chimney design should avoid the formation of excessive quantities of condensate and for this reason it is recommended that all chimneys are suitably insulated and lined Drain points should be fitted at the bottom of all vertical flue sections Drain pipes must be a minimum of 25mm internal diameter and manufactured from acid condensate resistant materials e g stainless steel and positioned so that pipe runs and discharge points are not subject to the effects of frost and that flue gases cannot leak into the room Any terminal fitted must be an approved type Do not use a flue smaller than the flue pipe connection on the unit Flue should be stainless steel aluminum or other suitable corrosion resistant material Install with a minimum upward slope from unit of 20mm per metre and suspend securely from overhead structure at points no greater than 1 metre apart For best flue operation install the vertical flue as c
16. ected before making wiring connections to prevent electrical shock and equipment damage All units must be wired strictly in accordance with the wiring diagram see Fig 6 page 9 The gas supply must be turned off before commencing installation of the heaters An isolating union gas cock or union and isolating gas cock MUST be fitted before the inlet to the gas valve to allow replacement of parts The gas supply pressure to the unit heater controls must never exceed 45mbar When leak testing the gas supply system the unit and its combination gas control must be isolated during any pressure testing in excess of 45mbar The unit should be isolated from the gas supply system by closing the manual shutoff valve Start up and adjustment procedures should be performed by a qualified engineer The gas inlet pressure should be checked upstream of the combination gas control The inlet pressure should be at least 20mbar on natural gas or 37mbar on propane Purging of gas piping should be performed as described in IM2 Supply pressure and setting pressure must be checked with heater in operation when making final adjustments All units must be flued to outside The units MUST NOT be installed in potentially explosive or flammable atmospheres laden with grain dust sawdust or similar airborne materials Installation of units in high humidity or salt water atmospheres should be avoided as this will cause accelerated corrosion resulting in a
17. ects or other reproductive harm Read the installation FOR YOUR SAFETY operating and maintenance instructions If you smell gas thoroughly before installing or servicing this 1 Open windows equipment 2 Don t touch electrical switches 3 Extinguish any open flame FOR YOUR SAFETY 4 Immediately call your gas supplier The use and storage of gasoline or other flammable vapours and liquids in open l gt an j THIS MANUAL IS THE PROPERTY OF THE OWNER containers in the vicinity of this appliance is PLEASE BE SURE TO LEAVE IT WITH THE OWNER WHEN hazardous YOU LEAVE THE JOB To prevent premature heat exchanger failure Inspection on Arrival 1 Inspect unit upon arrival In case of damage report do not install ANY gas fired units in areas immediately to transportation company and your local sales where chlorinated halogenated or acid vapours representative are present in the atmosphere 2 Inspect unit received for conformance with description of product ordered INSTALLATION SPECIAL PRECAUTIONS THE INSTALLATION AND MAINTENANCE INSTRUCTIONS IN THIS MANUAL MUST BE FOLLOWED TO ENSURE 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 1 10 11 12 Any power supply must be disconn
18. er controls must never exceed 45mbar When leak testing the gas supply system the appliance and its combination gas control must be isolated during any pressure testing in excess of 45mbar The appliance should be isolated from the gas supply system by closing the inlet manual shutoff valve 2 6 Gas Supply If there is any doubt regarding the capacity of the gas meter the available gas pressure the adequacy of existing service pipes or the size required for new service pipes then the advice of the gas supplier should be requested Installation pipework should be fitted and tested for gas soundness in accordance with BS 6891 for small installations or IGEUP1 and IGEUP2 for large installations The local gas supplier must be consulted if it is necessary to employ a gas pressure booster An isolating union gas cock or union and isolating gas cock MUST be fitted before the inlet to the gas valve to allow replacement of parts Before installation check that the local distribution conditions nature of gas and pressure and the current state of adjustment of the appliance are compatible 2 7 Electrical Supply A CAUTION Disconnect power supply before making wiring connections to prevent electrical shock and equipment damage ALL UNITS MUST BE WIRED STRICTLY IN ACCORDANCE WITH WIRING DIAGRAM SUPPLIED WITH HEATER ANY WIRING DIFFERENCE FROM WIRING DIAGRAM MAY BE HAZARDOUS TO PERSONS AND PROPERTY THIS APPLIANCE MUST BE C
19. gh a roof and at least 600mm higher than any portion of a building within a horizontal distance of 3m see Figure 3 Use a flue terminal to reduce downdraughts and moisture in the flue Check flue system to see that combustion products are being satisfactorily cleared Operate unit for several minutes and then pass a lighted match around the edge of the diverter relief opening If the flame is drawn into the opening the system is drawing properly If not make adjustments to provide adequate draught ADDITIONAL REQUIREMENTS FOR FLUEING INTO AN EXISTING MASONRY CHIMNEY In the case of brick or similar structures a stainless steel rigid or flexible flue liner grade 304 316 may be used in conjunction Figure 3 Unit Heater Installation 3 5m MIN TO WALL OR ADJOINING BUILDING APPROVED TERMINAL 1 METER MIN ROOF FLASHING a ZZ T USE THIMBLE THROUGH CEILING q j DRIP LEG WITH 635em CLEANOUT CAP UNIT SLOPE TO 30 5cm SIZE ACCORDING TO EXPECTED SNOW DEPTH with a 50mm minimum thick layer of vermiculite or perlite granules between the liner and the inner skin of the chimney body Liners should be sealed at both the top and the bottom In situations where a conventional flue is inappropriate a flue boost kit is available for all PDE models allowing up to 10 metres or equivalent length of horizontal flue 2 5 Piping A CAUTION Gas pressure to unit heat
20. ical connectors taking care to note their positions and lift out the timer Replace defective component and reassemble in reverse order If in doubt regarding the electrical connections consult the wiring diagram on page 9 5 7 Overheat Thermostat The overheat thermostat body is located in the junction box Remove the junction box cover by taking out the two retaining screws Remove the thermostat cover retaining nut from the outside of the junction box and pull back into the box Remove the left hand side casing of the heater looking from the front by taking out the two retaining screws at the rear and pull the side panel clear The overheat thermostat bulb is mounted in the air stream at the bottom left of the appliance Remove the two screws holding it in place and feed it back through the hole in the inner casing To refit remove the two lower front louvres which can be sprung out The thermostat bulb can now be positioned and the retaining screws fitted 5 8 Fan Fan Motor Capacitor The capacitor is mounted alongside the junction box Remove the junction box front cover by taking out two retaining screws Disconnect the wires from the terminal block noting their position The capacitor retaining nut can be seen on the left hand side of the junction box and should be removed Replace the defective component and reassemble in reverse order If in doubt regarding the electrical connections consult the wiring diagram on page 9 The fan f
21. is turned on b Check room thermostat and time switch if fitted are calling for heat c Check that knob on combination gas control is in ON position d Be sure pilot is lit correctly positioned and strong enough to ignite burner ports e Check wiring electrical power supply to combination gas control f If the above steps do not correct the condition consult your qualified installation and service contractor or gas supplier TABLE 3 SPARE PARTS LIST Description Combination gas valve Models 30 250 Models 300 400 Number per unit Modine part number 5H75043B 5H75116B Complete fan amp motor 400 HTPMG2304101 HTPMG31541 xx HTPMG3154107 HTPMG3504118 HTPMG3504106 HTPMG4104135 HTPMG45041 xx HTPMG5106130 HTPMG5106129 HTPMG56061 16 HTPMG56061 16 HTPMG61041 xx Fan motor 30 50 75 100 125 150 175 200 250 300 350 400 HTM44026112D HTM44080195A HTM44080195A HTM44180189A HTM44180189A HTPMG4106141 HTM44180189A HTM46370183A HTM46370183A HTM46500201A HTM46500201A HTM46500201A Fan guard HTSFB2290004 HTSFB2290002 HTSFB2290002 HTSFB2290002 HTSFB2290002 HTSFB2290001 HTSFB2290005 HTSFB2290000 HTSFB2290000 HTSFB2290003 HTSFB2290003 HTSFB2290006 400 HTFFF1241005 HTCF69200003 HTCF69218063 HTCF69224053 HTCF69200006 HTCF69218003 HTCF69218006 HTCF69231006 HTCF69227016 HTCF69227036 HTCF69227036 HTCF69212006 Limit thermostat HTLM7P0090
22. le a proportional temperature controller PTC 1 which can be used to provide this control If a room thermostat is to be used contact Harry Taylor for details of suitable models MODINE GAS FIRED UNIT HEATERS PDE MODELS GENERAL INTRODUCTION These instructions are for the PDE unit set up as a Category l4 heater to use natural gas G20 at a nominal supply pressure of 20mbar This is one of its many CE certified forms Information on the PDE unit set up as a Catergory ls heater to use propane G31 at a nominal suppy pressure of 37mbar another certified form is given in Table 4 page 12 Heaters must not use gases other than those for which they were designed and built These instructions should be read thoroughly before commencing installation of the appliance It is the law that all gas appliances are installed by competent persons e g CORGII Registered in accordance with the Gas Safety Installation and Use Regulations 1984 As Amended Failure to install the appliance correctly could lead to prosecution and it is therefore in your interest and that of safety to ensure the law is complied with The installation of the appliance must be in accordance with TABLE 1 TECHNICAL DATA DIMENSIONS PERFORMANCE PDE MIN DISTANCE TO WALL Dimensions mm Dimension the current I E E Regulations BS 7671 and relevant requirements of the local gas region local authority British Standard
23. lose to the unit as possible Avoid running flue through unheated space when possible When it does pass through an unheated space it is recommended that double walled flue pipe is used If single wall is used insulate runs of greater than 1 5m to minimize condensation Use insulation that is noncombustible with a rating of not less than 200 C Keep single wall flue pipe at least 150mm from combustible material see page 2 section 12 for permissible reductions For double wall pipe maintain clearances listed in manufacturer s literature The minimum distance from combustible material is based on the combustible material surface not exceeding 70 C Clearance from the flue connector or top of unit may be required to be greater than the minimum clearance if heat damage other than fire such as material distortion or discoloration may occur Where the flue passes through a combustible floor or roof a metal sleeve 100mm greater than the flue diameter is necessary If there is 2m or more of flue pipe in the open space between the unit and where the flue pipe passes through the floor or roof the sleeve need only to be 50mm greater than the diameter of the flue pipe If a sleeve is not used all combustible material must be cut away to provide the specified clearance to combustibles Any material used to close the opening must be noncombustible The top of the vertical flue should extend at least 600mm above the highest point where it passes throu
24. n by hand Check all electrical connections to ensure they are secure Check that all horizontal deflector blades are open a minimum of 30 as measured from vertical 3 2 Lighting Instructions 3 2 1 Set room thermostat to lowest setting 3 2 2 Drop down the bottom pan see 4 1 1 page 8 Set gas control knob to PILOT and push in while lighting the pilot with gas match or taper Hold in for 1 2 minute after pilot is lit 3 2 3 Check pilot flame adjustment The pilot burner is fitted with an injector such that it will operate correctly with an inlet pressure of 15 20 mbar on natural gas and 37mbar on propane but final adjustment must be made after installation Adjust to have a soft steady flame 20 25mm long and encompassing 8 to 12mm of the tip of the thermocouple Normally this flame will produce satisfactory results To adjust flame use the pilot adjustment screw on combination gas control for location see Figure 4 If the pilot flame is longer and larger than shown by Figure 5 it is possible that this will cause soot and or impinge on the heat exchanger causing burnout 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 injector Pilot flame condition should be observed periodically to ensure trouble free operation 3 2 4 Move gas control knob to ON 3 2 5 Set room thermostat to desired setting
25. r 45 to 75 seconds to allow the heat exchanger to cool down Figure 4 Combination Gas Control PRESSURE REGULATOR ADJUSTMENT SCREW UNDER CAP SCREW GAS CONTROL KNOB INLET PRESSURE TEST FITTING OUTLET PRESSURE TEST PROTECTIVE COVER FITTING PILOT ADJUSTMENT SCREW THERMOCOUPLE INTERRUPTER CONNECTION Figure 5 Pilot Flame Adjustment 4 SERVICING It is recommended that a full service be carried out at least once a year by a qualified heating engineer CORGI Registered A CAUTION Always turn off the gas supply at the gas cock and disconnect the electricity supply to the appliance before servicing or replacing any components 4 1 Cleaning the Heater 4 1 1 Main Burner Lower bottom pan by removing wing screws on the unit base Disconnect pilot pipe and thermocouple lead from multifunctional control Remove the two burner retaining pins holding the burner assembly in place IMPORTANT Do not attempt to remove the gas manifold to ease removal of the burner as this could seriously affect the correct operation of the appliance if it is not re positioned exactly as intended The assembly can now be lowered from the unit NOTE On refitting the burner assembly ensure that the slots at the front of the burner are correctly located on their shoulder rivets and that the retaining pins are refitted in the correct location Clean the burner ports avoid using hard sharp instr
26. reduction of the normal life span of the units To prevent premature heat exchanger failure do not locate ANY gas fired unit in areas where chlorinated halogenated or acid vapours are present in the atmosphere Do not install units in extremely draughty locations Draughts can cause burner flames to impinge on the heat exchanger thereby shortening its life Separation between units should be maintained to avoid discharge from one unit entering the inlet of another Do not install units in tightly sealed rooms or small compartments without provision for adequate combustion air and venting Combustion air must have access to the space through a minimum of two permanent openings in the enclosure one near the bottom and the other near the top They should provide a free area of at least the values given in Section 2 2 Ventilation Do not install units outdoors For all sizes required minimum clearance to combustible materials from the bottom of the unit is 300mm however see page 2 section 16 which may require greater clearances for servicing and from the sides 450mm For PDE units sizes 30 50 minimum clearance from the top is 25mm and from the flue collar 50mm for PDE units sizes 75 300 minimum clearance from the top is 50mm and from the flue collar is 75mm for PDE unit 350 minimum clearance from the top is 75mm and from the flue collar is 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27. s Light the appliance see Lighting Instructions on inside of casing and check the gas connections for soundness as follows Close gas supply cock at the meter Remove the screw in the inlet pressure test point and connect a manometer to the test nipple Open the gas supply cock at the meter and the appliance gas cock Record the static pressure Close the gas supply cock at the meter and watch the pressure gauge for approximately 3 minutes Any decrease in pressure after the first minute of temperature stabilization indicates a gas leak which must be cured first check connection of manometer to test nipple When satisfied remove manometer and refit test nipple sealing screw Figure 6 Air Heater Wiring Diagram CAUTION FAILURE TO WIRE THIS UNIT ACCORDING WIRING LEGEND TO THIS WIRING DIAGRAM MAY RESULT FACTORY IN INJURY TO THE INSTALLER OR USER FOR DEVIATIONS CONTACT THE FACTORY Junction Box Capacitor TD Relay Overheat Thermostat with interupter to gas valve amp capillary with sensor to heat exchanger Manual reset button located beneath black screw off cap 230V Thermostat By Others on installation 230V 50 Hz Supply Gas Valve Figure 7 Major Component Location TAPPED MOUNTING HOLES FLUE CONNECTION FLUE RELIEF OPENING SERIAL NUMBER REAR FRONT PLATE VIEW VIEW FAN amp MOTOR DIMPLED HEAT EXCHANGER JUNCTION BOX OVERHEAT i M
28. supply Power use watts Based on natural gas typical calorific value 37 78 MJ M At 18 C ambient and unit fired at full rated input Mounting height as measured from bottom of unit NOTE NOT ALL MODELS ARE AVAILABLE IN THE UK CHECK WITH YOUR SUPPLIER INSTALLATION Figure 1 Hinged Base for Servicing See Dimension C page 3 WING SCREWS THAT SECURE HINGED BOTTOM THIS IS DIMENSION C SEE PAGE 3 2 1 Positioning Unit Heaters A CAUTION Units must not be installed in potentially explosive flammable or corrosive atmosphere To prevent premature heat exchanger failure do not locate ANY gas fired unit in areas where chlorinated halogenated or acid vapours are present in the atmosphere When siting units consider general spaceheating requirements availability of gas and proximity to flue locations Unit heaters should be positioned so heated air streams wipe exposed walls without blowing directly against them In multiple unit installations arrange units so that each supports the air stream from another setting up circulatory air movement in the area but maintain separation between units so discharge from one unit will not be directed into the inlet of another In buildings exposed to prevailing winds a large portion of the heated air should be directed along the windward wall Avoid interference to air streams as much as possible Mounting heigh
29. t measured from bottom of unit at which unit heaters are installed is critical Maximum mounting heights are listed in the Table 1 on page 3 The maximum mounting height for any unit is that height above which the unit will not deliver heated air to the floor The maximum mounting heights must not be exceeded in order to ensure maximum comfort PDE unit heaters are designed for use in heating applications with ambient temperatures between O C and 32 C If an application exists where ambient temperatures can be expected to fall outside this range contact your local sales representative for recommendations 2 2 Ventilation Safe efficient and trouble free operation of conventionally flued appliances is vitally dependent on the provision of an adequate supply of fresh air to the room in which the appliance is installed In buildings having a design air change rate of less than 0 5 h and where indirect fired heaters are to be installed in heated spaces having volume less than a 4 7 m per kilowatt of total rated heat input for heaters fitted with natural draught burners or b 2 2 m per kilowatt of total rated heat input for heaters fitted with forced or induced draught burners grilles shall be provided at low level i e below the level of the appliance flue connection except that 1 for heaters of heat input less than 60 kW the total minimum free area shall be not less than 4 5 cm per kilowatt of rated heat input or
30. tch The contacts open to shut the combination gas control in the event of the unit overheating This overheat thermostat should operate only when something is wrong with the unit Whenever this thermostat operates the problem should be identified and corrected immediately or serious damage may result If the overheat thermostat cuts off the gas supply during normal operation 1 Make sure deflector blades are open and that there are not any obstructions in the air inlet or discharge outlet 2 Check actual input to unit against rated input 3 Check motor is operating 4 Check fan is not loose on motor shaft 5 Check fan speed against motor data plate 6 Check flue system is not damaged or blocked Also check unit is flued correctly and that there is not a negative pressure in the building adversely affecting draught 7 Clean heat exchanger tubes inside and out if necessary 8 Check operation of fan delay timer 9 If items 1 to 8 do not solve the problem check overheat thermostat and replace if necessary IMPORTANT NOTE The overheat thermostat on this unit heater will shut off the gas should excessive discharge temperatures occur Do not attempt to control the fan with the overheat thermostat Any change in wiring to attempt to control the fan with the overheat thermostat will result in hazardous conditions and invalidate the warranty 4 3 Testing after Servicing After re assembly restore the electrical and gas supplie
31. uments capable of damaging the ports and check the injector s for blockage Clean carefully as necessary 4 1 2 Pilot Burner Inspect the pilot burner and thermocouple Ensure they are clean and in good condition Check a The pilot burner is securely fixed b The thermocouple tip is not burned or cracked Replace if necessary c The pilot burner head is undamaged d The pilot pipe pilot connection is gastight 4 1 3 Heat Exchanger After removing the burner assembly clean heat exchanger tubes from bottom using a stiff brush not wire 4 1 4 Fan and Motor Remove fan guard Check fan is securely fitted to motor shaft and for damage to blades Clean fan blades as necessary taking care not to damage them NOTE Ensure all four fixings sleeves are fitted before re fixing fan as overtightening could result in reduced fan life 4 1 5 General Check wiring for possible loose connections paying particular attention to the overheat thermostat interrupter leads Check air louvres in bottom pan are clean and unobstructed Clean as necessary 4 2 Overheat Thermostat The overheat thermostat bulb mounted on the left inner side panel when facing front of unit body in junction box will shut off the gas supply to the main burner in the event of overheating The manual reset button is located beneath a black screw off cap positioned on the side of the junction box See Figs 6 and 7 It is a single pole single throw swi
32. uspension hangers UP Check with a level This is important to the operation and life of the unit Figure 2 Adjustable Mounting Brackets Remove side panels to adjust mounting brackets A CAUTION For all sizes required minimum clearance to combustible materials from the bottom of the unit is 300mm but see 2 1 16 and from the sides 450mm For PDE units sizes 30 50 minimum clearance from the top is 25mm and from the flue collar 50mm for PDE units sizes 75 300 minimum clearance from the top is 50mm and from the flue collar is 75mm for PDE unit 350 minimum clearance from the top is 75mm and from the flue collar is 100mm for PDE unit 400 minimum clearance from the top is 100mm and from the flue collar is 125mm Allow at least 300mm clearance at the rear or 150mm beyond the end of motor whichever is greater to provide sufficient air for combustion and correct operation of the fan Provide clearance for opening at the hinged bottom for servicing See Figure 1 PDE unit heaters must be flued to outside do not operate without a flue A built in draught diverter is fitted additional external draught diverters are not required or permitted 2 4 Flue System To ensure safe and satisfactory operation of the heater the flue system must be capable of the complete evacuation of flue products at all times The height of the flue terminal above the draught diverter must be at l
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