Modine 246455 User Manual

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Page 1

WARNING

6-583.9

5H8000400000

July, 2016

INSTALLATION AND SERVICE MANUAL

gas-fired unit heaters

model HD and HDB

All models approved for use in California by the CEC and in Massachusetts. Unit heater is certified for residential and commercial applications.

FOR YOUR SAFETY

The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous.

1. Improper installation, adjustment, alteration, service, or maintenance can cause property damage, injury, or death, and could cause exposure to substances which have been determined by various state agencies to cause cancer, birth defects, or other reproductive harm. Read the installation, operating, and maintenance instructions thoroughly before installing or servicing this equipment.

2. Do not locate ANY gas-fired units in areas where chlorinated, halogenated, or acid 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:

1. Open windows.

2. Do not try to light any appliance.

3. Do not touch any electrical switch; do not use any phone in your building.

4. 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.

THIS MANUAL IS THE PROPERTY OF THE OWNER.

PLEASE BE SURE TO LEAVE IT WITH THE OWNER WHEN YOU LEAVE THE JOB.

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 the transportation company and your local Modine sales representative.

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 ................................. 1

Special Precautions ................................. 2

SI (Metric) Conversion Factors......................... 3

Before You Begin ................................... 3

Unit Location....................................... 4

Combustible Material and Service Clearances ......... 4

Unit Mounting .................................. 5

Unit Installation ................................. 5

Venting ....................................... 6

Gas Connections............................... 12

High-Altitude Accessory Kit ....................... 13

Electrical ..................................... 15

Wiring/Blower Speed Adjustment .................. 16

Operation ........................................ 17

Unit Components .................................. 18

Dimensions....................................... 19

Service/Troubleshooting............................. 20

Unit Wiring Diagram ................................ 21

Model/Serial Number/Replacement Parts ............... 22

Commercial Warranty........................Back Cover

Page 2

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 SUBJECT TO ANY MORE RESTRICTIVE LOCAL OR NATIONAL CODES.

HAZARD INTENSITY LEVELS

1. DANGER: Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.

2. WARNING: Indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.

3. CAUTION: Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury.

4. IMPORTANT: Indicates a situation which, if not avoided,

MAY result in a potential safety concern.

DANGER

Appliances must not be installed where they may be exposed to a potentially explosive or flammable atmosphere.

WARNING

1. Gas fired heating equipment must be vented - do not operate unvented.

2. A built-in power exhauster is provided - additional external power exhausters are not required or permitted.

3. 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 Z223.1 (NFPA 54) or CSA-B149.1 - latest edition. Failure to follow these instructions can result in injury or death.

4. 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.

5. 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.

6. Gas pressure to appliance controls must never exceed

14" W.C. (1/2 psi).

7. 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.

8. Disconnect power supply before making wiring connections

to prevent electrical shock and equipment damage.

9. All appliances must be wired strictly in accordance with

wiring diagram furnished with the appliance. Any wiring different from the wiring diagram could result in a hazard to persons and property.

10. Any original factory wiring that requires replacement must

be replaced with wiring material having a temperature rating of at least 105°C.

11. Ensure that the supply voltage to the appliance, as indicated on the serial plate, is not 5% greater than the rated voltage.

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.

6-583.9

CAUTION

1. 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.

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.

4. Clearances to combustible materials are critical. Be sure to follow all listed requirements.

5. Do not locate units in tightly sealed rooms or small compartments (commonly referred to as confined spaces) without provisions for adequate combustion air and venting. Combustion air must have access to the confined space through a minimum of two permanent openings in the enclosure, at least one near the bottom. They should provide a free area of one square inch per 1,000 BTU/Hr input rating of the unit with a minimum of 100 square inches for each opening, whichever is greater.

6. Low profile 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.

7. Do not install unit outdoors.

8. In garages or other sections of aircraft hangars, such as offices and shops that communicate with areas used for servicing or storage, keep the bottom of the unit at least 7' above the floor unless the unit is properly guarded to provide user protection from moving parts. In parking garages, the unit must be installed in accordance with the standard for parking structures ANSI/NFPA 88A latest edition, and in repair garages the standard for repair garages

NFPA 30A - latest edition (Formerly NFPA 88B). In Canada, installation of heaters in airplane hangars must be in accordance with the requirements of the enforcing authority, and in public garages in accordance with the current CSA-B149 codes.

9. 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.

10. 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.

11. 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) and 5' measured from the bottom of the unit to the floor in residential applications.

12. Be sure no obstructions block air intake and discharge of unit heaters.

13. The minimum distance from combustible material is based on the combustible material surface not exceeding 160°F. Clearance from the top of the unit may be required to be greater than the minimum specified if heat damage, other than fire, may occur to materials above the unit heater at the temperature described.

14. Allow 18" of clearance at rear (or 6" beyond end of motor at rear of unit, whichever is greater) and access side to provide ample air for combustion and proper operation of fan.

15. 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.

16. Purging of air from gas supply line should be performed as

described in the National Fuel Gas Code, ANSI Z223.1 (NFPA 54) - latest edition. In Canada, installation must be in accordance with CSA-B149.1.

Page 3

SPECIAL PRECAUTIONS / SI (METRIC) CONVERSION FACTORS

BEFORE YOU BEGIN

CAUTION

17. 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).

18. 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.

19. Turn off all gas before installing appliance.

20. Ensure that the supply voltage to the appliance, as indicated on the serial plate, is less than 5% below the rated voltage.

21. 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.

22. Service or repair of this equipment must be performed by a qualified service agency.

23. Do not attempt to reuse any mechanical or electronic

ignition controllers which has been wet. Replace defective controller.

IMPORTANT

1. To prevent premature heat exchanger failure, do not locate ANY gas-fired appliances in areas where corrosive vapors (i.e. chlorinated, halogenated, or acidic) are present in the atmosphere.

2. To prevent premature heat exchanger failure, the input to the appliance as indicated on the serial plate must not exceed the rated input by more than 5%.

3. To check most of the Possible Remedies in the trouble- shooting guide listed in Table 19.1, refer to the applicable sections of the manual.

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 Z223.1 - latest edition (also known as NFPA 54) 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 Z223.1 (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 reduced speed.

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 °F (°F-32) x 5/9 °C Btu 1.06 kJ Btu/ft3 37.3 kJ/m Btu/hr 0.000293 kW CFH (ft3/hr) 0.000472 m3/min CFH (ft3/hr) 0.00000787 m3/s CFM (ft3/min) 0.0283 m3/min CFM (ft3/min) 0.000472 m3/s

To Convert Multiply By To Obtain

feet 0.305 m Gal/Hr. 0.00379 m3/hr Gal/Hr. 3.79 l/hr

gallons 3.79 l Horsepower 746 W inches 25.4 mm pound 0.454 kg psig 6.89 kPa psig 27.7 "W.C.

6-583.9

Page 4

UNIT LOCATION

DANGER

Appliances must not be installed where they may be exposed to a potentially explosive or flammable atmosphere.

CAUTION

1. Clearances to combustible materials are critical. Be sure to follow all listed requirements.

2. Do not locate units in tightly sealed rooms or small compartments (commonly referred to as confined spaces) without provisions for adequate combustion air and venting. Combustion air must have access to the confined space through a minimum of two permanent openings in the enclosure, at least one near the bottom. They should provide a free area of one square inch per 1,000 BTU/Hr input rating of the unit with a minimum of 100 square inches for each opening, whichever is greater.

3. Low profile 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.

4. Do not install unit outdoors.

5. 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 30A - latest edition (Formerly NFPA 88B). In Canada, installation of heaters in airplane hangars must be in accordance with the requirements of the enforcing authority, and in public garages in accordance with the current CSA-B149 codes.

6. 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.

7. 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.

IMPORTANT

To prevent premature heat exchanger failure, do not locate ANY gas-fired appliances in areas where corrosive vapors (i.e. chlorinated, halogenated or acid) are present in the atmosphere.

Location Recommendations

1. When locating the heater, consider general space and heating requirements, availability of gas and electrical supply, and proximity to vent locations.

2. When locating units, it is important to consider that the exhaust vent piping must be connected to the outside atmosphere.

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.

Table 4.1 Clearances

Unit Side Clearance To Recommended

Combustible Materials Service Clearance

Top and Bottom 1" 1" Access Side 18" 18" Non-Access Side 1" 1" Rear 18" 18" Vent Connector 4" 4"

5. Be sure that the minimum clearances to combustible materials and recommended service clearances are maintained. Units are designed for installation with the minimum clearances as shown in Table 4.1.

6. Do not install units in locations where the gas ignition system is exposed to water spray, rain, or dripping water.

7. Mounting height (measured from bottom of unit) at which unit heaters are installed is critical. Refer to mounting height and heat throw data on page 17 of this manual. The maximum mounting height for any unit is that height above which the unit will not deliver heated air to the floor.

Combustion Air Requirements

The National Fuel Gas Code defines an “unconfined space” as a space whose volume is greater 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).

It is not recommended to install these unit heaters into residential confined spaces. This recommendation is due to the concern that at some point in time, the combustion air openings provided by the installer may become blocked or eliminated by the owner, either intentionally or unintentionally. Despite this recommendation, if these units are installed into a residential confined space, see National Fuel Gas Code ANSI Z223.1 (NFPA 54) or CSA-B149.1 Installation Code - latest edition, for detailed combustion air provisions. The installation must adhere to these requirements.

Units installed in confined spaces in industrial/commercial installations must be provided with two permanent openings

- one near the top and one near the bottom of the confined

space. Each opening should have a free area of not less than one square inch per 1,000 Btu/Hr of the total input rating of all units in the confined space, freely communicating with interior areas that have adequate infiltration from the outside.

For further details on supplying combustion air to a confined (tightly sealed) space or unconfined space, see the National Fuel Gas Code ANSI Z223.1 (NFPA 54) or CSA-B149.1 Installation Code - latest edition.

Turning The Unit 180° (Model Sizes 30-75 Only)

All units are produced at the factory with left-side controls (when looking at the unit). If the installation requires the controls to be on the right side, all heaters - with the exception of the HD/HDB 100 and 125 - can be turned over by following the instructions below.

• Byturningtheunit180°fromthewayitwasreceivedfrom

the factory, the sides become opposite, but the front and back remain in the same relative position. The bottom panel now becomes the top panel and vice-versa.

• Removetheaccesspanel,turnit180°,andre-attachitto

the unit so that all the information labels can be read.

• Removethespringloadeddeflectorblades,turnthemover,

replace, and adjust so they are open and in a position to direct the heated air down to the floor.

6-583.9

Page 5

UNIT MOUNTING

CAUTION

1. 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) and 5' measured from the bottom of the unit to the floor in residential applications.

2. Be sure no obstructions block air intake and discharge of unit heaters.

3. The minimum distance from combustible material is based on the combustible material surface not exceeding 160°F. Clearance from the top of the unit may be required to be greater than the minimum specified if heat damage, other than fire, may occur to materials above the unit heater at the temperature described.

4. Allow 18" clearance at rear (or 6" beyond end of motor at rear of unit, whichever is greater) and access side to provide ample air for combustion and proper operation of fan.

Figure 5.2 - Unit Heater Turned 180° (30-75 units only) (Access panel and heated air outlet change sides)

1. Be sure the means of suspension is adequate to support the weight of the unit (see page 18 for unit weights).

2. For proper operation, the unit must be installed in a level horizontal position.

3. Clearances to combustibles as previously specified must be strictly maintained.

4. For model sizes 30-75, before lifting the heater for suspension, the mounting brackets must be installed as follows (for bracket accessory installation on model sizes 100-125, see the latest revision of literature 6-594):

• For standard (left side) control access, remove the 3 screws and mounting bracket along the top edge of both the front and back of the unit. Install the front bracket as shown in Figure 5.1 by aligning the screw holes on the bracket with the screw holes on the top edge of the unit. Repeat for the bracket on the back of the unit.

• For right side control access, remove the 3 screws and mounting bracket along the top edge of both the front and back of the unit. Turn the unit over and install the front bracket as shown in Figure 5.2 by aligning the screw holes on the bracket with the screw holes on the top edge of the unit (originally the bottom edge). Repeat for the bracket on the back of the unit.

5a. Suspension by screws/lag bolts: Secure the mounting

brackets to the ceiling joists or truss, using 1/4" screws with 1/2" washers. These unit mounting brackets are slotted to accommodate joists on 16" or 24" centerlines.

Figure 5.1 - Unit Heater in Standard Mounting Configuration (30-75 Units Only)

5b. Suspension by threaded rod: The unit can also be hung

with threaded rod utilizing the same mounting brackets. Attach the threaded rod to the unit mounting brackets, securing with a top and bottom nut. For model sizes 100125, the units are designed to be suspended by threaded rod without the use of brackets. On each piece of 3/8" threaded rod used, screw a nut a distance of about one inch 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.

Next, drill holes into a steel channel or angle iron at the

same centerline dimensions as those chosen for the heater 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 channel or angle iron and secure with washers and lock nuts, lock washers and nuts, or a washer with double nut arrangement. NOTE: A pipe hanger adapter kit, shown in Figure 5.3, 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 to install one unit.

5c. Shelf mounted units: The unit heater can also be installed

on a shelf. The mounting brackets will need to be attached to the heater the same manner as explained in note #4, however, to mount on a shelf the brackets must go on the bottom of the heater. The brackets must be affixed to the shelf using similar screws (1/4" screw with 1/2" washer) as overhead joist or truss mounting. Be sure all clearance to combustible requirements are met.

Figure 5.3 - Unit Heater Suspension Methods

(Threaded Rod) (Pipe Adaptor Kit)

6-583.9

Page 6

INSTALLATION - VENTING

WARNING

1. Gas fired heating equipment must be vented - do not operate unvented.

2. A built-in power exhauster is provided - additional external power exhausters are not required or permitted.

3. 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 Z223.1 (NFPA 54) or CSA-B149.1 Installation Code - latest edition. Failure to follow these instructions can result in serious injury or death.

4. 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.

CAUTION

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.

Model HD/HDB 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:

Instructions Applicable Installation Instructions Section by Vent System Type

A General instructions for ALL installations B VERTICAL Category I vent systems ➀ C HORIZONTAL Category III vent systems ➀

➀ The difference between Vertical Category I and Horizontal Category III 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 Codelatest 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 (except for Horizontal Category III vent systems, which will be covered in “Section C – Horizontal, Category III Vent System Installation”). 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 vent unit with PVC or other forms of plastic venting material.

A3. All heaters come with a factory installed vent adapter for

attaching the vent pipe to the heater. Attach the vent pipe to the adapter with 3 non-corrosive screws. (Drill pilot holes through the vent pipe and adapter prior to screwing in place).

A4. Refer to Table 6.1 for total equivalent vent pipe lengths,

making the vent system as straight as possible. The equivalent length of a 3" elbow is 1' and for a 4" elbow is 5'.

Table 6.1 - Vent Pipe Diameters and Total Equivalent Vent Pipe Lengths For Horizontal Venting Systems

Model Size Vent Pipe Diameter

30-75 3" 3' 30'

100-125 4" 3' 30'

Minimum

Eqv. Length

A5. 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 inch per foot and suspended securely from overhead structures at points not greater than 3' apart.

A7. Fasten individual lengths of vent together with at least 3

corrosion-resistant sheet metal screws.

A8. 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 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.

A10. When the vent passes through a combustible INTERIOR

wall or floor, a metal thimble 4" greater than the vent

Maximum

Eqv. Length

Figure 6.1 - Venting Through Combustible Roof or Wall

Single Wall Vent Pipe

Flashing

Listed Thimble

Single Wall

Non-Residential Single Wall Vent Pipe Terminating with Double Wall Vent Pipe ➀

Clearance Specified by Type B Vent Mfg.

Agency Approved Vent Kit or Single Wall Vent Pipe

➀ See Instruction A10 for attaching single wall pipe to double wall pipe

Listed Thimble

Listed Terminal

Double Wall Vent Pipe ➀

Flashing

Clearance Specified by Type B Vent Mfg.

Double Wall

Single Wall

Listed Terminal

Listed

Terminal

Listed

Terminal

6-583.9

Page 7

INSTALLATION - VENTING

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. 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 exhaust 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 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 two 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.

A12. Vent termination clearances must be maintained:

Table 7.1 - Vent Termination Clearances

Minimum Clearances for Structure Vent Terminal Location

Forced air inlet within 10 feet 3 feet above Combustion air inlet of another

appliance 6 feet all directions Door, window, gravity air inlet, 4 feet horizontal and below

or any building opening 1 foot above Electric meter, gas meter, gas 4 feet horizontal (U.S.)

regulator, and relief equipment ➀ 6 feet horizontal (Canada) Gas regulator ➀ 3 feet horizontal (U.S.) 6 feet horizontal (Canada)

Adjoining building or parapet wall 6 feet all directions Adjacent public walkways 7 feet all directions Grade (ground level) 3 feet above

➀

Do not terminate the vent directly above a gas meter or regulator.

A18. In addition to following these general instructions, specific

instructions for Vertical Category I or Horizontal Category III vent systems must also be followed. Table 7.3 outlines the differences:

Table 7.3 - ANSI Unit Heater Venting Requirements

Category Description Venting Requirements

I Negative vent pressure Follow standard

Non-condensing venting requirements. II Negative vent pressure Condensate must Condensing be drained. III Positive vent pressure Vent must be gas tight. Non-condensing IV Positive vent pressure Vent must be liquid and Condensing gastight. Condensate must be drained.

Note: Vent connectors serving Category I appliances shall not be connected into

any portion of mechanical draft systems operating under positive pressure.

Vertical Category I Vent System Determination

• Verticalventsystemsterminatevertically(up).

• 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 9.1), 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 III Vent System Determination

•Horizontalventsystemsterminatehorizontally(sideways).

•Aventsystemthatterminatesverticallybuthasahorizontal

run that exceeds 75% of the vertical rise is considered horizontal.

Horizontal vent configurations are Category III. For residential installations, this requires the use of an agency approved (UL1738) Category III vent system. Additional requirements, including those for commercial and industrial installations are covered in “Section C – Horizontal, Category III Vent System Installation”.

A13. Do NOT use dampers or other devices in the vent or

combustion air pipes.

A14. Precautions must be taken to prevent degradation of

building materials by flue products.

A15. Single wall vent pipe must not pass through any

unoccupied attic, inside wall, concealed space, or floor.

A16. 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.

A17. The vent terminal must be:

Table 7.2 - Vent Terminals

Model Size Modine PN Other Listed Terminals

30-75 5H0722850005 Gary Steel 1092

100-125 5H0722850001 Gary Steel 1092

6-583.9

Page 8

INSTALLATION - VENTING

Section B – Vertical Vent System Installation

B1. This section applies to vertically vented Category I

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 horizontal portion of the vent system cannot exceed 7.5').

B4. It is recommended to install a tee with drip leg and clean out

cap as shown in Figure 8.1.

B5. The vent terminates a minimum of 5’ above the vent

connector on the unit.

B6. All vertically vented heaters that are Category I must be

connected to a chimney or vent complying with a recognized standard, or a lined masonry (or concrete) chimney with a material acceptable to the authority having jurisdiction. Venting into an unlined masonry chimney is not permitted. Refer to the National Fuel Gas Code for common venting and pages 11-12 of this manual.

B7. Use a listed vent terminal to reduce down drafts and

moisture in the vent.

B8. Double wall vent pipe is recommended, although 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).

Figure 8.1 - Vertical Vent Termination for Double Wall Vent Pipe and Greater Than or Less Than 8’ Horizontally From a Vertical Wall or Obstruction

IF DISTANCE TO ADJACENT WALL IS LESS THAN 8 FEET, THEN VENT MUST TERMINATE AT LEAST 2 FEET ABOVE THE HIGHEST POINT OF THE WALL THAT IS WITHIN 8 FEET HORIZONTAL. OTHERWISE, REFER TO TABLE 8.1 FOR "H" DIMENSION.

LISTED TERMINAL

"H" MIN*

(SEE TABLE 8.1)

TEE WITH DRIP LEG AND CLEANOUT CAP

"H" MIN*

(SEE TABLE 8.1)

LISTED TERMINAL

ROOF FLASHING

ROOF PITCH IS:

X / 12

ROOF FLASHING

USE LISTED THIMBLE THROUGH CEILING AND ROOF

USE LISTED THIMBLE THROUGH ROOF

Table 8.1 - Minimum Height from Roof to Lowest Discharge Opening

Rise X (in) Roof Pitch Min Height H (ft) ➀ 0-6 Flat to 6/12 1.00 6-7 6/12 to 7/12 1.25 7-8 7/12 to 8/12 1.50 8-9 8/12 to 9/12 2.00 9-10 9/12 to 10/12 2.50 10-11 10/12 to 11/12 3.25 11-12 11/12 to 12/12 4.00 12-14 12/12 to 14/12 5.00 14-16 14/12 to 16/12 6.00 16-18 16/12 to 18/12 7.00 18-20 18/12 to 20/12 7.50 20-21 20/12 to 21/12 8.00

➀ Size according to expected snow depth.

6-583.9

BACK VIEW

4" MIN

USE LISTED THIMBLE THROUGH CEILING

TEE WITH DRIP LEG AND CLEANOUT CAP

12" MIN

RECOMMENDED

DOWNWARD SLOPE 1/4" PER FOOT TOWARD DRIP LEG

Page 9

INSTALLATION - VENTING

•Forsingle wall vent pipe and 10' or greater horizontal distance to any portion of a building, the vent must terminate at least 3' (2' for non-residential installations) 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 9.1).

Figure 9.1 - Vertical Vent Termination for Single Wall Vent Pipe and Greater Than 10’ Horizontally From Adjacent Wall or Building

•Forsingle wall vent pipe and less than 10' horizontal distance to any portion of a building, the vent must terminate 2' higher than any portion of that building (see Figure 9.2).

Figure 9.2 - Vertical Vent Termination for Single Wall Vent Pipe and 10’ or Less Horizontally From Adjacent

Building or Building

10 FEET OR LESS TO WALL OR ADJOINING

BUILDING

LISTED

TERMINAL

GREATER THAN 10 FEET TO WALL OR ADJOINING

BUILDING

LISTED

TERMINAL

5 FEET MIN

3 FEET MIN*

12" MIN

RECOMMENDED

GREATER

THAN 10 FEET

10 FEET

2 FEET MIN*

4" MIN

ROOF FLASHING

USE LISTED THIMBLE

THROUGH CEILING

TEE WITH DRIP LEG

AND CLEANOUT CAP

DOWNWARD SLOPE

1/4" PER FOOT

TOWARD DRIP LEG

LISTED TERMINAL

2 FEET MIN*

HEIGHT ABOVE ANY PORTION OF WALL OR ADJOINING BUILDING WITHIN 10 FEET

3 FEET MIN*

10 FEET OR

LESS

5 FEET MIN

4" MIN

12" MIN

RECOMMENDED

2 FEET MIN*

ROOF FLASHING

USE LISTED THIMBLE THROUGH CEILING

TEE WITH DRIP LEG AND CLEANOUT CAP

DOWNWARD SLOPE

1/4" PER FOOT

TOWARD DRIP LEG

LISTED TERMINAL

HEIGHT ABOVE

ANY ROOF SURFACE

WITHIN 10 FEET

* 2 FEET MINIMUM FOR

NON-RESIDENTIAL INSTALLATIONS, BUT SIZE ACCORDING TO EXPECTED SNOW DEPTH

USE LISTED THIMBLE

THROUGH ROOF

4" MIN

12" MIN

RECOMMENDED

3 FEET MIN*

ROOF FLASHING

USE LISTED THIMBLE

THROUGH CEILING

TEE WITH DRIP LEG

AND CLEANOUT CAP

DOWNWARD SLOPE

1/4" PER FOOT

TOWARD DRIP LEG

HEIGHT ABOVE ANY ROOF SURFACE WITHIN 10 FEET

* 2 FEET MINIMUM FOR

NON-RESIDENTIAL INSTALLATIONS, BUT SIZE ACCORDING TO EXPECTED SNOW DEPTH

USE LISTED THIMBLE THROUGH ROOF

RECOMMENDED

4" MIN

12" MIN

3 FEET MIN*

ROOF FLASHING

USE LISTED THIMBLE THROUGH CEILING

TEE WITH DRIP LEG AND CLEANOUT CAP

DOWNWARD SLOPE 1/4" PER FOOT TOWARD DRIP LEG

B10. Once venting is complete, proceed to the section titled

“Installation – Gas Connections”.

6-583.9

Page 10

INSTALLATION - VENTING

Section C – Horizontal, Category III Vent System Installation

C1. This section applies to horizontally vented Category III

vent systems and is in addition to “Section A – General Instructions – All Units”.

C2. All heaters that are horizontally vented perform as a

Category III appliance. Category III venting has special venting requirements as follows:

 •Allresidential, horizontally vented Category III heaters

must be vented with an agency certified (UL1738) Category III venting system. Agency certified Category III venting systems are available from your local vent pipe distributor. Follow the agency certified Category III vent manufacturer's instructions for installation.

 •Forcommercial and industrial horizontally vented

heaters you may use either agency certified Category III venting systems as noted above, or single wall galvanized or stainless steel vent pipe. For single wall vent systems, one continuous section of double wall vent pipe may be used within the vent system to pass through the wall to the listed terminal. Refer to instruction A10 in “Section A – General Instructions – All Units” for attaching double wall pipe to single wall pipe. If single wall vent pipe is used, 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.

C3. All horizontal Category III vents must be terminated with a

listed vent cap. The cap must terminate a minimum distance from the external wall, as summarized in Table 10.1.

Table 10.1 - Minimum Length Between External Wall and Vent

Model Min. Length Size Application A ➀

30-75 Residential & Commercial 11"

100, 125 Residential 12" 100, 125 Commercial 24"

➀

Refer to Figure 10.2 and 10.3.

C4. The vent must be supported as shown in Figure 10.1.

Figure 10.1 - Exhaust Vent Construction Through Combustible Walls and Support Bracket

PLATE

FIBER GLASS

INSULATION

MIN. 2"

VENT PIPE DIAMETER

2" MIN.

METAL

SLEEVE

METAL FACE

C7. 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 10.2. 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 10.3, or allow the condensate to drip out the end.

Figure 10.2 - Horizontal Category III Venting with Upward Pitch

Listed Terminal

Drip leg / Clean out cap

6" Above snow grade

Listed Thimble

/4" Slope per foot up towards termination

3' Min

30' Max

Figure 10.3 - Horizontal Category III Venting with Downward Pitch (with drip leg)

Listed Terminal

Drip leg / Clean out cap

Listed Thimble

/4" Slope per foot down towards termination

3' Min

30' Max

C8. 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.

C9. Once venting is complete, proceed to the section titled

“Installation – Gas Connections”.

2" MIN.

METAL

SLEEVE

VENT TERMINATION SUPPORT BRACKET

(where required)

(Make from 1" x 1" steel angle)

C5. 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 other equipment.

C6. The venting system must be exclusive to a single unit, and

no other unit is allowed to be vented into it.

6-583.9

Page 11

INSTALLATION - VENTING

USE THIMBLE THROUGH CELLING

TEE WITH DRIP LEG AND CLEANOUT CAP RECOMENDED

LISTED TERMINAL

UPWARD SLOPE VENT

1/4" PER FOOT TOWARDS DRIP LEG

USE LISTED THIMBLE

FLASHING

CATEGORY I APPLIANCE

TYPE B DOUBLE WALL VENT CONNECTOR

TYPE B DOUBLE WALL COMMON VENT

12" MIN.

REC.

3' MAX

VENT HEIGHT

Additional Requirements for Common Venting:

1. The common vent system and all attached appliances must be Category I.

2. The vent connector should be routed in the most direct route from the units to the common vent.

3. Where 2 or more vent connectors enter a common gas vent or chimney flue, the smaller connector shall enter at the highest level consistent with the available head room or clearance to combustible material.

4. Restrictions within the common vent such as elbows should be minimized. Each elbow installed within the common portion of the venting system reduces maximum common vent capacity by 10% (refer to Tables 11.2 and 11.3 for capacity).

5. The vent connector capacities included in these tables allow for the use of two 90° elbows (or turns). For each additional elbow, the vent connector capacity shall be reduced by 10%. Refer to NFPA54/ IFEC tables for capacity ratings.

6. The common vent cross sectional area must be equal to or greater than the largest vent connector cross-sectional area.

7. If all appliances are located on one level of the building, the vent height shall be measured from the highest draft hood or vent connector to be installed within the common vent system (refer to Figures 11.1 and 11.2).

8. All units must be vented in strict accordance of the common venting Tables 11.1 through 11.3.

9. All masonry chimneys must comply with all applicable local and national codes.

10. When combining multiple vent connectors into a manifold prior to the vertical portion of the common vent, the size of the common vent manifold and the common vent shall be determined by applying a 10% reduction (.90 x maximum vent capacity from Table 11.2 or 11.3) to the common vent capacity part of the common vent tables. The length of the common vent manifold (Lm) may not exceed 18 inches per inch of manifold diameter.

11. Refer to the National Fuel Gas Code for instructions on multi-level common venting and exterior masonry chimneys as well as additional installation of the listed applications.

Figure 11.1 - Common Venting into Double Wall B Vent

Table 11.1 - Maximum Vent Connector Horizontal Run (ft) - Type B Vent Connector

Connector

Dia.

3" 30,45,60,75 4.5

4" 100, 125 6

Based on ANSI Z223.1 (NFPA 54)-2009. For reference only.

Model Max Horiz. Run

Table 11.2 - Maximum Total Appliance Input Capacities (MBh) - Type B Vent Connector and Type B Common Vent

Diameter of Common Vent

Vent

4 in. 5 in. 6 in. 7 in.

Height

Fan+ Fan+ Fan+ Fan+ Fan+ Fan+ Fan+ Fan+

(ft)

Fan Nat Fan Nat Fan Nat Fan Nat

6 92 81 140 116 204 161 309 248 8 101 90 155 129 224 178 339 275 10 110 97 169 141 243 194 367 299 15 125 112 195 164 283 228 427 352 20 136 123 215 183 314 255 475 394 30 152 138 244 210 361 297 547 459

Based on ANSI Z223.1 (NFPA 54)-2009. For reference only.

Table 11.3 - Maximum Total Appliance Input Capacities (MBh) - Type B Vent Connector with Common Vent into Masonry Chimney

Vent

Height

(ft.)

12 in

Fan+

Fan

Fan+

Nat

6 NA 74 NA 119 NA 178 NA 257 8 NA 80 NA 130 NA 193 NA 279 10 NA 84 NA 138 NA 207 NA 299 15 NA NA NA 152 NA 233 NA 334 20 NA NA NA NA NA 250 NA 368 30 NA NA NA NA NA 270 NA 404

Based on ANSI Z223.1 (NFPA 54)-2009. For reference only.

Area of Common Vent

19 in

Fan+

Fan

Fan+

Nat

28 in

Fan+

Fan

Fan+

Nat

38 in

Fan+

Fan

Fan+

Nat

Figure 11.2 - Common Venting into Masonry Chimney

6-583.9

MASONRY CHIMNEY (COMMON VENT)

TYPE B DOUBLE WALL VENT CONNECTOR

UPWARD SLOPE VENT

1/4" PER FOOT TOWARDS CHIMNEY

CATEGORY I APPLIANCE

FLASHING

3' MAX

CHIMNEY HEIGHT

Page 12

INSTALLATION - GAS CONNECTIONS

WARNING

1. All field gas piping must be pressure/leak tested prior to operation. Never use an open flame. Use a soap solution or equivalent for testing.

2. Gas pressure to appliance controls must never exceed

14" W.C. (1/2 psi).

3. To reduce the opportunity for condensation, the minimum sea level input to the appliance, as indicated on the serial plate, must not be less than 5% below the rated input, or 5% below the minimum rated input of dual rated units.

CAUTION

1. Purging of air from gas lines should be performed as

described in the National Fuel Gas Code, ANSI Z223.1 (NFPA 54) - latest edition or in Canada CSA-B149 codes.

2. 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).

3. 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.

4. 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 Z223.1 (NFPA 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 12.1 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 12.2. 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 12.2 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 shutoff 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 12.1).

4. Use 2 wrenches when connecting field piping to units.

5. Provide a sediment trap before each unit in the line where low spots cannot be avoided (see Figure 12.1).

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.

Figure 12.1 - Recommended Sediment Trap/Manual Shut-off Valve Installation - Side or Bottom Gas Connection

➀ Manual shut-off valve is in the “OFF” position when handle is perpendicular to pipe.

➀

Table 12.1 - Sea Level Manifold Pressure & Gas Consumption

Natural Propane

Model BTU/Cu. Ft. 1050 2500 No. of Size Specific Gravity 0.60 1.53 Orifices

Manifold Pressure In. W.C. 3.5 10.0

CFH 28.6 12.0 2 Gal/Hr. Propane .33

Sec/cu. ft. 126 300 Orifice Drill Size 49 56

CFH 42.9 18.0 3 Gal/Hr. Propane .50

Sec/cu. ft. 84 200 Orifice Drill Size 49 56

CFH 57.1 24.0 4 Gal/Hr. Propane .66

Sec/cu. ft. 63 150 Orifice Drill Size 49 56

CFH 71.4 30.0 5 Gal/Hr. Propane .83

Sec/cu. ft. 50 180 Orifice Drill Size 49 56

CFH 95.2 40 5 Gal/Hr.Propane 1.09

100

Sec/cu.ft. 38 90 Orifice Drill Size 45 55

CFH 119 50 5 Gal/Hr.Propane 1.37

125

Sec/cu.ft. 30 72 Orifice Drill Size 42 53

Table 12.2 - Gas Pipe Capacities - Natural Gas ➀ ➁

Pipe

Length (ft)

10 132 278 520 1050 1600 3050 20 92 190 350 730 1100 2100 30 73 152 285 590 890 1650 40 63 130 245 500 760 1450 50 56 115 215 440 670 1270 60 50 105 195 400 610 1150 70 46 96 180 370 560 1050

80 43 90 170 350 530 930 100 38 79 150 305 460 870 125 34 72 130 275 410 780 150 31 64 120 250 380 710

➀ 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.

➁ For pipe capacity with propane gas, divide natural gas capacity by 1.6.

Example: What is the propane gas pipe capacity for 60 feet of 1-1/4" pipe? The natural gas capacity is 400 CFH. Divide by 1.6 to get 250 CFH for propane gas.

1/2" 3/4" 1" 1-1/4" 1-1/2" 2"

Natural Gas

6-583.9

Page 13

INSTALLATION - HIGH ALTITUDE ACCESSORY KIT

HIGH ALTITUDE ACCESSORY KIT

Modine’s gas-fired equipment standard input ratings are certified by ETL. For elevations above 2,000', ANSI Z223.1 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 Z223.1 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

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.

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 75-515.

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

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 13.1 through 13.3. The pressure charts are differentiated by elevation, fuel type, and country the product is being installed in. The selection 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

BTU/ft3 for natural gas or 2,500 BTU/ft3 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 BTU content (heating value) before operating any heater. Tables 13.1 and 13.2 show the standard derated heating values (4% per 1,000' of elevation in the USA and 10% 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 13.1 and 13.2, 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.

charts include the proper kit suffix, when required.

Table 13.1 - Natural Gas Heating Values at Altitude ➀ ➂ ➃

Altitude (ft)

0-2,000 1,050 1,050

2,001-3,000 929

4,001-4,500 874

4,501-5,000 856 856

5,001-6,000 822 822

6,001-7,000 789 789

7,001-8,000 757 757

8,001-9,000 727 727

9,001-10,000 698 698

➀ Values shown are for 3.5" W.C. manifold pressure, for other BTU content values (available from local utility) use Equation 14.1 to calculate manifold pressure. ➁ Values shown are for 10.0" W.C. manifold pressure, for other BTU content values (available from local utility) use Equation 14.1 to calculate manifold pressure. ➂ When installed at altitudes above 2,000', a pressure switch may need to be changed. Refer to Table 13.3 to determine if a switch change is required. ➃ 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 Z223.1

and CSA-B149, respectively.

Gas Heating Values at Altitude (BTU/ft3)

USA Canada

9453,001-4,000 892

Table 13.2 - Propane Gas Heating Values at Altitude ➁ ➂ ➃

Altitude (ft)

0-2,000 2,500 2,500

2,001-3,000 2,212

4,001-4,500 2,080

4,501-5,000 2,038 2,038

5,001-6,000 1,957 1,957

6,001-7,000 1,879 1,879

7,001-8,000 1,803 1,803

8,001-9,000 1,731 1,731

9,001-10,000 1,662 1,662

Gas Heating Values at Altitude (BTU/ft3)

USA Canada

2,2503,001-4,000 2,123

Table 13.3 - High Altitude Kits for HD/HDB ➀

Model

Size

30-60

100

125

➀ ForLabelOnlykits,Modinepartnumber5H0807146005isrequiredtobelledoutandattachedtotheunitbytheinstaller.

Please contact the local Modine representative at 1.866.828.4328 (HEAT).

Details

Kit Sufx

Item Code

Kit Sufx

Item Code 68405 68405

Kit Sufx

Item Code 68408 68408 68408 68408

Kit Sufx

Item Code 68408 68408 68408 68408 68408

0-2,000 ft 2,001-4,500 ft 4,501-5,500 ft 5,501-6,500 ft 6,501-7,500 ft 7,501-8,500 ft

Not Required Label Only Label Only Label Only Label Only Label Only Label Only Label Only

Not Required Label Only Label Only Label Only Label Only Label Only

Not Required Label Only Label Only Label Only

Not Required Label Only Label Only

U.S.A and Canada

8,501 - 9,500 ft 9,501-10,000 ft

0001 0001

0004 0004 0004 0004

0004 0004 0004 0004 0004

6-583.9

Page 14

INSTALLATION - HIGH ALTITUDE ACCESSORY KIT

If the heating value of the gas being supplied is different than the values shown in Tables 13.1 and 13.2, use the following equation to determine the appropriate manifold pressure for the altitude and gas heating value being supplied.

Equation 14.1 - Manifold Pressure for Derated Gas

WHERE:

= Manifold Pressure (in. W.C.) at Altitude –

ACT

BTU

MPSL = Manifold Pressure (in. W.C.), at Sea Level –

NOTE: Only the primary manifold pressure should be adjusted

on units equipped with two-stage or modulating gas controls. No adjustments to the low fire manifold pressure are necessary on these units.

Manifold pressure setting for the heater being installed

= BTU/ft3 Content of Gas –

TBL

Obtained from Tables 13.1 or 13.2 (whichever is applicable)

= BTU/ft3 Content of Gas –

ACT

Obtained from the local utility company

Use 3.5" W.C. for natural gas and 10.0" W.C. for propane gas

6-583.9

Page 15

INSTALLATION - ELECTRICAL CONNECTIONS

ELECTRICAL CONNECTIONS

W ARNING

1. Disconnect power supply before making wiring connections to prevent electrical shock and equipment damage.

2. All appliances must be wired strictly in accordance with

wiring diagram furnished with the appliance. Any wiring different from the wiring diagram could result in a hazard to persons and property.

3. Any original factory wiring that requires replacement must

be replaced with wiring material having a temperature rating of at least 105°C.

4. Ensure that the supply voltage to the appliance, as

indicated on the serial plate, is not 5% greater than rated voltage.

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 electri cally grounded in conformance to this code. In Canada, wiring must comply with CSA C22.1, Part 1, Electrical Code.

2. Two copies of the unit wiring diagram are provided with each unit. One is located in the side access control compartment and the other is supplied in the literature packet. Refer to this diagram for all wiring connections.

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 5 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 (115, 208, 230, 460, or 575 volts). b. Connection of thermostats, or any other accessory control

devices that may be supplied (24 volts).

NOTE: All units with supply voltage 208V and greater must use a field installed step-down transformer, available as a separate accessory. Refer to Table 15.1 for additional information on the required transformer.

7. Refer to Figures 18.1 and 18.2 for the side access control compartment location.

8. All supply power electrical connections are made in the side access control compartment of the unit. The low voltage (thermostat and accessory control devices) can be wired to the terminals in the side access control compartment. Refer to the wiring diagram for the terminal location of all low voltage wiring.

6-583.9

Page 16

INSTALLATION - ELECTRICAL CONNECTIONS

Low Medium High

External Static Pressure (IN. WC)

ELECTRICAL CONNECTIONS

Location of thermostat should be determined by heating requirements and be mounted on an inside wall about 5' above floor level where it will not be affected by heat from the unit or other sources, or drafts from frequently opened doors. See instructions packed with thermostat.

Wiring Adjustments for Blower Motors

The blowers used on Modine HDB units are direct drive and equipped with three speed motors. Air temperature rise of the unit is determined by the speed setting and the amount of static pressure in the system. Units are normally shipped with motors set at high speed. Motor speed is changed by connecting the motor lead for the desired fan speed to the “EAC” or “BLO” terminal of the control board. Unused motor leads for other speeds are placed on the “PARK” terminals of the board (see the wiring diagram on page 21).

When applying a blower equipped unit to a duct system or other load, consult the performance curves on this page to determine the air temperature rise for a given motor speed range and static pressure. Verify that the static pressure on the outlet of the unit does not exceed the maximum specified for the unit. If static pressure is too high it must be reduced either by modifications to the system or using the medium or low motor speed. If the unit shuts down on high limit during normal operation, a higher motor speed should be used.

Blower Curve Models (HDB 60-125 Only)

Speeds

Temperature Rise (Deg. F)

0.00

0.10

Temperature Rise (Deg. F)

0.00

0.10

HDB 60

0.30

0.20

External Static Pressure (IN. WC)

0.40

0.50

HDB 75

0.30

0.20

External Static Pressure (IN. WC)

0.40

0.50

0.60

635

684

741

808

889

988

1111

1270

0.70

794

855

926

1010

1111

1235

1389

1587

0.70

CFM

Temperature Rise (Deg. F)

0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80

Temperature Rise (Deg. F)

0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80

HDB 100

HDB 125

External Static Pressure (IN. WC)

1140

1235

1347

1481

1646

1852

2116

1235

1323

1425

1543

1684

1852

2058

2315

CFM

6-583.9

Page 17

INSTALLATION - OPERATION

OPERATION

Prior to Operation

IMPORTANT

1. To prevent premature heat exchanger failure, observe heat exchanger tubes. If the bottom 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 16 for wiring adjustments for blower motors.

2. Start-up and adjustment procedures must be performed by a qualified service agency.

Although this unit has been assembled and fire-tested at the factory, the following pre-operational procedures should be performed to assure proper on-site operation.

1. Turn off power to the unit at the disconnect switch. Check that fuses or circuit breakers are in place and sized correctly. Turn all hand gas valves to the “OFF” position.

2. Remove the side control access panel.

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. Before you start use the following steps to verify that the venting system is adequately sized:

a. Seal any unused openings in the venting system. b. 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.

c. Insofar as practical, close all building doors and windows

and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building. Turn on clothes dryers and any exhaust fans such as range hoods and bathroom exhausts, so they shall operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

d. Follow the lighting instructions. Place the appliance being

inspected in operation. Adjust thermostat so that the appliance will operate continuously.

e. After it has been determined that each appliance connected

to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to their previous conditions of use.

f. If improper venting is observed during any of the above

tests, the venting system must be corrected.

5. Check to see that there are no obstructions to the intake and discharge of the unit.

Check fan clearance. Fan should not contact casing when spun by hand.

7. Check to make sure that all filters are in place and that they are installed properly according to direction of air flow (if applicable).

8. Perform a visual inspection of the unit to make sure no damage has occurred during installation. 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.

9. Check that all horizontal deflector blades are open a minimum of 30° as measured from vertical.

6-583.9

10. Turn on power to the unit at the disconnect switch.

11. Check the thermostat, ignition control, gas valve, and supply fan blower motor for electrical operation. If these do not function, check that the wiring is per the diagram.

12. 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.

13. For blower units, check the blower speed (RPM). Refer to “Blower Adjustments” for modification.

14. Check the motor speed (RPM).

15. Check the motor voltage.

16. Check the motor amp draw to make sure it does not exceed the motor nameplate rating.

17. 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.

18. Open the field installed manual gas shut-off valve.

19. Place the manual main gas valve on the combination gas valve in the “ON” position. Call for heat with the thermostat.

20. Check to make sure that the main gas valve opens. Check the manifold gas pressure (See “Main Burner Adjustment”) while the supply fan blower is operating.

21. Check to insure that gas controls sequence properly (see “Control Operating Sequence”). If you are not familiar with the unit’s controls (i.e. combination gas control), refer to the control manufacturer’s literature supplied with the unit.

22. Once proper operation of the unit has been verified, remove any jumper wires that were required for testing.

24. Replace the side control access panel.

25. If installed at altitudes above 2,000', affix label included with high altitude kit and fill in all fields with a permanent marker.

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.

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 from the outlet pressure tap on

the 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. Refer to Table 12.1 to determine the correct high fire manifold

pressure for the gas type of the unit. 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 on page 13. 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.

Page 18

CONTROL OPERATING SEQUENCE / UNIT COMPONENTS

CONTROL OPERATING SEQUENCE

Upon a call for heat from the thermostat, power is supplied to the power exhauster motor. The unit will go through a purge period and then the direct spark igniter will be energized. At the same time, the main valve in the combination control valve will open to allow gas to flow to the burners. If the fan motor has not

Figure 18.1 - Major Gas, Electrical Service, Safety and Other Components

all ready started it will start shortly. If a flame is not sensed for any reason the main valve will close and there will be a short purge period before ignition is tried again. If the flame is not sensed after 4 tries, there will be at least a 1 hour wait before ignition is tried again.

➁

➀

1. Power Exhauster

2. Pressure Switch

3. Integrated Direct Spark Control Board

4. Combination Gas Control

➃

➉

➂

5. Control Transformer

6. Flame Sensor (hidden)

7. Flame Rollout Switch

8. Auto Reset Limit Control (hidden)

➄

➈

➅

➇

➆

9. Direct Spark Igniter (hidden)

10. Manual Reset Control (hidden, propeller 100-125 only)

Table 18.1 - Control Options

Code No. Voltage Voltage Gas Size

Single-Stage, Direct Spark Ignition, 100% Shut-Off with Continuous Retry 11 115V 24V Natural 30-125

- Utilizes a single-stage combination gas control with ignition control. Gas is lit with a direct spark igniter on call for heat. 21 115V 24V Propane 30-125

Two-Stage, Direct Spark Ignition, 100% Shut-Off with Continuous Retry 12 115V 24V Natural 75-125

- Utilizes a two-stage combination gas control with built-in ignition control. Firing rate is 100% and 50% of full rated input. Gas is lit with a direct spark igniter on call for heat.

Control Description

Table 18.2 - Propeller Model HD Performance

30 45 60 75 100 125

Btu/Hr Input 30,000 45,000 60,000 75,000 100,000 125,000

Btu/Hr Output 24,600 36,900 49,200 61,500 82,000 102,500

Entering Airow (CFM) @ 70°F 505 720 990 1160 1490 1980

Outlet Velocity (FPM) 523 725 653 769 565 747

Air Temp. Rise (°F) 44 46 45 48 50 47

Max. Mounting Height (Ft.) 10 10 12 14 12 16

Heat Throw (Ft.)

(@ Max Mtg Ht.)

Motor Type SP SP PSC PSC SP PSC

Motor HP 1/15 1/15 1/12 1/12 1/6 1/8

Motor RPM 1550 1550 1625 1625 1050 1625

25 27 36 38 42 56

Control Service Thermostat Type of Model

22 115V 24V Propane 75-125

Table 18.3 - Blower Model HDB Performance

Model HD Sizes

6-583.9

60 75 100 125

Btu/Hr Input 

Btu/Hr Output 

Entering Airow Range (CFM) 635-1111 794-1389 1140-2116 1235-2058

Outlet Velocity (FPM) 437-726 546-908 443-781 488-773

Air Temp. Rise (°F) 40-70 40-70 35-65 45-75

Max. Mounting Height (Ft.) 

Heat Throw (Ft.)

(@ Max Mtg Ht.) 

Motor Type 

Motor HP 1/4 1/3 1/2 1/2

Motor RPM Max 1100 Max 1100 Max 1100 Max 1100

 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.

60,000 75,000 100,000 125,000

49,200 61,500 82,000 102,500

7-13 7-16 8-19 8-17

20-45 24-57 27-68 27-59

P.S.C. P.S.C. P.S.C. P.S.C.

Model HDB Sizes

Page 19

REAR VIEW

DIMENSIONAL DATA - MODEL HD/HDB

Propeller Units - Model HD

Figure 19.1 - Dimensional Drawings - Model HD

14.9" BETWEEN 3/8"-16 MOUNTING HOLES MOUNTING HOLES TYP 3/8 x 1" LONG

1.00

10"

(MODEL SIZES 100 AND 125 ONLY)

13.5" BETWEEN 3/8"-16 MOUNTING HOLES (MODEL SIZES 100 AND 125 ONLY)

ACCESS VIEW

POWER VENTER VENT PIPE CONNECTION

3.5"

OPENING

ADJUSTABLE LOUVERS

MOUNTING BRACKET SIZE 30-75

ELECTRICAL CONNECTION

GAS CONNECTION

Blower Units - Model HDB

Figure 19.2 - Dimensional Drawings - Model HDB

14.9" BETWEEN 3/8"-16 MOUNTING HOLES (MODEL SIZES 100 AND 125 ONLY)

1.0"

MOUNTING HOLES TYP 3/8 X 1" LONG

14.9" BETWEEN 3/8"-16 MOUNTING HOLES (MODEL SIZES 100 AND 125 ONLY)

10.0"

ACCESS VIEW

POWER VENTER VENT PIPE

CONNECTION

3.5"

OPENING

MOUNTING BRACKETS SIZE 30-75

ELECTRICAL CONNECTIONS

GAS CONNECTION

ACCESS PANEL

ADJUSTABLE LOUVERS

D OPENING

REAR VIEW

Table 19.1 - Dimensions (inches) - HD

Models

A B C D E

F G H

Gas Connection

Fan Diameter

Approx. Shipping Weight (lbs.)

Vent Connector Size (in)

HD30 HD45 HD60 HD75 HD100/125

26.8 26.8 26.8 26.8 35.5

12.2 12.2 18.0 18.0 20.5

16.5 16.5 16.5 16.5 22.0

14.9 14.9 14.9 14.9 22.5

10.1 10.1 15.9 15.9 18.4

7.5 7.5 10.7 10.7 14.0

18.5 18.5 18.5 18.5 -

7.6 7.6 7.8 7.8 8.4 1/2 1/2 1/2 1/2 1/2

34.5 34.5 34.5 34.5 43.0 22 22 25 25 31.0 10 10 14 14 18.0 55 60 80 85 125

3 3 3 3 4

ACCESS PANEL

Table 19.2 - Dimensions (inches) - HDB

Approx.Shipping Weight (lbs.)

Vent Connector Size (in)

D OPENING

Models

A B C D E F

Gas Connection

Blower

Table 19.3 - Clearance to Combustibles, Model HD/HDB Figure 19.3 - Mounting

Unit Side

Combustible Materials Service Clearance

Top and Bottom 1" 1" Access Side 1" 18" Non-Access Side 1" 1" Rear 18" 18" Vent Connector 4" 4"

Clearance To Recommended

Mounting brackets are slotted to accomodate

joists on 16" or 24" centerlines.

.00

1.10

3.10

5.10

7.10

9.10

HDB60 HDB75 HDB100/125

26.8 26.8 35.5

18.0 18.0 20.5

16.5 16.5 22.0

14.9 14.9 22.5

15.9 15.9 18.4

10.7 10.7 14.0

18.5 18.5 -

7.8 7.8 8.4 1/2 1/2 1/2

34.5 34.5 44.5

25.0 25.0 41.5 9 - 7 9 - 7 10 - 10 92 97 151

3 3 4

HD/HDB

30-75

21.10

19.10

17.10

23.10

25.10

26.20

6-583.9

HD/HDB

.00

1.50

5.50

7.50

3.50

9.50

100/125

(Accessory)

25.50

27.50

29.50

31.50

33.50

35.00

Page 20

SERVICE / MAINTENANCE / TROUBLESHOOTING

1. Service air moving components annually.

WARNING

When servicing or repairing this equipment, use only factoryapproved 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.

CAUTION

1. Service or repair of 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.

IMPORTANT

To check most of the Possible Remedies in the troubleshooting guide listed in Table 20.1, 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.

a. Check fan for fit on motor shaft and for damage to blades.

2. Keep unit free from dust, dirt, grease, and foreign matter, paying particular attention to: a. Combustion air inlets. b. Burners and burner orifices. Turn off gas ahead of the

combination gas control and shut off electric power to the heater. Remove the access panel, open the union on the gas line, and disconnect the igniter and sensor wires. Remove the screws that attach the burner tray to the header plate and remove the burner tray and manifold assembly from the heater. Carefully clean the burners with a wire brush or other suitable means. Replace any damaged or deteriorating burners or orifices. Install the burner assembly back on to the header making certain that

all screws, pipes and electrical connections are tight. CAUTION: Be careful when handling the igniter and flame sensor.

3. Inspect the flame sensor and igniter for deterioration and/or

cracks.

4. Verify that the burners are touching each other at the

carryover points. This will ensure flame carryover from burner to burner. a. Clean exterior of heat exchanger tubes. b. Fan blades.

5. Check wiring for possible loose connections.

6. Controls – The gas valves and piping should be checked

annually for general cleanliness and tightness. The gas controls should be checked to insure that the unit is operating properly. See control instruction sheets furnished separately with the unit heater.

7. Power exhaust assembly/motor – The power exhaust motor

bearings have been lubricated for long life and do not require additional lubrication. In dirty environments, it may be desirable to clean the motors and blower housing and blow out the cooling air passages of the motor with compressed air.

8. Perform periodic cleaning of inlet and vent terminal screens.

Table 20.1 - Troubleshooting

TROUBLE POSSIBLE CAUSE POSSIBLE REMEDY

Unit does nothing 1. Power supply is off 1. Turn on main power

2. No 24V power to thermostat 2 a. Check control transformer b. If failed transformer - check thermostat wire gage and length

3. Thermostat malfunction 3 a. Verify wire connections to R&W terminals only b. Check / replace thermostat

4. LED flashes 4. Check LED flash code

5. Blown fuse on control board 5. Replace fuse

6. Defective control 6. Replace control

LED light off or 1. Blown fuse on control board 1. Replace fuse flashing 2. Multiple causes 2. Control board LED flash codes vary with control type. A decal is

installed in the unit giving a brief description of the applicable codes for your heater. For more detail, see the control board data sheet included with the unit.

Unit starts but does 1. Main gas is off 1. Open manual gas valve not ignite 2. Air in gas line 2. Purge gas line

3. Main or manifold gas pressure 3. Set gas pressures per manual instructions

4. Check gas valve switch 4. Set gas valve switch to “ON” position

Unit goes through cycle 1. Reversed main power polarity 1. Black wire - HOT, White wire - NEUTRAL, Green wire - GROUND but the burners go out 2. Unit not grounded 2. Ground unit and verify quality of ground connection in less then 10 seconds 3. Flame not sensed 3. Check flame sense probe and connection

Air circulating fan 1. Loose connections 1. Check all connections inoperable 2. Defective control board 2. Check control board data sheet and function

3. Defective fan motor 3. Check fan motor

6-583.9

Page 21

UNIT WIRING

Wiring Diagram Selection

Since internal or factory wiring may vary depending on the controls manufacturer, the wiring diagrams must be appropriately selected with the proper gas valve and ignition

Figure 21.1 - Unit Heater Wiring Diagram (Single and Two Stage, Direct Spark Ignition)

GAS

VALV E

type. The following wiring diagram represents a unit equipped with a single or two stage gas valve and direct spark ignition.

FLAME

SENSOR

SPARK

IGNITOR

GND

GR, (G)

L2, (WH)

115V/60HZ/1Ø POWER

L1, (BK)

CIRCUIT BREAKER (BY OTHERS)

SWITCH

REFER NOTE 7

MULTIPLE RETRY W/AUTO RESET FROM LOCKOUT

SINGLE STAGE, DIRECT SPARK IGNITION, 100% SHUTOFF,

CALL FOR FAN

CALL FOR HEAT

LOW VOLTAGE

THERMOSTAT (BY OTHERS)

PRESSURE

SWITCH

LIMIT

CONTROL

WHITE ROGERS

GAS VALVE

CALL FOR FAN

1ST STAGE 2ND STAGE

LOW VOLTAGE

THERMOSTAT (BY OTHERS)

PRESSURE

SWITCH

LIMIT CONTROL

COM

HIM

IGNITION

CONTROL

PIN 5

PIN 6

(SEE NOTE 5)

PIN 8

1 4 7

852

3 6 9

FLAME ROLLOUTS

(SEE NOTE 6)

SINGLE STAGE, DIRECT SPARK IGNITION,

SHUT-OFF, MULTIPLE RETRY W/ AUTO RESET FROM LOCKOUT

1 4 7

852

3 6 9

LABEL

PARK

EAC

IND

SEC

COM

FLAME

SENSOR

IGNITION

CONTROL

LABEL

PARK

HEAT

IND

24V

COM

IGNITOR

N E U T R A L

SPARK

L1, (BK)

L2, (WH)

R Y

L1, (BK)

L2, (WH)

R Y

MOTOR

FAN

MOTOR

SWITCH

120

COM

GND

115V/60HZ/1Ø POWER

L2, (WH)

CIRCUIT BREAKER (BY OTHERS)

L1, (BK)

REFER NOTE 7

MOTOR

120

COM

XFMR

FAN

MOTOR

XFMR

MULTIPLE RETRY W/AUTO RESET FROM LOCKOUT

TWO STAGE, DIRECT SPARK IGNITION, 100% SHUTOFF,

LIMIT

CONTROL

LIMIT CONTROL

(SEE NOTE 5)

100% SHUT-OFF, MULTIPLE RETRY W/ AUTO RESET FROM LOCKOUT

FLAME ROLLOUTS

(SEE NOTE 6)

5H0799630002 REV M

TWO STAGE, DIRECT SPARK IGNITION,

6-583.9

Page 22

MODEL & SERIAL NUMBER / REPLACEMENT PARTS

Figure 22.1 - Model Number Designations (Remove access cover to locate)

HD 45 A S 01 11 S B A N

HD - Tubular Power Vented

Propeller Unit

HDB - Tubular Power

Vented Blower Unit

30 - 30,000 Btu/hr input 45 - 45,000 Btu/hr input 60 - 60,000 Btu/hr input

75 - 75,000 Btu/hr input 100 - 100,000 Btu/hr input 125 - 125,000 Btu/hr input

MBH Input

Heat Exchanger Type

S - Stainless Steel

A - Aluminized

Ignition Type

S - Direct Spark

01 - 115 volt, 60 hertz,

Power Code

single phase

Dev Digit

Fan Guard Digit N - None (all blower models) F - Fingerproof

Control Code 11 - Single Stage, Natural Gas 12 - Two Stage, Natural Gas 21 - Single Stage, Propane Gas 22 - Two Stage, Propane Gas

Factory Installed Option Digit N - None

Future A - All

Figure 22.2 - Serial Number Designations (Remove access cover to locate)

SERIAL NUMBER

SPO MODEL

MOTOR SUPPLIER 05 - Universal 15 - Marathon

CONTROL SUPPLIER

01 - RobertShaw 05 - Honeywell 08 - Fenwal

3 0 0 1 1 7 9 9 8 2 3 41 1 100 0 0 0 0 0 0

18 - Franklin 38 - A.O. Smith

20 - Morrison 10 - Lau 19 - Air Drive

09 - White Rogers 17 - United Tech

UNIT SERIES

00 - Original 01 - Modified

FAN VENDOR CODE

01 - Revcor 08 - Brookside

GAS VALVE SUPPLIER

01 - RobertShaw 05 - Honeywell 09 - White Rogers

MANUFACTURE

Same as Requirements

Planning Shop Calendar

WEEK OF

YEAR OF MANUFACTURE

SEQUENTIAL NUMBER

Number varies from 0000 to 9999.

Each unit within same week of

manufacture is to have unique number.

SPO NUMBER

Replacement Parts

When requesting parts please contact your local representative. Please have full model and serial number available. If you require assistance in locating your representative, please call the number located on the back page.

Table 22.1 - Common Replacement Parts (The list is subject to change. Please refer to unit mounted parts list for most up-to-date list.)

Model

Size

Power

Exhauster

Limit Control Switch

Flame

Roll-out

Switch

Transformer

Pressure

Switch

Igniter

Ignition Control

(1 Stage)

Combination Gas

Valve (1 Stage)

Code 11

Code 21

Ignition Control

(2 Stage)

HD30 5H75038 5H75769-1 5H75002-7 5H75029 5H75030-3 5H79636 5H79749 5H79751 5H79869 NA NA NA

HD45 5H75038 5H75769-1 5H75002-7 5H75029 5H75030-3 5H79636 5H79749 5H79751 5H79869 NA NA NA

HD60 5H75038 5H75769-2 5H75002-7 5H75029 5H75030-3 5H79636 5H79749 5H79751 5H79869 NA NA NA

HDB60 5H75038 5H75769-4 5H75002-7 5H75029 5H75030-3 5H79636 5H79749 5H79751 5H79869 NA NA NA

HD75 5H75038 5H75769-2 5H75002-7 5H75029 5H75030-4 5H79636 5H79749 5H79751 5H79869 5H79804 5H79748 5H79871

HDB75 5H75038 5H75769-2 5H75002-7 5H75029 5H75030-4 5H79636 5H79749 5H79751 5H79869 5H79804 5H79748 5H79871

HD100 5H79795 5H75769-2 5H75002-4 5H75029 5H79441-9 5H79636 5H79749 5H79751 5H79869 5H79804 5H79748 5H79871

HDB100 5H79795 5H75769-3 5H75002-4 5H75029 5H79441-9 5H79636 5H79749 5H79751 5H79869 5H79804 5H79748 5H79871

HD125 5H79795 5H75769-1 5H75002-4 5H75029 5H79441-9 5H79636 5H79749 5H79751 5H79869 5H79804 5H79748 5H79871

HDB125 5H79795 5H75769-2 5H75002-4 5H75029 5H79441-9 5H79636 5H79749 5H79751 5H79869 5H79804 5H79748 5H79871

6-583.9

Combination Gas

Valve (2 Stage)

Code 12

Code 22

Page 23

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6-583.9

Page 24

COMMERCIAL WARRANTY

Seller warrants its products to be free from defects in material and workmanship, EXCLUSIVE, HOWEVER, of failures attributable to the use of materials substituted under emergency conditions for materials normally employed. This warranty covers replacement of any parts furnished from the factory of Seller, but does not cover labor of any kind and materials not furnished by Seller, or any charges for any such labor or materials, whether such labor, materials or charges thereon are due to replacement of parts, adjustments, repairs, or any other work done. This warranty does not apply to any equipment which shall have been repaired or altered outside the factory of Seller in any way so as, in the judgment of Seller, to affect its stability, nor which has been subjected to misuse, negligence, or operating conditions in excess of those for which such equipment was designed. This warranty does not cover the effects of physical or chemical properties of water or steam or other liquids or gases used in the equipment.

BUYER AGREES THAT SELLER’S WARRANTY OF ITS PRODUCTS TO BE FREE FROM DEFECT IN MATERIAL AND WORKMANSHIP, AS LIMITED HEREIN, SHALL BE IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES, 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 FROM BREACH OF WARRANTY, NONCONFORMITY TO ORDERED SPECIFICATIONS, DELAY IN DELIVERY, OR ANY LOSS SUSTAINED BY THE BUYER.

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 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 & 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.

Component

Applicable Models

Heat Exchangers

Gas-Fired Units

Heat Exchangers

Low Intensity Infrared Units

Compressors

Condensing Units for Cassettes

Burners

Low Intensity Infrared Units

Other

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, Ventilators, Geothermal Units

Compressors

Vertical Unit Ventilators, Ventilators, Geothermal Units

Burners

High Intensity Infrared Units

Sheet Metal Parts

All Products

TEN YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER, WITHIN TEN YEARS FROM DATE OF RESALE BY BUYER OR ANY 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 OCCURS FIRST

FIVE YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER, WITHIN FIVE YEARS FROM DATE OF RESALE BY BUYER OR ANY OTHER USER, WITHIN FIVE YEARS FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION, OR WITHIN SIXTY-SIX MONTHS FROM DATE OF SHIPMENT FROM SELLER, WHICHEVER OCCURS FIRST

TWO YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER, WITHIN TWO YEARS FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION, OR WITHIN THIRTY MONTHS FROM DATE OF SHIPMENT FROM SELLER, WHICHEVER OCCURS FIRST

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

“APPLICABLE WARRANTY PERIOD”

As Modine Manufacturing Company has a continuous product improvement program, it reserves the right to change design and specifications without notice.

Modine Manufacturing Company

1500 DeKoven Avenue Racine, WI 53403 Phone: 1.800.828.4328 (HEAT) www.modinehvac.com