Modine Manufacturing BTS Service Manual
6-561.11
5H0801060000
September, 2018
INSTALLATION AND SERVICE MANUAL
separated combustion gas-fired unit heaters
model PTS and BTS
All models approved for use in California by the CEC and in
Massachusetts. Unit heater is certified for non-residential
applications.
FOR YOUR SAFETY
The use and storage of gasoline or other flammable
vapors and liquids in open containers in the vicinity of this
appliance is hazardous.
W ARNING
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 acidic vapors are present
in the atmosphere. These substances can cause
premature heat exchanger failure due to corrosion,
which can cause property damage, serious injury, or
death.
FOR YOUR SAFETY
WHAT TO DO IF YOU SMELL GAS:
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. Extinguish any open flame.
5. 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.
PLEASE BE SURE TO LEAVE IT WITH THE OWNER WHEN YOU LEAVE THE JOB.
IMPOR T ANT
The use of this manual is specifically intended for a
qualified installation and service agency. All installation
and service of these units must be performed by a
qualified installation and service agency.
Inspection on Arrival
1. Inspect unit upon arrival. In case of damage, report it
immediately to transportation company and your local
Modine sales representative.
2.
Check rating plate on unit to verify that power supply meets
available electric power at the point of installation.
3. Inspect unit upon arrival for conformance with description of
product ordered (including specifications where applicable).
Table of Contents
Inspection on Arrival ................................. 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
Installation ........................................ 6
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Gas Connections .................................11
High-Altitude Accessory Kit ........................ 12
Electrical ...................................... 13
Installation with Ductwork.......................... 15
Requirements/Adjustments and Data for Blower Units.... 15
Start-Up Procedure/Operation ........................ 20
Unit Components .................................. 21
Performance Data - General ......................... 22
Performance Data - Downturn Hoods .................. 23
Dimensions....................................... 24
Service/Troubleshooting............................. 26
Model/Serial Number/Replacement Parts ............... 27
Commercial Warranty........................Back Cover
THIS MANUAL IS THE PROPERTY OF THE OWNER.
SPECIAL PRECAUTIONS
SPECIAL PRECAUTIONS
THE INSTALLATION AND MAINTENANCE INSTRUCTIONS IN
THIS MANUAL MUST BE FOLLOWED TO PROVIDE SAFE, EFFICIENT
AND TROUBLE-FREE OPERATION. IN ADDITION, PARTICULAR CARE
MUST BE EXERCISED REGARDING THE SPECIAL PRECAUTIONS LISTED
BELOW. FAILURE TO PROPERLY ADDRESS THESE CRITICAL AREAS
COULD RESULT IN PROPERTY DAMAGE OR LOSS, PERSONAL INJURY,
OR DEATH. THESE INSTRUCTIONS ARE SUBJECT TO ANY MORE
RESTRICTIVE LOCAL OR NATIONAL CODES.
HAZARD INTENSITY LEVELS
1. DANGER: Indicates an imminently hazardous situation
which, if not avoided, WILL result in death or serious injury.
2. WARNING: Indicates a potentially hazardous situation
which, if not avoided, COULD result in death or serious injury.
3. CAUTION: Indicates a potentially hazardous situation which,
if not avoided, MAY result in minor or moderate injury.
4. IMPORTANT: Indicates a situation which, if not avoided,
MAY result in a potential safety concern.
DANGER
Appliances must not be installed where they may be exposed
to a potentially explosive or flammable atmosphere.
W ARNING
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.
W ARNING
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.
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. 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.
6. Do not install unit outdoors.
7. 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. 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.
8. 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 (Formerly
NFPA 88B).
9. 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.
10. 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).
11. Be sure no obstructions block air intake and discharge of
unit heaters.
12. 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 then the minimum specified if heat damage, other
than fire, may occur to materials above the unit heater at
the temperature described.
13. Allow 18" of clearance at rear (or 12" beyond end of
motor at rear of unit, whichever is greater) and access
side to provide ample air for proper operation of fan.
14. Installation must conform with local building codes or in
the absence of local codes, the National Fuel Gas Code,
ANSI Z223.1 (NFPA 54) - latest edition. In Canada
installation must be in accordance with CSA-B149.1.
15. The concentric vent adapter box must be installed inside
of the structure or building. Do not install this box on the
exterior of a building or structure.
2
6-561.11
SPECIAL PRECAUTIONS / SI (METRIC) CONVERSION FACTORS
BEFORE YOU BEGIN
CAUTION
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.
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 controller which has been wet. Replace defective
controller.
IMPOR T ANT
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 then 5%.
3. To prevent premature heat exchanger failure, observe
heat exchanger tubes. If 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 15 for Blower Adjustments.
4. Start-up and adjustment procedures should be performed
by a qualified service agency.
5. To check most of the Possible Remedies in the trouble-
shooting guide listed in Table 26.1 refer to the applicable
sections of the manual.
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 (NFPA 54) - latest edition
and other applicable local building codes. In Canada, the
installation of these units must comply with local plumbing or
waste water codes and other applicable codes and with the
current code CSA-B149.1.
1. All installation and service of these units must be
performed by a qualified installation and service agency
only as defined in ANSI 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 speeds below what is shown in this
manual.
4. Information on controls is supplied separately.
5. The same burner is used for natural and propane gas.
SI (Metric) Conversion Factors
To Convert Multiply By To Obtain
°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
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.
"W.C. 0.249 kPa
CAUTION
3
6-561.11
3
UNIT LOCATION
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. 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.
3. Do not install unit outdoors.
4. 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.
5. 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.
6. 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.
Figure 4.1 - Combustible Material and Service Clearances
TOP
NON
ACCESS
SIDE
BOTTOM
ACCESS
SIDE
Table 4.1 - Clearances
Combustible Materials Service Clearance
Top and Bottom 6" 18"
Access Side 6" 18"
Non-Access Side 6" 18"
Rear 18" 18"
Vent Connector 6" 18"
6. Do not install units in locations where 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 22 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.
Clearance To Recommended
Unit Side
IMPOR T ANT
To prevent premature heat exchanger failure, do not locate
ANY gas-fired appliances in areas where corrosive vapors
(i.e. chlorinated, halogenated or acidic) are present in the
atmosphere.
Location Recommendations
1. When locating the heater, consider general space and
heating requirements, availability of gas and electrical supply,
and proximity to vent locations.
2. When locating units, it is important to consider that the
combustion air and exhaust vent piping must be connected
to the outside atmosphere. Vent terminals should be located
adjacent to one another. Maximum equivalent vent lengths
are listed in “Section A - General Instruction - All Units” of the
Venting instructions.
3. Be sure the structural support at the unit location site is
adequate to support the unit's weight. Refer to pages 24-25
for unit weights. 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 with the
minimum clearances as shown in Figure 4.1 and Table 4.1.
4
Sound and Vibration Levels
All standard mechanical equipment generates some sound and
vibration that may require attenuation. Libraries, private offices
and hospital facilities will require more attenuation, and in such
cases, an acoustical consultant may be retained to assist in the
application. Locating the equipment away from the critical area
is desirable within ducting limitations. Generally, a unit should
be located within 15' of a primary support beam. Smaller
deflections typically result in reduced vibration and noise
transmission.
6-561.11
UNIT MOUNTING
1. Be sure the means of suspension is adequate to support
the weight of the unit (see pages 24-25 for unit weights).
2. For proper operation, the unit must be installed in a level
horizontal position.
3. Clearances to combustibles as specified in Table 4.1 must be
strictly maintained.
4. All standard units are shipped fully boxed. Larger units are
also supplied with skid supports on the bottom of the box.
The larger units may be lifted from the bottom by means of a
fork lift or other lifting device only if the shipping support skids
are left in place and the forks support the whole depth of the
unit. If the unit must be lifted from the bottom for final
installation without the carton in place, be sure to properly
support the unit over its entire length and width to prevent
damage. When lifting units, make sure the load is balanced.
5. Propeller models have four mounting holes and blower
models have 6 mounting holes. The units can be mounted
with 3/8"-16 threaded rod as follows:
•Oneachpieceofthreadedrodused,screwanutadistance
of about 1" onto the end of the threaded rods that will be
screwed into the unit heater.
•Placeawasherovertheendofthethreadedrodandscrew
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.
•Drillholesintoasteelchannelorangleironatthesame
center-line dimensions as the heater that is being installed.
The steel channels or angle iron pieces need to span and
be fastened to appropriate structural members.
•Cutthethreadedrodstothepreferredlength,placethem
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).
•Donotinstallstandardunitheatersabovethemaximum
mounting height shown in Tables 22.1 or 22.2.
NOTE: A pipe hanger adapter kit, as shown in Figure 5.1, is
available as an accessory. One kit consists of two drilled 3/4"
IPS pipe caps and two 3/8" - 16 x 1-3/4" capscrews to
facilitate threaded pipe suspension. Two kits would be
required for PTS units and 3 kits for BTS units.
Figure 5.1 - Unit Heater Suspension Methods
(Threaded Rod) (Pipe Adapter Kit)
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).
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 12" beyond end of motor
at rear of unit, whichever is greater) and access side to
provide ample air for proper operation of fan.
6-561.11
5
INSTALLATION - VENTING
W ARNING
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
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 PTS/BTS 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 heaters must also have a separate
combustion air intake pipe to bring in fresh air for combustion
from the outside atmosphere.
The venting instructions are organized in sections, based on
installation type. The sections are identified as follows:
Applicable Installation Instructions
Instructions by Vent System Type
A General Instructions for ALL installations
B VERTICAL 2-PIPE vent systems
C HORIZONTAL 2-PIPE vent systems
vent systems
The differences between vertical and horizontal vent systems in 2-Pipe or
HORIZONTAL AND VERTICAL CONCENTRIC
D
concentricventcongurationswillbeidentiedin“SectionA-General
Instructions – All Units”.
A3. All heaters come with factory installed vent and combustion
air adapters for attaching the vent pipe to the heater:
Table 6.1 - Vent Pipe Diameters, Transitions, and Total
Equivalent Vent Pipe Lengths For Horizontal and Vertical
Venting Systems
Equivalent Vent Length
Minimum Maximum
Model
Size
150
175-200
250-400
Vent Pipe Diameter
4" 5' 25'
4" 5' 50'
6" 5' 50'
Attach the vent pipe to the adapter with 3 corrosion-
resistant screws (Drill pilot holes through the vent pipe and
adapter prior to screwing in place). Vent pipe must not be
smaller than the connector size.
A4. Refer to Table 6.1 for total equivalent vent pipe lengths,
making the vent system as straight as possible. The
equivalent length of a 4" elbow is 5' and for a 6" elbow is 7'.
A5. 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.
A6. Fasten individual lengths of vent together with at least three
corrosion resistant sheet metal screws.
A7. 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).
A8. 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
Figure 6.1 - Venting Through Combustible Roof or Wall
Single Wall Vent Pipe
Flashing
Double Wall Vent Pipe
Specified
Terminal
Specified
Terminal
Flashing
Section A - General Instructions - All Units
A1. If the unit heater being installed is replacing existing
equipment and using the existing vent system from that
equipment, inspect the venting system for proper size and
horizontal pitch, as required in the National Fuel Gas Code,
ANSI Z223.1 (NFPA 54) or CSA B149.1 Installation Code latest edition and these instructions. Determine that there is
no blockage or restriction, leakage, corrosion and other
deficiencies, which could cause an unsafe condition.
A2. The vent pipe should be galvanized steel or other suitable
corrosion resistant material. Follow the National Fuel Gas
Code for minimum thickness of vent material. The minimum
thickness for connectors varies depending on the pipe
diameter. Do not vent unit with PVC or other forms of
plastic venting material.
6
Listed
Thimble
Single
Wall
Single Wall Vent Pipe Terminating
with Double wall vent pipe.
Clearance Specified
by Type B Vent Mfg.
Single Wall Vent Pipe
Listed
Thimble
See Instruction A12 for attaching single wall pipe to double wall pipe.
6-561.11
Clearance Specified
by Type B Vent Mfg.
Double
Wall
Specified
Terminal
Single
Wall
Specified
Terminal
INSTALLATION - VENTING
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.
A9. When the vent passes through a combustible INTERIOR
wall or floor, a metal thimble 4" greater than the vent
diameter is necessary. If there is 6' or more of vent pipe in
the open space between the appliance and where the vent
pipe passes through the wall or floor, the thimble need only
be 2" greater than the diameter of the vent pipe. If a
thimble is not used, all combustible material must be cut
away to provide 6" of clearance. Where authorities have
jurisdiction, Type B vent may be used for the last section of
vent pipe to maintain clearance to combustibles while
passing through wall or floor (see Figure 6.1). Any material
used to close the opening must be noncombustible.
A10. Seal all seams and joints of un-gasketed single wall pipe
with metal tape or Silastic suitable for temperatures up to
400°F. Wrap the tape 2 full turns around the vent pipe. One
continuous section of double wall vent pipe may be used
within the vent system to pass through the wall to the listed
vent cap. Refer to instruction A12 in “Section A – General
Instructions – All Units” for attaching double wall pipe to
single wall pipe.
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 a double wall
(Type B) vent pipe:
1. Slide the single wall pipe inside the inner wall of the
double wall pipe.
2. Drill 3 holes through both walls of the single and double
wall vent pipes. Using 3/4" sheet metal screws, attach
the 2 pieces of pipe. Do not overtighten.
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.
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
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 6 feet horizontal (Canada)
Gas regulator
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
Do not terminate the vent directly above a gas meter or regulator.
3 feet horizontal (U.S.)
6 feet all directions
A12. Vent termination clearances must be maintained:
A13. Do NOT vent this appliance into a masonry chimney.
A14. Do NOT use dampers or other devices in the vent or
combustion air pipes.
A15. The venting system must be exclusive to a single
appliance and no other appliance is allowed to be vented
into it.
A16. Precautions must be taken to prevent degradation of
building materials by flue products.
A17. Single wall vent pipe must not pass through any
unoccupied attic, inside wall, concealed space, or floor.
A18. 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.
A19. Long runs of horizontal or vertical combustion air pipes
may require insulation in very cold climates to prevent the
buildup of condensation on the outside of the pipe where
the pipe passes through conditioned spaces.
A20. Vertical combustion air pipes should be fitted with a tee
with a drip leg and a clean out cap to prevent against the
possibility of any moisture in the combustion air pipe from
entering the unit. The drip leg should be inspected and
cleaned out periodically during the heating season.
A21. The vent terminal must be:
Table 7.2 - Vent Terminals
Model Size Modine PN Other Listed Terminals
150-200 5H0722850001 Gary Steel 1092
250-400 5H0722850002 Gary Steel 1092
A22. In addition to following these general instructions, specific
instructions for vertical and horizontal vent systems in
2-Pipe or concentric vent configurations must also be
followed. The following outlines the differences:
Vertical Category III Vent System Determination
• Verticalventsystemsterminatevertically(up)
(an example is shown in Figure 8.1).
• Determinetheventingconfigurationasfollows:
> For two building penetrations through the wall or roof
(one for the combustion air inlet pipe and one for the
vent pipe), proceed to “Section B - Vertical 2-Pipe
Venting".
> For a single larger building penetration through the
wall or roof, through which both the combustion air
inlet and vent pipes will pass, proceed to “Section D Horizontal and Vertical Concentric Venting".
> For all other cases, proceed to the next section for
Horizontal Vent System Determination.
Horizontal Category III Vent System Determination
• Horizontalventsystemsterminatehorizontally
(sideways) (an example is shown in Figure 8.2).
• Determinetheventingconfigurationasfollows:
> For 2 building penetrations through the wall or roof
(1 for the combustion air inlet pipe and 1 for the vent
pipe), proceed to “Section C - Horizontal 2-Pipe
Venting".
> For a single larger building penetration through the
wall or roof, through which both the combustion air
inlet and vent pipes will pass, proceed to “Section D Horizontal and Vertical Concentric Venting".
6-561.11
7
INSTALLATION - VENTING
Section B - Vertical 2-Pipe Vent System Installation
B1. This section applies to vertically vented 2-pipe
(1 combustion air inlet pipe and 1 vent pipe) vent systems
and is in addition to “Section A - General Instructions -
All Units”.
B2. Vertical vent systems terminate vertically (up).
B3. It is recommended to install a tee with drip leg and clean
out cap as shown in Figure 8.1.
B4. The combustion air and vent pipes must be terminated with
2 listed vent caps.
B5. Vertical vents must terminate a minimum horizontal and
vertical distance from roof lines and adjacent walls or
obstructions. These minimum distances are outlined in
Figure 8.1 and Table 8.1.
B6. The vent must terminate at least 1' above and 6"
horizontally from the combustion air inlet.
B7. Once venting is complete, proceed to section titled
“Installation - Gas Connections".
Figure 8.1 - Vertical 2-Pipe Vent System
LISTED TERMINAL
4" MIN
EXHAUST
COMBUSTION AIR
12" MIN
6" MIN
"H" MIN*
"H" MIN*
(SEE TABLE 8.1)
TEE WITH DRIP LEG
AND CLEANOUT CAP
(SLOPE 1/4" PER
FOOT DOWNWARD
TOWARD DRIP LEG)
TERMINAL
ROOF FLASHING
* SIZE ACCORNING
TO EXPECTED
SNOW DEPTH.
ROOF FLASHING
X
ROOF PITCH IS:
X / 12
USE LISTED THIMBLE
THROUGH ROOF AND
CEILING
BACK VIEW
TO WALL OR ADJOINING BUILDING
2' MIN
TERMINAL
USE THIMBLE
THROUGH
CELLING
12
RECOMMENDED
12" MIN
12" MIN*
4" MIN
EXHAUST
Table 8.1 - Minimum Height from Roof to Lowest Discharge
Opening
Rise X (in) Roof Pitch Min Height 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.
Section C - Horizontal 2-Pipe Vent System Installation
C1. This section applies to horizontally vented 2-pipe vent
systems (1 combustion air inlet pipe and 1 vent pipe) and is
in addition to “Section A - General Instructions - All Units”.
Category III vent systems listed by a nationally recognized
agency and matching the diameters specified may be used.
Different brands of vent pipe materials may not be
intermixed. 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.
C2. Horizontal vent systems terminate horizontally (sideways).
C3. All horizontal vents must be terminated with a listed vent
cap. The cap must terminate a minimum distance from the
external wall, as summarized in Figure 8.2.
C4. The termination of horizontally vented system must extend
16" beyond the exterior surface of an exterior wall.
C5. The combustion air pipe must be a minimum of 12" below
the vent pipe, and 6" from the exterior wall.
C6. Construct the vent system as shown in Figure 8.2.
Figure 8.2 - Horizontal Venting with Downward Pitch
ADJACENT
BUILDING
2' MIN
6" MIN
LISTED
TERMINAL
SUPPORT BRACKET
12"
4" MIN
EXHAUST
COMBUSTION AIR
TEE WITH DRIP LEG AND
CLEANOUT CAP AT LOW
POINT OF VENT SYSTEM
SLOPE 1/4" PER FOOT
DOWNWARD FROM UNIT
COMBUSTION AIR
12" MIN
RECOMMENDED
TEE WITH DRIP LEG
AND CLEANOUT CAP
(SLOPE 1/4" PER
FOOT DOWNWARD
TOWARD DRIP LEG)
8
6-561.11
INSTALLATION - VENTING
C7. When horizontal vents pass through a combustible wall
(up to 22" thick), the vent passage must be constructed and
insulated as shown in Figure 9.1.
C8. The vent must be supported as shown in Figure 9.1.
Figure 9.1 - Exhaust Vent Construction Through
Combustible Walls and Support Bracket
METAL FACE
PLATE
45
1"
FIBER GLASS
INSULATION
MIN. 2"
1"
9"
9"
VENT TERMINATION
SUPPORT BRACKET
(where required)
(Make from 1" x 1" steel angle)
METAL
SLEEVE
2" MIN.
VENT PIPE
DIAMETER
METAL
SLEEVE
2" MIN.
C9. 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.
C10. Maintain a 1/4" per foot downward slope away from the
heater and place a drip leg with clean out near the exit of
the vent as shown in Figure 8.2, or allow the condensate
to drip out the end.
C11. 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.
C12. Once venting is complete, proceed to section titled
“Installation - Gas Connections”.
Figure 9.2 - Vertical Concentric Vent Kit Components
Outlet Vent
Combustion Air
Inlet Terminal
Concentric
Vent Adapter
Box
Combustion Air Exhaust
6" Min.
12" Min.*
Termination Cap
* Size according
to expected
snow depth.
Building
Roof / Ceiling
Figure 9.3 - Horizontal Concentric Vent Kit
Components
CAUTION
The concentric vent adapter box must be installed inside of
the structure or building. Do not install this box on the exterior
of a building or structure.
Section D - Concentric Vent System Installation
D1. This section applies to both horizontally and vertically
vented concentric vent systems as defined in “Section A –
General Instructions – All Units”, and is in addition to the
instructions in that section.
D2. When utilizing the concentric vent option, it should have
been predetermined whether the appliance will be
horizontally or vertically vented. Before proceeding, verify
that the concentric vent kit received contains the correct
components for the installation:
For Vertically Vented Units (Refer to Figure 9.2):
Concentric adapter assembly (same for horizontal and
vertical kits)
Standard listed vent cap
Specially designed inlet terminal (part #5H0751540001)
For Horizontally Vented Units (Refer to Figure 9.3):
Concentric adapter assembly (same for horizontal and
vertical kits)
Special vent termination cap (part #5H0751500001)
Special inlet air guard
D3. Once the kit contents have been verified as correct for the
direction of venting, the concentric vent adapter box is to
be installed. Determine the location of the box. Be sure to
maintain all clearances as listed in these instructions.
D4. The adapter box is to be mounted on the interior side of
the building. It must not be mounted outside the building.
The adapter box has integral mounting holes for ease of
installation.
D5. The adapter box can be mounted flush to the wall (for
horizontal kits) or to the ceiling (for vertical kits). The box
can also be offset from the wall or ceiling by using field
supplied brackets. When mounting the box, consider
serviceability and access to the vent and combustion air
pipes. If the box is to be mounted using field supplied
brackets, these brackets must be strong enough to rigidly
secure the box to the wall or ceiling, and should be made
from corrosion resistant material.
D6. Determine the length of the vent pipe and combustion air
inlet pipe for the selected location. THE VENT PIPE WILL
PASS THROUGH THE CONCENTRIC VENT BOX. THE
LAST SECTION OF VENT PIPE IS A CONTINUOUS
LENGTH OF DOUBLE WALL “B” VENT. See section A12
for attaching and terminating double wall pipe. Begin with
pipe lengths on the concentric pipe side of the adapter box,
referring to Figure 10.1. These pipes will extend through the
building wall or roof as well as any added length for the
thickness of the wall and the offset from any field installed
brackets.
6-561.11
9
INSTALLATION - VENTING
For Vertical Concentric Vent Kits
(Refer to Figure 9.2):
•Thebottomofthecombustionairintakepipemust
terminate above the snow line, or at least 12" above
the roof, whichever distance is greater.
•Thebottomoftheventcapmustterminateatleast6"
above the top of the combustion air intake cap.
For Horizontal Concentric Vent Kits
(Refer to Figure 9.3):
•Thecombustionairintakepipemustterminateatleast
1" from the wall to prevent water from running down the
wall and into the pipe.
•Thebackoftheventcapmustterminateatleast
14" from the combustion air intake pipe.
D7. Cut the concentric side vent and combustion air pipes to
the proper length as determined in the previous step. See
Table 10.1 for combustion air and vent pipe sizes. The
pipes must be single wall galvanized or stainless steel
material, except for the last section of vent pipe, which
must be one continuous length of double wall B-vent
extended through the concentric vent box and combustion
air inlet pipe on the concentric side of the box.
NOTE - No clearance to combustible material is required
for the building penetration, which should be sized according
to the external combustion air Inlet pipe diameter.
D8. Allow the concentric side vent pipe to pass through the
concentric vent adapter box, as shown in Figure 10.1.
Attach the double wall vent pipe to the single wall vent
pipe that goes to the unit. Be sure to seal the joint and the
open area around the double wall vent. Seal all joints and
seams using sealant suitable for temperatures up to 400°F.
D9 Slide the combustion air pipe over the vent pipe and
attach to the air inlet of the concentric adapter box, as
shown in Figure 10.1, using at least 3 corrosion-resistant
sheet metal screws. Seal the joint and seam using sealant
suitable for temperatures up to 400°F.
D10. Place this assembly (the adapter box, vent pipe and
combustion air pipe) through the wall or roof and verify
that the distance requirements as defined in Step D7 are
met. Securely attach the assembly to the building.
D11. From outside the building, caulk the gap between the
combustion air intake pipe and the building penetration.
D12. Attach the combustion air intake and vent pipe
terminations as follows:
For Vertical Concentric Vent Kits
(Refer to Figure 9.2):
•Slidethecombustionaircapdownovertheventpipe
and fasten it to the combustion air pipe with at least
3 corrosion-resistant sheet metal screws.
•Attachtheventcaptotheventpipeusingatleast
3 corrosion-resistant sheet metal screws. Refer to
instruction A11 for connecting terminal to double wall
pipe.
•Caulkthegapbetweenthecombustionaircapandthe
vent pipe with silicone sealant, or other appropriate
sealants suitable for metal to metal contact and for
temperatures up to 400° F.
For Horizontal Concentric Vent Kits
(Refer to Figure 9.3):
•Attachthecombustionairintakeguardusingcorrosion-
resistant screws at the end of the combustion air intake
pipe to prevent animals and debris from entering.
•Attachtheventcaptotheventpipeusingatleast
3 corrosion-resistant sheet metal screws.
D13. Install vent pipe and combustion air pipe between unit
heater and concentric vent adapter box as outlined in
“Section A – General Instructions – All Units”.
D14. Once venting is complete, proceed to the section titled
“Installation - Gas Connections”.
Table 10.1 - Concentric Vent Pipe Sizes
Single Wall Pipe
Model Size
150-200
250-400
B-Vent must have 1/4" air gap (OD is 1/2" larger than ID).
Combustion Air (To
Unit)
4" 6" 4"
6" 8" 6"
Combustion Air
(External)
Type B Vent Pipe
Vent
(Pass-Through)
Figure 10.2 - Adapter Box Exploded Assembly
Figure 10.1 - Adapter Box with Combustion Air Intake Pipe
Attached
Outlet Vent
Pipe Extended
Through Box
A
10
Combustion Air
Pipe Attached
B
Model Sizes A B
150-200 13.33" 18.84"
250-400 17.00" 15.27"
4.57"
6-561.11
INSTALLATION - GAS CONNECTIONS
GAS CONNECTIONS
W ARNING
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.
IMPOR T ANT
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 11.1 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 11.2. 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 11.2
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
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 11.1).
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 11.1).
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 11.1 - Recommended Sediment Trap/Manual Shut-off
Valve Installation - Side or Bottom Gas Connection
Manual shut-off valve is in the
“OFF” position when handle is
perpendicular to pipe.
Table 11.1 - Sea Level Manifold Pressure
& Gas Consumption
Natural Propane
Model
Manifold Pressure
Size
150
175
200
250
300
350
400
("W.C.):
CFH 142.9 60.0
OriceDrillSize 42 53
CFH 166.7 70.0
OriceDrillSize 42 53
CFH 190.5 80.0
OriceDrillSize 38 52
CFH 238.1 100.0
OriceDrillSize 39 1.55 mm
CFH 285.7 120.0
Gal/Hr.Propane n/a 3.3
OriceDrillSize 36 51
CFH 333.3 140.0
OriceDrillSize 38 52
CFH 381.0 160.0
Gal/Hr.Propane n/a 4.4
OriceDrillSize 36 51
3.5 10
# of
Orifices
6Gal/Hr.Propane n/a 1.6
7Gal/Hr.Propane n/a 1.9
7Gal/Hr.Propane n/a 2.2
9Gal/Hr.Propane n/a 2.7
9
12Gal/Hr.Propane n/a 3.8
12
Table 11.2 - Gas Pipe Capacities - Natural Gas ➀
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
Capacities in cubic feet per hour through schedule 40 pipe with maximum
0.3" W.C. pressure drop with up to 14" W.C. gas pressure. Specific gravity is 0.60
for natural gas and 1.50 for propane gas.
For pipe capacity with propane gas, divide natural gas capacity by 1.6. Example:
What is the propane gas pipe capacity for 60 feet of 1-1/4" pipe? The natural gas
capacity is 400 CFH. Divide by 1.6 to get 250 CFH for propane gas.
1/2" 3/4" 1" 1-1/4" 1-1/2" 2"
Natural Gas
6-561.11
11
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 BTU/ft3 for natural gas or 2,500 BTU/ft3 for propane gas
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 12.1 through 12.3. 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
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 12.1 and 12.2 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 12.1 and 12.2, 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.
be used (if applicable). Selection charts include the proper kit
suffix, when required.
Table 12.1 - Natural Gas Heating Values at
Table 12.2 - Propane Gas Heating Values at Altitude ➁ ➂ ➃
Altitude ➀ ➂ ➃
Altitude (ft)
0-2,000
2,001-3,000
3,001-4,000
4,001-4,500
4,501-5,000
5,001-6,000
6,001-7,000
7,001-8,000
8,001-9,000
9,001-10,000
➀ Values shown are for 3.5" W.C. manifold pressure, for other BTU content values (available from local utility) use Equation 12.1 to calculate manifold pressure.
➁ Values shown are for 10.0" W.C. manifold pressure, for other BTU content values (available from local utility) use Equation 12.1 to calculate manifold pressure.
➂ When installed at altitudes above 2,000', a pressure switch may need to be changed. Refer to Table 12.3 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
1,050 1,050
929
892
874
856 856
822 822
789 789
757 757
727 727
698 698
945
Altitude (ft)
0-2,000
2,001-3,000
3,001-4,000
4,001-4,500
4,501-5,000
5,001-6,000
6,001-7,000
7,001-8,000
8,001-9,000
9,001-10,000
Gas Heating Values at Altitude (BTU/ft3)
USA Canada
2,500 2,500
2,212
2,123
2,080
2,038 2,038
1,957 1,957
1,879 1,879
1,803 1,803
1,731 1,731
1,662 1,662
2,250
Table 12.3 - High Altitude Kits for PTS/BTS ➀
Model Size Details
150-250
300
350
400
Kit Suffix
Item Code
Kit Suffix
Item Code 68412 68412
Kit Suffix
Item Code
Kit Suffix
Item Code 68413 68413 68413 68413
12
0-2,000 ft. 2,001-4,500 ft. 4,501-5,500 ft. 5,501-6,500 ft. 6,501-7,500 ft.
Not Required Label Only Label Only Label Only Label Only
Not Required Label Only Label Only
Not Required Label Only Label Only Label Only Label Only
Not Required
U.S.A. and Canada
0008 0008
0009 0009 0009 0009
6-561.11
➀ For Label Only kits, Modine
part number 5H0807146005
isrequiredtobelledoutand
attached to the unit by the
installer. Please contact the
local Modine representative
at 1.866.828.4328 (HEAT).
INSTALLATION - HIGH ALTITUDE ACCESSORY KIT
If the heating value of the gas being supplied is different than the values
shown in Tables 12.1 and 12.2, use the following equation to determine the
appropriate manifold pressure for the altitude and gas heating value being
supplied.
Equation 13.1 - Manifold Pressure for Derated Gas
WHERE:
MP
= Manifold Pressure (in. W.C.) at Altitude –
ACT
BTU
TBL
BTU
ACT
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 lowf fire manifold pressure are necessary
on these units.
Manifold pressure setting for the heater being
installed
= BTU/ft3 Content of Gas –
Obtained from Tables 12.1 or 12.2 (whichever is
applicable)
= BTU/ft3 Content of Gas –
Obtained from the local utility company
Use 3.5" W.C. for natural gas and 10.0" W.C. for
propane gas
6-561.11
13
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.
5. When the unit on/off toggle switch is in the “OFF” position,
supply power remains energized at the rear of the switch.
When a factory or field installed motor starting device
such as a relay or contactor are present, supply power
terminals of these components may remain energized
even in the “OFF” position. When providing service on or
near these terminals, de-energize building supply power
to the unit.
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, 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 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 Tables 14.1 through 14.4 for additional information on the
required transformer.
7. Refer to Figure 21.1 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.
9. Separated combustion models include a factory installed on/off
toggle switch. The function of this switch is to disconnect power to
the unit for maintenance or to shut the unit off in warm weather.
Toggle switch is rated at 15amps at 125 volts or up to 3/4 HP at
125 volts.
14
6-561.11
INSTALLATION WITH DUCTWORK
A
BAFFLE
B
30,5 CM
MIN.
A
B
CLOISON
AILETTE S
ROTATIVES
12" MIN.
B
3" MAX .
TUR NING
VANES
3" MIN.
A
A
3" MIN.
12"
MIN.
3" MAX.
TUR NING
VANES
12"
B
BAFFLE
A
B
12"
MIN.
BAFFLE
TURNING
VANES
30,5 CM
MIN.
AILE TTE S
ROTATIVES
Figure 15.1- Typical Duct & Airflow Installation
Recommended Installations
SIDE VIEW SIDE VIEW
SIDE VIEW SIDE VIEW TOP VIEW
IMPOR T ANT
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 15.1.
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 15.1).
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 23.
Additional Requirements for Installation of Blower Models
(model BTS)
Determining Blower Speed
The drive assembly and motor on gas-fired blower unit heaters
with motors 2HP and below are factory assembled. 3HP and
larger motors are shipped loose to prevent shipping damage.
The adjustable motor sheave has been pre-set to permit
operation of this unit 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 22 and the temperature rise range shown on
the unit’s rating plate.
Dimension “B” Should Never
Be Less than 1/2 of “A”
CBA
TOP VIEW
FED
To determine the proper blower speed and motor sheave turns
open, the conditions under which the unit is to operate must be
known. If the blower unit is to be used without duct work or
filters, the only criteria for determining the motor sheave turns
open and blower speed is the amount of air to be delivered. The
performance tables for blower models are shown on pages 18
and 19. As an example, a model BTS 350 unit, operating with
no external static pressure, that is, no duct work, filters, etc.,
and is to deliver an air volume of 6481 cfm (cfm = cubic feet of
air per minute) requires that the unit be supplied with a 5 hp
motor, a -207 drive, and the drive sheave must be set at
2.5 turns open to achieve a blower speed of 960 rpm (see
performance table for units with or without blower enclosure,
page 19). See “Blower Adjustments” on page 16 for setting of
drive pulley turns open.
If a blower unit is to be used with ductwork or filters, etc., the
total external static pressure under which the unit is to operate,
and the required air flow must be known before the unit can be
properly adjusted.
If Modine filters are used, the expected pressure loss through
the filters is included in the performance data on page 17. If
filters or ductwork are to be used with the unit, and they are not
supplied by Modine, the design engineer or installing contractor
must determine the pressure loss for the externally added
devices or ductwork to arrive at the total external static pressure
under which the unit is to operate.
Once the total static pressure and the required air flow are
known, the operating speed of the blower can be determined
and the correct motor sheave adjustments made. As an
example, a model BTS 350 is to be used with a Modine
supplied blower enclosure and Modine supplied filters attached
to ductwork. The unit is to move 6481 cfm of air flow against an
external static pressure of 0.2" W.C. Also, 0.2" W.C. must be
added for the filter pressure drop for a total of 0.4" W.C. total
pressure drop. Entering the performance table on page 18 for a
BTS 350, at 6481 cfm and 0.4" W.C. static pressure, it is seen
that the unit will require a 5 hp motor using a -207 drive, and
the motor sheave should be set at .5 turns open to achieve a
blower speed of 1050 rpm. You can see this example differs
from similar conditions in paragraph 2 by the number of turns
open and a higher rpm, which is needed to overcome the added
external static pressure from the filters.
6-561.11
15
TOWARD MOTOR
SET SC REW
AD JUSTABLE HALF
OF SHEAVE
3/4" DEFLECTION
WITH 5 LBS. FORC
INSTALLATION
To Install
1. Remove and discard the motor tie down strap and the
shipping block beneath the motor adjustment screw (not used
on all models.)
2. For 3 and 5 HP motors, affix sheave to the motor shaft and
install motor on the motor mounting bracket. Install belt on
blower and motor sheaves.
Figure 16.1 - Blower Model
MOUNTING BRACKETS ON BLOWER
BLOWER
SHEAVE
ASSEMBLY
BLOWER
HOUSING
ADJUSTMENT
3. Adjust motor adjusting screw for a belt deflection of
approximately 3/4" with 5 pounds of force applied midway
between the sheaves (refer to Figure 16.3). Since the belt
tension will decrease dramatically after an initial run-in period,
it is necessary to periodically re-check the tension. Excessive
tension will cause bearing wear and noise.
4. The blower bearings are lubricated for life; however, before
initial unit operation the blower shaft should be lubricated at
the bearings with SAE 20 oil. This will reduce initial friction
and start the plastic lubricant flowing.
5. Make electrical connections according to the wiring diagram.
6. Check rotation of the blower. Motor should be in clockwise
rotation when facing motor pulley. If rotation is incorrect,
correction should be made by interchanging wiring within the
motor. See wiring diagram on the motor.
7. The actual current draw of the motor should be determined.
Under no condition should the current draw exceed that
shown on the motor rating plate.
8. It is the installer’s responsibility to adjust the motor sheave to
provide the specified blower performance as listed on pages
18 & 19 for blower settings different from the factory set
performance. The drive number on the unit may be identified
by referring to the Power Code number on the serial plate of
the unit (see page 27 for model number nomenclature) and
matching that number with those shown on page 17. From
the listing, the drive number can be determined.
MOTOR MOUNTING
MOTOR
SCREW
BRACKET
ADJUSTABLE
MOTOR SHEAVE
Blower Adjustments
Following electrical connections, check blower rotation to assure
blow-through heating. If necessary interchange wiring to reverse
blower rotation. Start fan motor and check blower sheave RPM
with a hand-held or strobe-type tachometer. RPM should check
out with the speeds listed in performance data shown on pages
18 and 19. A single-speed motor with an adjustable motor
sheave is supplied with these units. If blower fan speed
changes are required, adjust motor sheave as follows:
NOTE: Do not fire unit until blower adjustment has been made or unit
may cycle on limit (overheat) control.
1. Shut-off power before making blower speed
adjustments. Refer to “Determining Blower Speed” on
page 15 and to “Performance Data” on pages 18 and 19 to
determine proper blower RPM.
2. Loosen belt and take belt off of motor sheave.
3. Loosen set screw on outer side of adjustable motor sheave
(see Figure 16.2).
4. To reduce the speed of the blower, turn outer side of motor
sheave counterclockwise.
5. To increase the speed of the blower, turn outer side of motor
sheave clockwise.
6. Retighten motor sheave set screw, replace belt and
retighten motor base. Adjust motor adjusting screw such
that there is 3/4" belt deflection when pressed with 5 pounds
of force midway between the blower and motor sheaves
(see Figure 16.3). Since the belt tension will decrease
dramatically after an initial run-in period, it is necessary to
periodically re-check the tension to assure continual proper
belt adjustment.
7. Check to make certain motor sheave and blower sheave are
aligned. Re-align if necessary.
8. Re-check blower speed after adjustment.
9. Check motor amps. Do not exceed amps shown on motor
nameplate. Slow blower if necessary.
10. Check air temperature rise across unit. Check temperature
rise against values shown in performance tables on pages
18 and 19 to assure actual desired air flow is being achieved.
11. If adjustments are required, recheck motor amps after final
blower speed adjustment.
Figure 16.2 - Motor Sheave Adjustment
Figure 16.3 - Belt Tension Adjustment
16
6-561.11
BLOWER PERFORMANCE DATA - MODEL BTS
Table 17.1 - Power Code Description - Blower Model BTS -
Power
Code
01
02
08
11
13
19
22
24
30
33
35
41
44
52
55
63
66
74
77
For selection of correct power code, refer to the tables on pages 18-19.
Voltage Phase
115 1 1/4 230 - - - - - - - - - - - -
115/230 1 1/3 230 1/3 238 1/2 233 1/2 204 1 240 1 1/2 250 1 1/2 247
208-230/460 3 1/3 230 1/3 238 1/2 233 1/2 204 1 257 1 1/2 251 1 1/2 248
575 3 1/3 231 1/3 239 1/2 233 1/2 204 1 257 1 1/2 251 1 1/2 248
115/230 1 1/3 232 1/2 229 1 229 1 241 1 241 1 1/2 247 - -
208-230/460 3 1/3 232 1/2 229 1 259 1 258 1 258 1 1/2 248 2 177
575 3 1/3 233 1/2 229 1 259 1 258 1 258 1 1/2 248 2 177
115/230 1 1/2 229 1 175 1 175 1.5 23 1 1/2 243 1 1/2 252 - -
208-230/460 3 1/2 229 1 253 1 253 1.5 177 1 1/2 244 1 1/2 180 3 246
575 3 1/2 229 1 253 1 253 1.5 177 1 1/2 244 1 1/2 180 3 246
115/230 1 1 175 1 1/2 237 1 1/2 235 - - 1 1/2 23 - - - -
208-230/460 3 1 253 1 1/2 234 1 1/2 236 2 180 1 1/2 177 2 177 5 245
575 3 1 253 1 1/2 234 1 1/2 236 2 180 1 1/2 177 2 177 5 245
208-230/460 3 - - - - - - - - 2 177 2 180 - -
575 3 - - - - - - - - 2 177 2 180 - -
208-230/460 3 - - - - - - - - 3 11 2 3 246 - -
575 3 - - - - - - - - 3 112 3 246 - -
208-230/460 3 - - - - - - - - - - 5 245 - -
575 3 - - - - - - - - - - 5 245 - -
BTS150 BTS175 BTS200 BTS250 BTS300 BTS350 BTS400
HP Drive HP Drive HP Drive HP Drive HP Drive HP Drive HP Drive
Table 17.2 - Filter Static Pressure Drop
BTS150 BTS175 BTS200 BTS250 BTS300 BTS350 BTS400
Filter Static ("W.C.) 0.1 0.2 0.1 0.2 0.2 0.2 0.2
Forblowerunitswithenclosureandlter,addthefollowingstaticpressurestothestaticpressuredeterminedbythesystemdesignerfortotal
external static pressure.
6-561.11
17
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