Modine PDP, BDP User Manual
6-580.5
5H78213A
April, 2010
INSTALLATION AND SERVICE MANUAL
gas-fired unit heaters
models PDP and BDP
All models approved for use in California by the CEC (when
equipped with IPI), in New York by the MEA division, and in
Massachusetts. Unit heater is certified for non-residential
applications.
FOR YOUR SAFETY
If you smell gas:
1. Open windows.
2. Don’t touch electrical switches.
3. Extinguish any open flame.
4. Immediately call your gas supplier.
WARNING
1. Improper installation, adjustment, alteration,
service or maintenance can cause property
damage, injury or death, and could cause
exposure to substances which have been
determined by various state agencies
to cause cancer, birth defects or other
reproductive harm. Read the installation,
operating and maintenance instructions
thoroughly before installing or servicing this
equipment.
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
The use and storage of gasoline or other
flammable vapors and liquids in open containers
in the vicinity of this appliance is hazardous.
IMPORTANT
The use of this manual is specifically intended
for a qualified installation and service agency.
A qualified installation and service agency must
perform all installation and service of these
appliances.
Inspection on Arrival
1. Inspect unit upon arrival. In case of damage, report
immediately to transportation company and your local
Modine sales representative.
2.
Check rating plate on unit to verify that power supply meets
available electric power at the point of installation.
3. Inspect unit received for conformance with description of
product ordered (including specifications where applicable).
THIS MANUAL IS THE PROPERTY OF THE OWNER.
PLEASE BE SURE TO LEAVE IT WITH THE OWNER WHEN YOU LEAVE THE JOB.
SPECIAL PRECAUTIONS / TABLE OF CONTENTS
Special Precautions
THE INSTALLATION AND MAINTENANCE INSTRUCTIONS
IN THIS MANUAL MUST BE FOLLOWED TO PROVIDE
SAFE, EFFICIENT AND TROUBLE-FREE OPERATION.
IN ADDITION, PARTICULAR CARE MUST BE EXERCISED
REGARDING THE SPECIAL PRECAUTIONS LISTED BELOW.
FAILURE TO PROPERLY ADDRESS THESE CRITICAL
AREAS COULD RESULT IN PROPERTY DAMAGE OR LOSS,
PERSONAL INJURY, OR DEATH. THESE INSTRUCTIONS
ARE SUBJECT TO ANY MORE RESTRICTIVE LOCAL OR
NATIONAL CODES.
HAZARD INTENSITY LEVELS
1. DANGER: Indicates an imminently hazardous situation
which, if not avoided, WILL result in death or serious injury.
2. WARNING: Indicates a potentially hazardous situation which,
if not avoided, COULD result in death or serious injury.
3. CAUTION: Indicates a potentially hazardous situation which,
if not avoided, MAY result in minor or moderate injury.
4. IMPORTANT: Indicates a situation which, if not avoided,
MAY result in a potential safety concern.
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. 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.
4. Gas pressure to appliance controls must never exceed 14"
W.C. (1/2 psi).
5. Disconnect power supply before making wiring connections
to prevent electrical shock and equipment damage.
6. 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.
7. Any original factory wiring that requires replacement
must be replaced with wiring material having a
temperature rating of at least 105°C.
8. When servicing or repairing this equipment, use only
factory-approved service replacement parts. A complete
replacement parts list may be obtained by contacting
Modine Manufacturing Company. Refer to the rating
plate on the appliance for complete appliance model
number, serial number, and company address. Any
substitution of parts or controls not approved by the
factory will be at the owners risk.
9. 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.
10. Ensure that the supply voltage to the appliance, as
indicated on the serial plate, is not 5% greater than the
rated voltage.
cAUTION
1. Purging of air from gas supply line should be performed
as described in ANSI Z223.1 - latest edition “National Fuel
Gas Code”, or in Canada in CAN/CGA-B149 codes.
2. Do not attempt to reuse any mechanical or electronic
ignition controllers which has been wet. Replace defective
controller.
3. Ensure that the supply voltage to the appliance, as
indicated on the serial plate, is not 5% less than the rated
voltage.
1. To prevent premature heat exchanger failure, do not
locate ANY gas-fired appliances in areas where corrosive
vapors (i.e. chlorinated, halogenated or acid) are present
in the atmosphere.
2. Do not attempt to attach ductwork of any kind to propeller
models.
3. 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 9 for Blower Adjustments.
4. Start-up and adjustment procedures should be performed
by a qualified service agency.
5. To check most of the Possible Remedies in the troubleshooting guide listed in Table 21.1, refer to the applicable
sections of the manual.
6. 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%.
Table of Contents
Inspection on Arrival................................. 1
Special Precautions ................................. 2
SI (Metric) Conversion Factors ........................3
Unit Location ...................................... 3
Combustible Material and Service Clearances ......... 3
Combustion Air Requirements .....................3
Unit Lifting and Unit Mounting...................... 4
Installation ........................................4
Venting ....................................... 4
Gas Connections................................ 7
Electrical Connections............................ 8
Duct Installation................................. 8
Blower Adjustment .............................8-9
Start-Up Procedure ................................ 10
Pilot Burner Adjustment.......................... 10
Main Burner Adjustment ......................... 10
Control Operating Sequence...................... 11
Options .......................................... 12
General Performance Data ....................... 13-15
Performance Data Hoods/Nozzles .................. 16-17
Dimensions Unit ................................ 18-19
Maintenance...................................... 20
Service & Troubleshooting ........................ 21-22
Model Nomenclature/Serial Plate....................22-23
Commercial Warranty........................ Back Page
IMPORTANT
2
6-580.5
SI (METRIC) CONVERSION FACTORS / UNIT LOCATION
A
D
B
C
Access
Side
Table 3.1 - SI (Metric) Conversion Factors
To Convert Multiply By To Obtain
"W.C. 0.24 kPa
psig 6.893 kPa
°F (°F-32) x 0.555 °C
inches 25.4 mm
feet 0.305 meters
CFM 0.028 m3/min
To Convert Multiply By To Obtain
CFH 1.699 m3/min
Btu/ft3 0.0374 mJ/m
pound 0.453 kg
Btu/hr 0.000293 kW/hr
gallons 3.785 liters
psig 27.7 "W.C.
3
UNIT LOCATION
dANGER
Appliances must not be installed where they may be exposed
to a potentially explosive or flammable atmosphere.
IMPORTANT
To prevent premature heat exchanger failure, do not locate
ANY gas-fired appliances in areas where corrosive vapors (i.e.
chlorinated, halogenated or acid) are present in the atmosphere.
Location Recommendations
1. When locating the furnace, consider general space and
heating requirements, availability of gas and electrical
supply, and proximity to vent locations.
2. Avoid installing units in extremely drafty locations. Drafts
can cause burner flames to impinge on heat exchangers
which shortens life. Maintain separation between units so
discharge from one unit will not be directed into the inlet
of another.
3. Be sure the structural support at the unit location site is
adequate to support the weight of the unit. For proper
operation the unit must be installed in a level horizontal
position.
4. Do not install units in locations where the flue products can
be drawn into the adjacent building openings such as
windows, fresh air intakes, etc.
5. Be sure that the minimum clearances to combustible
materials and recommended service clearances are
maintained. Units are designed for installation on non-
combustible surfaces with the minimum clearances shown
in Figure 3.1 and Tables 3.2 and 3.3.
6. Units exposed to inlet air temperatures of 40°F or less,
may experience condensation, therefore, provisions should
be made for disposal of condensate.
7. When locating units, it is important to consider that the
exhaust vent piping must be connected to the outside
atmosphere.
8. 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 feet above the floor unless the unit is properly guarded
to provide user protection from moving parts. In parking
garages, the unit must be installed in accordance with the
standard for parking structures ANSI/NFPA 88A, and in
repair garages the standard for repair garages NFPA #88B.
In Canada, installation of heaters in airplane hangars must
be in accordance with the requirements of the enforcing
authority, and in public garages in accordance with the
current CAN/CGA-B149 codes.
9. Do not install units in locations where gas ignition system
is exposed to water spray, rain, or dripping water.
10. Do not install units below 7 feet, measured from the bottom
of the unit to the floor, unless properly guarded to provide
protection from moving parts.
11. In aircraft hangars, keep the bottom of the unit at least 10
feet from the highest surface of the wings or engine
enclosure of the highest aircraft housed in the hangar
and in accordance with the requirements of the enforcing
authority and/or NFPA No. 409 - Latest Edition.
Figure 3.1 - Combustible Material and Service Clearances
Table 3.2 - Combustible Material Clearances ➀
Model Side Side Top Bottom Exhauster
Size (A) (B) (C) (D) (Not shown)
150-175 1 1 4 12 2
200-400 1 1 5 12 3
➀ Provide sufficient room around the heater to allow for proper
combustion and operation of fan. Free area around the heater must
not be less than 1-1/2 times the discharge area of the unit.
Access Non-Access Top of Power
Table 3.3 - Recommended Service Clearances
Model Side Side Top Bottom Exhauster
Size (A) (B) (C) (D) (Not shown)
150-175 18 18 6 22 1
200-400 18 18 6 25 1
Access Non-Access Top of Power
Combustion Air Requirements
Units installed in tightly sealed buildings or confined spaces
must be provided with two permanent openings, one near the
top of the confined space and one near the bottom. Each
opening should have a free area of not less than one square
inch per 1,000 BTU per hour of the total input rating off all units
in the enclosure, freely communicating with interior areas
having, in turn adequate infiltration from the outside.
For further details on supplying combustion air to a confined
(tightly sealed) space or unconfined space, see the National
Fuel Gas Code ANSI Z223.1 of CAN/CGA B149.1 or .2
Installation Code, latest edition.
Sound and Vibration Levels
All standard mechanical equipment generates some sound and
vibration that may require attenuation. Libraries, private offices
and hospital facilities will require more attenuation, and in such
cases, an acoustical consultant may be retained to assist in the
application. Locating the equipment away from the critical area
is desirable within ducting limitations. Generally, a unit should
be located within 15 feet of a primary support beam. Smaller
deflections typically result in reduced vibration and noise
transmission.
6-580.5
3
INSTALLATION
UNIT LIFTING
All units are shipped fully boxed. Larger units are also supplied
with skid supports on the bottom of the box. The larger units
may be lifted from the bottom by means of a fork lift or other
lifting device only if the shipping support skids are left in place
and the forks support the whole depth of the unit. If the unit
must be lifted from the bottom for final installation without the
carton in place, be sure to properly support the unit over its
entire length and width to prevent damage. When lifting units,
make sure the load is balanced.
UNIT SUSPENSION
Be sure the method of unit suspension is adequate to support
the weight of the unit (see Weights for base unit and factory
installed option weights). For proper operation, the unit must be
installed in a level horizontal position. Combustible material and
service clearances as specified in Figure 3.1 and Tables 3.2
and 3.3 must be strictly maintained. To assure that flames are
directed into the center of the heat exchanger tubes, the unit
must be level in a horizontal position. Use a spirit level to
ensure that the unit is suspended correctly.
The most common method of suspending Modine gas unit
heaters is to utilize 3/8” threaded rod. On each piece of
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. Then place a washer over the end of the threaded
rod and screw the threaded rod into the unit heater weld nuts
on the top of the heater at least 5 turns, and no more than 10
turns. Tighten the nut first installed onto the threaded rod to
prevent the rod from turning. Drill holes into a steel channel or
angle iron at the same centerline dimensions as the heater that
is being installed. The steel channels or angle iron pieces need
to span and be fastened to appropriate structural members. Cut
the threaded rods to the preferred length, place them through
the holes in the steel channel or angle iron and secure with
washers and lock nuts or lock washers and nuts. A double nut
arrangement can be used here instead of at the unit heater (a
double nut can be used both places but is not necessary). Do
not install standard unit heaters above the maximum mounting
height shown in Table 13.1.
On all propeller units, except sizes 350 and 400, two tapped
holes (3/8-16) are located in the top of the unit to receive
threaded rods.
Units with two point suspension, sizes 150 through 300,
incorporate a level hanging feature. Depending on what options
and accessories are being used, the heater may not hang level
as received from the factory. Do not hang heaters with deflector
hoods until referring to the “Installation Manual for Deflector
Hoods” and making the recommended preliminary adjustments
on the heater. These preliminary adjustments need to be made
with the heater resting on the floor.
Propeller sizes 150 through 300 units without deflector hoods
that do not hang level after being installed, can be corrected in
place. Simply remove both outer side panels (screws to remove
are on back flange of side panel) and you will see the
(adjustable) mounting brackets (Fig. 4.1). Loosen the set
screws holding the mounting brackets in place and using a
rubber mallet or similar, tap the heater into a position where the
unit hangs level. Re-tighten set screws and replace the outer
side panels.
Propeller sizes 350 and 400 have four mounting holes. On
all blower units, except the 350 and 400, two tapped holes
are provided in the top of the unit and two holes in the blower
support bracket. The 350 and 400 have four tapped holes in
the top of the unit and two in the blower support bracket for
mounting.
4
Figure 4.1 - Adjustable Mounting Brackets - To Adjust:
1. Remove outer side panels.
2. “Set screws” - loosen and
position bracket where needed
– then tighten set screws.
3. Re-attach outer side panels.
A pipe hanger adapter kit, shown in Figure 4.2 is available as
an accessory. One kit consists of two drilled 3/4” IPS pipe caps
and two 3/8 - 13 x 1-3/4” capscrews to facilitate threaded pipe
suspension.
Figure 4.2 - Suspension Methods
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.
NOTE: A vent is the vertical passageway used to convey
flue gases from the unit or the vent connector to the outside
atmosphere. A vent connector is the pipe which connects the
unit to a vent or chimney. Vent connectors serving Category
I appliances shall not be connected into any portion of
mechanical draft systems operating under positive pressure.
General Venting Air Instructions
1. Installation of venting must conform with local building
codes, or in the absence of local codes, with the National
Fuel Gas Code, ANSI Z223.1 (NFPA 54) - Latest Edition.
In Canada, installation must be in accordance with CAN/
CGA-B149.1 for natural gas units and CAN/CGA-B149.2 for
propane units.
2. All vertically vented units are Category I. All horizontally
vented units are category III. The installation must conform
to the requirements from Table 5.1 in addition to those listed
below.
3. From Table 18.9 or 19.1, select the size of vent pipe that fits
the flue outlet for the unit. Do not use a vent pipe smaller
than the size of the outlet or vent transition of the appliance.
The pipe should be suitable corrosion resistant material.
Follow the National Fuel Gas Code for minimum thickness
and composition of vent material. The minimum thickness for
connectors varies depending on the pipe diameter.
6-580.5
INSTALLATION
Slope 1/4" to
The Foot
Unit
Drip Leg with
Cleanout Cap
Use Thimble
Through Ceiling
H
1'0"
1/4"
x
12
Roof Pitch is x/12
Listed
Te rminal
Roof
Flashing
1/4"
Slope 1/4" to
The Foot
*Size according to
expected snow depth
Drip Leg with
Cleanout Cap
Use Thimble
Through Ceiling
Roof Flashing
Listed
Terminal
2� Min.
2�*
Min.
To wall or adjoining building
10"
Unit
4. For Category I vent systems limit length of horizontal runs to
75% of vertical height. Install with a minimum upward slope
from unit of 1/4 inch per foot and suspend securely from
overhead structure at points no greater than 3 feet apart.
For best venting, put vertical vent as close to the unit as
possible. A minimum of 12" straight pipe is recommended
from the power exhauster outlet before turns in the vent
system. Fasten individual lengths of vent together with at
least three corrosion-resistant sheet-metal screws.
5. It is recommended that vent pipes be fitted with a tee with
a drip leg and a clean out cap to prevent any moisture in the
vent pipe from entering the unit. The drip leg should be
inspected and cleaned out periodically during the heating
season.
6. The National Fuel Gas Code requires a minimum clearance
of 6 inches from combustible materials for single wall vent
pipe. The minimum distance from combustible materials is
based on the combustible material surface not exceeding
160°F. Clearance from the vent pipe (or the top of the unit)
may be required to be greater than 6 inches if heat damage
other than fire (such as material distortion or discoloration)
could result.
7. Avoid venting through unheated space. When venting does
pass through an unheated space, insulate runs greater than
5 feet to minimize condensation. Inspect for leakage prior to
insulating and use insulation that is noncombustible with a
rating of not less than 350°F. Install a tee fitting at the low
point of the vent system and provide a drip leg with a clean
out cap as shown in Figure 5.1.
8. When the vent passes through a combustible wall or floor, a
metal thimble 4 inches greater than the vent diameter is
necessary. If there is 6 feet or more of vent pipe in the open
space between the appliance and where the vent pipe
passes through the wall or floor, the thimble need only be
2 inches greater than the diameter of the vent pipe. If a
thimble is not used, all combustible material must be cut
away to provide 6 inches of clearance. Any material used
to close the opening must be noncombustible.
Table 5.1 - ANSI Venting Requirements
Appliance Venting
Category Description Requirements
I Negative vent pressure Follow standard venting
Non-condensing requirements.
II Negative vent pressure Condensate must be
Condensing drained.
III Positive vent pressure Vent must be gastight.
Non-condensing
IV Positive vent pressure Vent must be liquid and
Condensing gastight. Condensate must
be drained.
13. For instructions on common venting refer to the National
Fuel Gas Code.
14. The vent must terminate no less than 5' above the vent
connector for category I vent systems.
15. A unit located within an unoccupied attic or concealed space
shall not be vented with single wall vent pipe.
16. Single wall vent pipe must not pass through any attic, inside
wall, concealed space, or floor.
17. Do NOT vent this appliance into a masonry chimney.
18. When condensation may be a problem, the venting system
shall not terminate over public walkways or over an area
where condensation or vapor could create a nuisance or
hazard or could be detrimental to the operation of
regulator/relief openings or other equipment.
Figure 5.1 - Unit Venting Category I (pitched roof)
T
able 5.2 - Minimum Height from Roof to Vent Discharge
Rise Roof Pitch Min Height
X (in) H (ft)*
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
* Size according to expected snow depth.
Figure 5.2 - Unit Venting Category (obstructed)
9. Do NOT use dampers or other devices in the vent pipes.
10. Precautions must be taken to prevent degradation of
building materials by flue products.
11. For category I vent systems the outlet of the vent should
extend as shown in Figure 5.1 and Table 5.2 if the following
conditions are met:
Vent diameter is less than 12 inches, vent is of double wall
construction and is a listed product, and the vent does not
terminate within 2' of a vertical wall or similar obstruction.
For vents that have a diameter of 12 inches or larger,
constructed of single wall, or terminate within 2' of a vertical
wall or similar obstruction, the vent pipe shall extend at least
2' higher than any portion of a building within a horizontal
distance of 10' (refer to Figure 5.2).
12. Use a listed vent terminal to reduce downdrafts and
moisture in vent.
6-580.5
5
INSTALLATION
METAL
SLEEVE
FIBER GLASS
INSULATION
MIN. 2"
2" MIN.
VENT TERMINATION
SUPPORT BRACKET
(where required)
(Make from 1" x 1" steel angle)
9"
9"
45
1"
METAL
SLEEVE
2" MIN.
VENT PIPE
DIAMETER
METAL FACE
PLATE
1"
12" min
TEE WITH DRIP LEG
AND CLEANOUT CAP
AT LOW POINT OF
VENT SYSTEM
POWER EXHAUSTER
PITCH VENT PIPE DOWNWARD
FROM UNIT 1/4" PER FOOT
12"
Min.
GARY STEEL
MODEL 1092 TERMINAL
19. In cold ambient conditions, such as Canada, the following
items are recommended for proper operation and
equipment life:
· The vent pipe must not pass through an unheated space
or interior part of an open chimney unless the vent pipe is
insulated.
· Where the vent pipe may be exposed to extreme cold, or
come into contact with snow or ice, the entire vent must be
insulated or double wall (includes outdoors). It is preferred
that the double wall vent is one continuous piece but a
joint is allowed outside the building.
· The vent terminal must extend 12 inches beyond the
exterior surface of an exterior wall and be supported as
shown in Figure 6.1.
· The heater system shall be checked at least once a year
by a qualified service technician.
20. If left hand (facing front of heater with air blowing in face)
power exhauster discharge is desired, the power exhauster
may be rotated 180°. To do this, remove screws in vent
collar, rotate power exhauster, replace screws.
Additional Requirements for Horizontally Vented
Category III units.
1. Seal the joints with a metallic tape or silastic suitable for
temperatures up to 350°F. (3M tapes 433 or 363 are
acceptable.) Wrap the tape two full turns around the
vent pipe.
2. Refer to Table 6.1 for total minimum and maximum vent
lengths making the vent system as straight as possible. The
equivalent length of a 90° elbow is 6 feet for 5" diameter and
7 feet for 6" diameter.
7. The vent system shall terminate at least 3 feet above any
forced air inlet (except direct vent units) located within
10 feet, and at least 4 feet below, 4 feet horizontally from, or
1 foot above any door, window, or gravity air inlet into any
building. The bottom of the vent terminal shall be located
above the snow line or at least 1 foot above grade;
whichever is greater. When located adjacent to public
walkways the vent system shall terminate not less than
7 feet above grade.
Figure 6.1 - Vent Construction Through Combustible Walls
Figure 6.2 - Horizontal Venting - Breidert or Gary Steel
Vent Terminal
Table 6.1 - Vent Pipe Diameters, Transitions, and
Total Equivalent Vent Pipe Lengths for Horizontal
Vent Systems
Model Vent Transition Vent Pipe Minimum Maximum
Size Included Diameter Eqv Length Eqv Length
150, 175 4" to 5" 5" 2' 60'
200 6" to 5" 5" 2' 60'
250- 400 Not Required 6" 2' 70'
3. The vent terminal must be a Gary Steel 1092, Tjernlund
VH1, Starkap, Selkirk, or Constant Air -Flo 2433 style
terminal or equivalent.
4. If a Gary Steel 1092 vent terminal or equivalent is used, the
vent can extend 6 inches beyond the exterior surface of an
exterior wall rather than 12 inches as shown in Figure 6.2.
Precautions must be taken to prevent degradation of building
materials by flue products.
5. If a Tjernlund VH1 or equivalent vent terminal is used the
vent may be flush with the exterior surface of an exterior
wall. Precautions must be taken to prevent degradation of
building materials by flue products. Where the terminal is
not available in the appropriate size for the unit to be
installed, use a transition and the next larger size terminal.
6. If a Constant Air-Flo, Starkap, Selkirk, or equivalent vent
terminal is used the vent must extend 12 inches beyond
the exterior surface of an exterior wall. Precautions must
be taken to prevent degradation of building materials by
flue products.
8. The venting system must be exclusive to a single unit, and
no other unit is allowed to be vented into it.
9. Horizontally vented units must use single wall vent pipe
although one continuous section of double wall vent pipe
may be used with the vent system. Under no circumstances
should two sections of double wall vent pipe be joined
together within one vent system due to the inability to verify
complete seal of inner pipes.
6
6-580.5
INSTALLATION
GAS
SUPPLY LINE
GAS
SUPPLY LINE
GROUND
JOINT
UNION
W/ BRASS
SEAT
MANUAL GAS
SHUT-OFF VALVE
3"
MIN.
SEDIMENT
TRAP
PLUGGED
1/8" NPT TEST
GAGE CONNECTION
TO
CONTROLS
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
Purging of air from gas supply line should be performed as
described in ANSI Z223.1 - latest edition “National Fuel Gas
Code”, or in Canada in CAN/CGA-B149 codes.
IMPORTANT
To prevent premature heat exchanger failure, the input to
the appliance, as indicated on the serial plate, must not
exceed the rated input by more than 5%.
1. Installation of piping must conform with local building
codes, or in the absence of local codes, with the National
Fuel Gas Code, ANSI Z223.1 (NFPA 54) - Latest Edition.
In Canada, installation must be in accordance with CAN/CGA B149.1 for natural gas units and CAN/CGA-B149.2 for
propane units.
2. Piping to 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 7.1 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 7.2. 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
7.1 allows for a 0.3" W.C. pressure drop in the supply
pressure from the building main to the unit. The inlet
pressure to the unit must be 6-7" W.C. for natural gas and
11-14" W.C. for propane gas. When sizing the inlet gas
pipe diameter, make sure that the unit supply pressure
can be met after the 0.3" W.C. has been subtracted. If the
0.3" W.C. pressure drop is too high, refer to the Gas
Engineer’s Handbook for other gas pipe capacities.
3. Install a ground joint union with brass seat and a manual
shut-off valve adjacent to the unit for emergency shut-off
and easy servicing of controls, including a 1/8" NPT
plugged tapping accessible for test gauge connection
(see Figure 7.1).
4. Provide a sediment trap before each unit and in the line
where low spots cannot be avoided (see Figure 7.1).
5. When Pressure/Leak testing, pressures above 14" W.C.
(1/2 psi), close the field installed shut-off valve, disconnect
the appliance and its combination gas control from the
gas supply line, and plug the supply line before testing.
When testing pressures 14" W.C. (1/2 psi) or below, close
the manual shut-off valve on the appliance before testing.
Figure 7.1 - Recommended Sediment Trap/Manual
Shut-off Valve Installation for Gas Connection
➀
➀ Manual shut-off valve is in the “OFF” position when handle is perpendicular
to pipe.
Table 7.1 - Manifold Pressure & Gas Consumption ➀
Natural Propane
BTU/Cu. Ft. 1050 2500 No. of
Model Specific Gravity 0.60 1.53 Orifices
Manifold Pressure In. W.C. 3.5 10.0
CFH 138.1 58.0
PDP 150
Gal/Hr. Propane – 1.64 2
BDP 150
Orifice Drill Size 21 39
CFH 166.7 70.0
PDP 175
Gal/Hr. Propane – 1.86 3
BDP 175
Orifice Drill Size 28 43
CFH 190.5 80.0
PDP 200
Gal/Hr. Propane – 2.19 3
BDP 200
Orifice Drill Size 25 42
CFH 238.1 100.0
PDP 250
Gal/Hr. Propane – 2.74 3
BDP 250
Orifice Drill Size 18 36
CFH 285.7 120.0
PDP 300
Gal/Hr. Propane – 3.29 4
BDP 300
Orifice Drill Size 21 39
CFH 333.3 140.0
PDP 350
Gal/Hr. Propane – 3.84 5
BDP 350
Orifice Drill Size 23 41
CFH 381.0 160.0
PDP 400 Gal/Hr. Propane – 4.38 6
Orifice Drill Size 25 42
Table 7.2 - 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
1/2” 3/4” 1” 1-1/4” 1-1/2” 2”
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 graivity 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.
6-580.5
Natural Gas
7
A
BAFFLE
B
12" MIN.
B
3" MAX.
TURNING
VANES
3" MIN.
A
A
3" MIN.
12"
MIN.
3" MAX.
TURNING
VANES
12"
B
BAFFLE
A
B
12"
MIN.
BAFFLE
TURNING
VANES
INSTALLATION
Electrical Connections
WARNING
1. Disconnect power supply before making wiring connections
to prevent electrical shock and equipment damage.
2. All appliances must be wired strictly in accordance with
wiring diagram furnished with the appliance. Any wiring
different from the wiring diagram could result in a hazard to
persons and property.
3. Any original factory wiring that requires replacement must
be replaced with wiring material having a temperature rating
of at least 105°C.
4. Ensure that the supply voltage to the appliance, as indicated
on the serial plate, is not 5% greater than rated voltage.
cAUTION
1. 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 electrical junction box and
the other is suppled in the literature packet. Refer to this
diagram for all wiring connections.
3. Make sure all multi-voltage components (motors,
transform ers, etc.) are wired in accordance with the power
supply voltage.
4. The power supply to the unit must be protected with a
fused or circuit breaker switch.
5. The power supply must be within 10 percent of the voltage
rating and each phase must be balanced within 2 percent
of each other. If not, advise the utility company.
6. External electrical service connections that must be
installed include:
a. Supply power connection (120, 208, 240, 480, or 600 volts).
b. Thermostats, summer/winter switches, or other accessory
control devices that may be supplied (24 volts).
NOTE: Certain units will require the use of a field step-down
transformer. Refer to the serial plate to determine the unit
supply voltage required. Additional information may be found in
Tables 13.2 and 13.3 and in the step down transformer
installation instructions.
7. Refer to Figure 12.1 for the electrical junction box locations.
8. All supply power electrical connections are made in the
electrical junction box of the unit. The low voltage (thermostat
and accessory control devices) can be wired to the terminals
on the electrical junction box. Refer to the wiring diagram for
the terminal location of all low voltage wiring.
Duct Installation
IMPORTANT
Do not attempt to attach ductwork of any kind to propeller
models.
When installing the heater, always follow good duct design
practices for even distribution of the air across the heat
exchanger. Recommended layouts are shown in Figure 8.1.
When installing blower units with ductwork the following must
be done.
1. Provide uniform air distribution over the heat exchanger.
Use turning vanes where required. See Figure 8.1.
2. Provide removable access panels in the ductwork on the
downstream side of the unit heater. These openings should
be large enough to view smoke or reflect light inside the
casing to indicate leaks in the heat exchanger and to check
for hot spots on exchanger due to poor air distribution or
lack of sufficient air.
3. If ductwork is connected to the rear of the unit use Modine
blower enclosure kit or if using field designed enclosure
maintain dimensions of blower enclosure as shown on
page 19.
Figure 8.1 - Recommended Ductwork Installations
SIDE VIEW
SIDE VIEW TOP VIEW
Dimension “B” Should Never Be Less than 1/2 of “A”
Additional Requirements for Blower Model BDP
Determining Blower Speed
The drive assembly and motor on all blower units are factory
assembled and adjusted for operation under average conditions
of air flow and without any external static pressure. The
motor sheave should be adjusted as required when the unit
is to be operated at other than average air flows and/or with
external static pressures. Adjustment must always be within the
performance range shown on page 14 and the temperature rise
range shown on the unit’s rating plate.
SIDE VIEW
8
To determine the proper blower speed and motor sheave turns
open, the operating conditions must be known. For example, a
model BDP350 unit, operating with no external static pressure,
(e.g. no ductwork, nozzles, etc.) is to deliver an air volume
of 6481 cfm (cfm = cubic feet per minute). This requires the
unit be supplied with a 5 hp motor, a -207 drive, and the drive
sheave set at 2.5 turns open to achieve a blower speed of 960
6-580.5
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